0.13 Mm2 - 6 Mm2 Wire, Repairing

Special tools and workshop equipment required 

• Wiring Harness Repair - Crimping Plier - Base Tool:VAS 1978/1-2 
• Wiring Harness Repair Set - Hot Air Blower:VAS 1978/14A 
• Wiring Harness Repair - Blower - Shrink Element:VAS 1978/15A 
• Wiring Harness Repair - Interchangeable Head:VAS 1978/1-3 
• Wiring Harness Repair - Crimping Head -.35-2.5mm:VAS 1978/1-1 
• Wiring Harness Repair Set - Crimping Head - 4-6mm:VAS 1978/2A 

-- Install the Wiring Harness Repair - Interchangeable Head:VAS 1978/1-3  or Wiring Harness Repair - Crimping Head -.35-2.5mm:VAS 1978/1-1  or Wiring Harness Repair Set - Crimping Head - 4-6mm:VAS 1978/2A  on the Wiring Harness Repair - Crimping Plier - Base Tool:VAS 1978/1-2  depending on the wire cross-section.

-- Cut off the damaged part of the wiring harness.

Conditions

• If both ends are too short to repair with a crimp connector after cutting out the damaged section of the wiring harness, a yellow repair wire with two crimp connectors must be used.

-- Insert the wire end -2- all the way -arrow- in the cross section fitting mount on the interchangeable head -1-.

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-- Press together the crimping pliers and hold.

-- Remove the wiring eyelet -2- to the wire stripper out of the interchangeable head -1-.

-- Open the crimping pliers.

Conditions

• The insulation must be cut cleanly and removed from the wires.
• The single wires must not be damaged.

-- Repeat the process of stripping off the end of the wire -2- on the other wire.

0.13 mm² wires

-- Slide the heat-shrinkable tube onto the wire, refer to the appropriate Electronic Parts Information.

Continuation for all vehicles

-- Push the crimp connector -2- in the -direction of arrow A- all the way into the crimping opening.

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-- Push the stripped wire -1- in the -direction of arrow B- into the crimp connector -2-.

Conditions

• All single wires must be pushed in the crimp connector -2-.
• Do not crimp the wire insulation -arrow C-.

-- Push the crimping pliers together and then open.

-- Remove the wire -1- with the crimp connector -2-.

-- Crimp the wire -1- with the crimp connector -2- on the other side as described.

-- Remove the locking pin -1- all the way in the -direction of the arrow A-.

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-- Pivot the upper section on the interchangeable head -2- in the -direction of the arrow B-.

-- Remove the crimped crimp connector.

-- Shrink the crimp connector -1- using the Wiring Harness Repair Set - Hot Air Blower:VAS 1978/14A  -A- and the Wiring Harness Repair - Blower - Shrink Element:VAS 1978/15A  -B-.

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0.13 mm² wires

-- Slide the heat-shrinkable tube -1- until it is centered over the crimp connector -2-.

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Conditions

• The dimension -A- must be the same on both sides.

-- Shrink the heat-shrinkable tube -1- from the inside toward the outside using a hot air gun and shrink element.

-- Check the completed repair area -3-.

Conditions

• The heat-shrinkable tube -1- must be fully shrunk.
• Adhesive must escape at the ends.

Continuation for all vehicles

Early release

-- Release the release lever -1- in the -direction of arrow A-.

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-- At the same time push the crimping pliers together and then open.