Wire Break With Dual Repair Point

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

Repair Point with Intermediate Wire Section

Fig 1: Identifying Wire Break With Dual Repair Point

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-- Free up the wire to be repaired at two places (approximately 20 cm on both sides of the respective repair point).

-- Remove the wiring harness wrapping using a switchblade.

-- Place the yellow repair wire next to the damaged wiring harness and cut the repair wire to the required length using the : VAS1978/3 .

Fig 2: Cutting Wire

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-- Cut the damaged piece of wire from the vehicle-specific single wire.

-- Strip the wire ends 6 to 7 mm using the : VAS1978/3 .

Fig 3: Identifying Stripping Pliers To Strip Wiring Insulation

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-- Slide the crimp connector onto the vehicle-specific single wire at one side and onto the repair wire at the other side.

-- Crimp the crimp connector at both wire ends using the : VAS1978/1A .

Fig 4: Crimping A Single Break Point

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-- Repeat the process on the other end of the repair wire.

NOTE:

Always be sure to use the correct crimping slot for the crimping connection used.

Do not crimp wire insulation.

After crimping, the crimp connectors must be heat-shrunk using the : VAS1978/14A to prevent moisture penetration.

-- Place the : VAS1978/15A on the : VAS1978/14A .

-- Heat the crimp connector using the : VAS1978/14A lengthwise from the center outward until it is sealed completely and the adhesive comes out at the ends.

Fig 5: Heating Crimp Connection Using Hot Air Gun

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CAUTION:

When heat-shrinking crimp connections, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the : VAS1978/14A .

Always follow the : VAS1978/14A Operating Instructions!

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 6: 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.