Terminal Housings and Connectors

Terminal Housings and Connectors

=> [ Terminal Housing and Harness Connector Repairs, General Information ]

=> [ Contacts in Terminal Housing, Repairing ]

=> [ Single Wire Seals, Assembly ]

=> [ Terminal Housings with Insulation Displacement Terminal, Repairing ]

Terminal Housing and Harness Connector Repairs, General Information

• Observe general notes for repairs on the vehicle electrical system => [ Vehicle Electrical System, General Information ] Wiring Harnesses and Connectors.

• Allocation of crimp contacts with correct fit to contact housing is performed according to the part number stamped in on the contact housing. Terminal housing part numbers in conjunction with the appropriate crimp contacts.

• Damaged contact housings must always be replaced.

Contacts in Terminal Housing, Repairing

Procedure





- First, open or release secondary lock of the contact housing (where applicable) => [ Terminal Housings ] Terminal Housings.

- Release contact (primary lock) using appropriate release tool - A - => [ Terminal Housings ] Terminal Housings.

- Pull contact back out of housing - arrow - at single wire (with single wire seal if necessary).

- Cut off old contact (with the single wire seal) from vehicle-specific wiring harness.





- Determine yellow repair wire with correct contact from Wiring Harness Repair Set (VAS 1978A).

- Free up 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, remove wiring harness wrapping using knife.

- Slide new repair wire contact into corresponding contact housing compartment until it engages.





- If necessary, install single wire seal on repair wire => [ Single Wire Seals, Assembly ].

- Shorten repair wire and vehicle-specific wiring harness single wire as needed using the Wire Stripper (VAS 1978/3).





- Remove insulation from ends of repair wire and vehicle-specific single wire and crimp ends with crimping wires and a crimp connector => [ Wire, 0.25 mm with Individual Crimp Connector, Repairing ] Wiring Harnesses and Connectors or => [ Wire, 0.35 mm or Larger with Intermediate Wire Section, Repairing ] Wiring Harnesses and Connectors.

Single Wire Seals, Assembly

Procedure

• Single wire seals prevent the penetration of water and dirt into the contact housing. They are installed e.g. in the engine compartment and must be reinstalled after a repair.

• Single wire seal is crimped on at the factory together with contact on the wire, this is not the case for repair wires. The single wire seal must be slid onto the wire before crimping the repair wire.

• Single wire seals must always fit with the repair wire cross-section. Outer circumference of single wire seal is aligned according to chamber circumference of the contact housing. Perform assembly using only the assembly tool with correct fit.

- Put single wire seal - A - on to free end of repair wire.





• When doing this, the single wire seal small diameter must point toward the contact housing.

- Slide the single wire seal - A - onto the repair wire up to the contact housing and then into the housing as far as the stop using the appropriate assembly tool - B -.





Terminal Housings with Insulation Displacement Terminal, Repairing

• For technical reasons, contact housings for insulation displacement application can be supplied only with insulation displacement contacts slid on.





• If these contacts are not needed, they can be removed as on any other contact housing.

• Repair wires that already have the corresponding contacts crimped on are available.