Wire, 0.25 mm With Individual Crimp Connector, Repairing

Wire, 0.25 mm With Individual Crimp Connector, Repairing

Procedure
- Free up the wire to be repaired approximately 20 cm on both sides of the repair point.

CAUTION:
Risk of damaging the electrical wires.
- Free up wrapped wiring harnesses carefully.

- If necessary, removing the wiring harness wrapping using a knife.







- Cut out the damaged wire section using wire stripper VAS 1978/3.

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 connector, insert a repair wire section of matching length with two crimp connections.







- Adjust the sliding stop in the Wire Stripper VAS 1978/3 pliers jaws to 12 to 14 mm for the wire to be stripped.
- Insert wire end from front up to stop into jaws of pliers and squeeze the pliers completely.
- Open pliers again and remove the stripped wire end.
- Twist bare strands one-half turn.
- For the repair of a 0.25 sq.mm wire, use a small yellow crimp connector from the Wiring Harness Repair Set VAS 1978A.







- To press the crimp connector, use the Crimping Pliers (Base Tool) VAS 1978/1-2 with Exchangeable Head, 0.35-2.5 sq.mm VAS 1978/1-1.







- Slide the small yellow crimp connector onto both stripped, uninsulated wire ends on the vehicle-specific single wire and crimp them using crimp pliers.

NOTE: Do not crimp wire insulation.







After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.
- Put Shrink Tip For Hot Air Gun VAS 1978/15 on to Hot Air Gun, 220 V/50 Hz VAS 1978/14.

CAUTION:
Risk of damaging surrounding components.
- 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.







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

- This is how the completed repair location with individual crimp connector should appear.







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.
- If the repair point was previous taped, this point must be taped again with yellow insulating tape after repairs.
- Secure the repaired wiring harness if necessary with a cable tie to prevent flapping noises while driving.