Aluminum Wire With Single Butt Connector 2.5 Mm2, 4 Mm2 Or 6 Mm2, Repairing With Crimp Connector

Special tools and workshop equipment required 

• Wiring Harness Repair Set - Hot Air Blower: VAS1978/14A 
• Wiring Harness Repair Set VAS631 003: VAS631 003 
• Wiring Harness Repair - Blower - Shrink Element: VAS1978/15A 

Conditions

• Copper wire sections are available for the repair.

Removing 

-- Install a crimp insert, crimp stamp and contact positioner with contact cross bar for the wire cross-section on the crimping pliers from the Wiring Harness Repair Set - Copper: VAS631 003  .

-- Cut out the damaged wiring harness wire.

-- Insert the wire end from the front all the way into the fitting mount for the wire cross-section into the wire stripper from the Wiring Harness Repair Set - Aluminum: VAS631 001  .

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-- Push the wire stripper completely together and then open.

-- Remove the stripped wire.

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 the wire end on the other wire as described.

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

-- Place the crimp connector -1- in the contact positioner -2-.

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Conditions

• The crimp connector -1- must end flush -arrow A- with the contact positioner -2-.

-- Move the contact cross bar -3- all the way in direction of -arrow B-, until the crimp connector -1- is secured.

Conditions

• The tabs -4- on the crimp connector -1- must engage in the groove -5- on the contact cross bar -3-.

-- Push the wire -2- with the stripped wire end in the direction of -arrow- all the way into the crimp connector -1-.

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Conditions

• All single wires must be pushed into the crimp connector -1-.
• The insulation end of the wire -2- can at a maximum be flush with the front edge of the insulation crimps.

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

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

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-- Remove the crimp connector -1- from the contact positioner -3-.

-- Turn the crimping pliers.

-- Repeat the wire crimping with the crimp connector -1- on the other side.

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

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

-- Remove the crimped crimp connector.

-- Check the crimped crimp connector.

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Conditions

• Dimension -a- = 0.1 to 1.0 mm
• The insulation end -arrow- can at a maximum be flush with the front edge of the insulation crimps.

-- Slide the heat-shrinkable tube -1- centrally 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- 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 -1- must be fully shrunk.
• Adhesive must leak at the ends.