Wire, 0.25 mm With Intermediate Wire Section, Repairing
Wire, 0.25 mm With Intermediate Wire Section, Repairing
NOTE:
- Only 0.5 sq.mm repair wires are available for repairing a 0.25 sq.mm wire.
Procedure
- Free up the wire to be repaired at two places 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.
- Route yellow repair wire next to damaged wiring harness and cut repair wire to the required length using wire stripper VAS 1978/3.
- Cut damaged wire section from the vehicle-specific single wire.
- 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 the vehicle-specific single wire end from the front into the pliers jaws as far as the stop and squeeze the pliers together completely.
- Open pliers again and remove the stripped wire end.
- Twist bare strands one-half turn.
- Repeat the procedure on the other end of the vehicle-specific individual wire.
- Adjust the sliding stop in the Wire Stripper VAS 1978/3 pliers jaws to 6 to 7 mm for the wire to be stripped.
- Insert the yellow repair wire end from the front into the pliers jaws as far as the stop and squeeze the pliers together completely.
- Open pliers again and remove the stripped wire end.
- Repeat this procedure on the other repair wire end.
- 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 from the Wiring Harness Repair Set VAS 1978A with the Exchangeable Head, 0.35 mm-2.5 mm VAS 1978/1-1.
- Slide the small yellow crimp connector onto the vehicle-specific single wire at one side and onto the repair wire at the other side.
- Crimp the crimp connection at both wire ends using crimp pliers.
- Repeat this procedure at the other repair wire end.
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 the inserted wire and two crimp connectors should look.
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.