Wire Break With Dual Repair Point

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.

Repair point with intermediate wire section

Fig 1: Identifying Wire Break With Dual Repair Point

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Free up wire intended for repair at two points (approximately 20 cm to both sides of respective repair points).

-- If required, remove wiring harness wrapping using a folding knife.

-- Route the yellow repair wire next to the damaged wiring harness and cut the repair wire to the required length using the Wiring Harness Repair Set - Wire Strippers:VAS 1978/3 .

Fig 2: Cutting Wire

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Cut damaged wire section from the vehicle-specific single wire.

-- Strip the wire ends using the 6 to 7 mm wire stripper.

Fig 3: Identifying Stripping Pliers To Strip Wiring Insulation

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Crimp the crimp connection at both wire ends using crimp pliers.

Fig 4: Crimping A Single Break Point

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Repeat this procedure at the other repair wire end.

NOTE:

Always be sure to use the correct crimping slot for the crimping connection used. Refer to CRIMPING PLIERS WITH INSERT .

Do not crimp wire insulation.

After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.

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

-- Heat crimp connection using hot air gun lengthwise from center outward until it is sealed completely and adhesive comes out the ends.

Fig 5: Heating Crimp Connection Using Hot Air Gun

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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 hot air gun.

Always observe operating instructions of heat gun.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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 if necessary with a cable tie to prevent flapping noises while driving.