Wire, 0.35 mm or Larger With Intermediate Wire Section, Repairing

Wire, 0.35 mm Or Larger With Intermediate Wire Section, Repairing

NOTE: Only 0.5 sq. mm repair wires are available for repairing a 0.35 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 6 to 7 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.
- Repeat the procedure on the other end of the vehicle-specific individual wire.
- For the repair, use two suitable crimp connectors form the Wiring Harness Repair Set VAS 1978A.







- Use the Crimping Pliers (Base Tool) VAS 1978/1-2 to press the crimp connector.

The following exchangeable heads are available for the Crimping Pliers (Base Tool) VAS 1978/1-2 :
- Exchangeable Head, 0.35-2.5mm VAS 1978/1-1
- Exchangeable head, 4.0-6.0 sq.mm VAS 1978/2 A

- Slide the crimp connector onto the vehicle-specific single wire at one side and onto repair wire at the other side.







- Crimp the crimp connection at both wire ends using crimp pliers.
- Repeat this procedure on the other wire ends.

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.