0.13MM2 - 6MM2 Wiring, Repairing

Special tools and workshop equipment required 

• Wiring Harness Repair - Crimping Plier - Base Tool: VAS1978/1-2 
• Wiring Harness Repair Set - Hot Air Blower: VAS1978/14A 
• Wiring Harness Repair - Blower - Shrink Element: VAS1978/15A 
• Wiring Harness Repair - Interchangeable Head: VAS1978/1-3 
• Wiring Harness Repair - Crimping Head -.35-2.5mm: VAS1978/1-1 
• Wiring Harness Repair Set - Crimping Head - 4-6mm: VAS1978/2A 

-- Install the Wiring Harness Repair - Interchangeable Head: VAS1978/1-3  or Wiring Harness Repair - Crimping Head -.35-2.5mm: VAS1978/1-1  or Wiring Harness Repair Set - Crimping Head - 4-6mm: VAS1978/2A  on the Wiring Harness Repair - Crimping Plier - Base Tool: VAS1978/1-2  depending on the wire cross-section.

-- Cut out the damaged wiring harness wire.

Conditions

• When both ends of the wiring harness are too short after cutting out the damaged wire section for a repair with a crimp connector, insert a corresponding long wire piece (yellow repair wire) with two crimp connectors.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Press the Wiring Harness Repair - Crimping Plier - Base Tool: VAS1978/1-2  together and keep it pressed.

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

-- Open the Wiring Harness Repair - Crimping Plier - Base Tool: VAS1978/1-2  .

Conditions

• 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.

-- Repeat the stripping of the wire end -2- of the other wire as described.

0, 13Mm² wires

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

Continuation for all vehicles

-- Push the crimp connector -2- all the way in the direction of -arrow A- in the clamp opening on the interchangeable head.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Conditions

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

-- Press the Wiring Harness Repair - Crimping Plier - Base Tool: VAS1978/1-2  together and open it afterward.

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

-- Repeat the crimping of the wire -1- on the other side as shown, using the crimp connector -2-.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Remove the crimped crimp connector.

-- Shrink the crimp connector -1- using the Wiring Harness Repair Set - Hot Air Blower: VAS1978/14A  -A- and the Wiring Harness Repair - Blower - Shrink Element: VAS1978/15A  -B-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

0, 13Mm² wires

-- Slide the heat-shrinkable tube -1- centrally over the crimp connector -2-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Conditions

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

-- Shrink the heat-shrinkable tube -1- using the Wiring Harness Repair Set - Hot Air Blower: VAS1978/14A  and the Wiring Harness Repair - Blower - Shrink Element: VAS1978/15A  starting from the center going outward.

-- Check the completed repair area -3-.

Conditions

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

Continuation for all vehicles

Early release

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- At the same time press the Wiring Harness Repair - Crimping Plier - Base Tool: VAS1978/1-2  slightly together and open it afterward.