Contacts In Contact Housing, Repairing

-- First, open or release if necessary the secondary lock of the contact housing. Refer to CONTACT HOUSINGS, RELEASING AND DISASSEMBLING .

-- Release contact (primary lock) using the appropriate release tool. Refer to CONTACT HOUSINGS, RELEASING AND DISASSEMBLING .

Fig 1: Identifying Use Of Release Tool On Primary Terminal Lock

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-- Pull contact at single wire out of contact housing.

-- Take the yellow repair wire with the correct contact out of the Wiring Harness Repair Set.

-- Free up repair point of vehicle-specific wiring harness (approximately 20 cm to both sides of repair point).

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

-- Insert new contact of repair wire into contact housing until it engages.

Fig 2: Identifying Procedure To Insert New Terminal

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-- Slide a single wire seal onto the repair wire.

NOTE:

When doing this, small diameter of single seal must point toward contact housing.

-- Slide single wire seal into contact housing using the correct assembly tool. Refer to SINGLE WIRE SEALS, INSTALLING .

-- Shorten the repair wire and the vehicle-specific wiring harness single wire as needed using the Wiring Harness Repair Set - Wire Strippers: VAS1978/3 .

Fig 3: Cutting Wire

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-- Strip ends of repair wire and of vehicle-specific single wire using 6 - 7 mm wire stripper.

Fig 4: Identifying Stripping Pliers To Strip Wiring Insulation

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-- Crimp the stripped ends of repair wire and single wire of vehicle-specific wiring harness using crimp pliers and a crimp connection as described in "Wire break with single repair point". Refer to WIRE BREAK WITH SINGLE REPAIR POINT .

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 5: Identifying Offset Positions Of Crimped Connections

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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.