Contacts In Contact Housing, Repairing

WARNING: This page is about a different variant/trim than selected.

Procedure

-- First, open or release the secondary lock on the connector housing.

-- Release the contact (primary lock) using the appropriate release tool.

Fig 1: Identifying Use Of Release Tool On Primary Terminal Lock

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-- Pull contact at the single wire out of the connector housing.

-- Take the yellow repair wire with the correct contact out of the : VAS1978 /: VAS1978A /: VAS978B .

-- Free up repair point of vehicle-specific wiring harness (approximately 20 cm to both sides of repair point).

-- Remove the wiring harness wrapping using a switchblade.

-- Insert the new repair wire contact into the connector housing until it engages.

Fig 2: Identifying Procedure To Insert New Terminal

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-- Slide the single wire seal on the repair wire.

NOTE:

When doing this, the small diameter of single wire seal must point toward the connector housing.

-- Slide the single wire seal into the connector housing using the correct assembly tool. Refer to SINGLE WIRE SEALS, INSTALLING .

-- Shorten the repair wire and the vehicle-specific wiring harness single wire using the : VAS1978/3 .

Fig 3: Cutting Wire

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-- Strip the ends of the repair wire and the vehicle-specific single wire 6 to 7 mm using the : VAS1978/3 .

Fig 4: Identifying Stripping Pliers To Strip Wiring Insulation

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-- Crimp the stripped ends of the repair wire and single wire of vehicle-specific wiring harness using the : VAS1978/1A and a crimp connector as described in "Open circuit with single repair point".

NOTE:

Make sure that crimp connections do not lie directly next to each other when several wires need to be repaired. Arrange the crimp connectors at a slight offset so that the circumference of the wiring harness does not become too large.

Fig 5: Identifying Offset Positions Of Crimped Connections

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In the event the repair point was previous taped, this point must be taped anew with yellow insulating tape after repairs.

Secure the repaired wiring harness with a cable tie to prevent flapping noises while driving.