2.5 Mm2, 4 Mm2 Or 6 Mm2 Aluminum Wires With Separate Butt Connectors, Repairing

WARNING: This page is about a different car, the 2023 Volkswagen Arteon. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Wiring Harness Repair Set - Hot Air Blower:VAS 1978/14A from the Wiring Harness Repair Set:VAS 1978 B

Fig 1: Identifying VAS 1978 B
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Wiring Harness Repair - Blower - Shrink Element:VAS 1978/15A from the Wiring Harness Repair Set:VAS 1978 B
Wiring Harness Repair Set:VAS 631 001

NOTE:

For the repair there are copper repair wires with a 2.5mm² or 4 mm² or 6 mm² cross section.

There are also separate copper repair wires with a crimped on contacts available for the repair.

Procedure

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-- Install the corresponding crimp insert, crimp stamp and contact positioner for the wire cross-section with the contact cross bar as follows on the crimping tool.

-- Open the crimping tool from the Wiring Harness Repair Set:VAS 631 001 .

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

-- Open the mount -2- in the -direction of the arrow B-.

-- Insert the crimp insert -1- in the crimping tool so that the crimp insert -1- is flush with the front of the clamps.

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-- Tighten the crimp insert with the pins -2- -arrow A- and the knurled screw hand tight.

-- Insert the crimp stamp -3- that fits the crimp insert in the mount.

-- Secure the crimp stamp with the pin -4- -arrow B- and the knurled screw hand-tight.

-- Close the adapter -1- in the -direction of the arrow A-.

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-- Push the locking pin -2- in the -direction of the arrow- all the way.

-- Insert the contact cross bar -1- in the contact positioner -2-.

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-- Position the contact positioner with the contact cross bar on the crimping tool -5- at the same time push the holes in the contact positioner -2- over the knurled screw -4-.

-- Install the knurled bolt -3- and tighten hand-tight.

-- Free up the wire to be repaired approximately 20 cm on both sides of the repair point.

CAUTION:

Risk of damaging the electrical wires.

Expose wrapped wiring harnesses carefully.

-- If necessary, removing the wiring harness wrapping using a knife.

-- Cut the damaged section of the wire with a wire stripper from the Wiring Harness Repair Set:VAS 631 001 .

Fig 2: Cutting Wire

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NOTE:

When both ends of the vehicle-specific single wire are too short after cutting out the damaged wire section for a repair with a separate butt connector, insert a corresponding long piece of yellow copper repair wire with two butt connectors.

-- Insert the wire end from the front all the way in to the wire cross-section corresponding mount in the jaws of the pliers.

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-- Push the pliers completely together.

-- Open pliers again and remove the stripped wire end.

The insulation must be cut cleanly and removed from the wires.
No insulation can remain on bare wires.
The single wires must not be damaged.

-- For the repair remove the corresponding butt connection with a heat-shrinkable tube from the Wiring Harness Repair Set:VAS 631 001 .

-- Push the heat-shrinkable tube on one of the wires.

-- Place the butt connection -1- in the contact positioner -2-.

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The butt connection -1- must be flush with the contact positioner -2- -arrow A-.

-- Push the contact cross bar -3- all the way in the -direction of the arrow B- and secure it with the butt clamp -1-.

The tab -4- on the butt connection -1- must engage in the groove -5- on the contact cross bar -3-.

-- Insert the wire -2- with the bare wire end all the way in the butt connection -1- -arrow-.

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All single wires must be pushed into the butt connection.
The insulation end can at a maximum be flush with the front edge of the insulation crimps.

-- Close the crimping tool completely until it reopens by itself.

-- Push the contact cross bar -2- all the way in the -direction of the arrow-.

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-- Remove the butt connection -1- from the contact positioner -3-.

-- Turn the crimping tool for the second crimping.

-- Repeat the wire crimping on the other side as described.

-- Remove the securing pin -1- in the -direction of the arrow A- until it stops.

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-- Open the mount -2- in the -direction of the arrow B-.

-- Remove the crimped butt connectors.

Correct crimping results

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The wire ends must project 0.1 mm to 1.0 mm on the front edge of the wire crimps, dimension -a-
The insulation end must not be crimped in the wire crimps.
The insulation end can at a maximum be flush with the front edge of the insulation crimps -arrows-.

After crimping the heat-shrinkable tube must positioned over the butt connection and heat-shrunk with a hot air gun, to prevent moisture from entering.

Fig 3: Heating Crimp Connection Using Hot Air Gun

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-- Insert the Wiring Harness Repair - Blower - Shrink Element:VAS 1978/15A on the Wiring Harness Repair Set - Hot Air Blower:VAS 1978/14A .

CAUTION:

Risk of damaging surrounding components.

When heat-shrinking the heat-shrinkable tube, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the hot air blower.
Always observe operating instructions of heat gun.

-- Position the heat-shrinkable tube -1- centered over the butt connection -2-.

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The dimension -a- must be approximately the same on both sides

-- Heat the heat-shrinkable tube using the hot air blower lengthwise from center outward until it is sealed completely and adhesive comes out the ends.

The completed repair location -3- must look like so.

NOTE:

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

Fig 4: Identifying Offset Positions Of Crimped Connections

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If the repair point was previous taped, this point must be taped again with yellow insulating tape after repairs.

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