Wire Break With Single 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 single crimp connection

Fig 1: Identifying Single Crimp Connection

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Free up wire intended for repair (approximately 20 cm to both sides of repair point).

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

-- Cut out the damaged section of wire using the Wiring Harness Repair Set - Wire Strippers:VAS 1978/3 .

Fig 2: Cutting Wire

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

If, by cutting out the damaged wire section, both ends of the vehicle-specific single wire are too short for a repair using a single crimp connection, insert a repair wire section of matching length with two crimp connections. Refer to WIRE BREAK WITH DUAL REPAIR POINT .

-- 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 both stripped wire ends of vehicle-specific single wire and crimp them using crimp pliers.

Fig 4: Crimping A Single Break Point

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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.