FlexRay Wire, Repairing

FlexRay Wire, Repairing

Special tools, testers and auxiliary items required

• Wiring Harness Repair Set VAS 1978/A (VAS 1978 B)

• Repairs to the wiring harnesses and connectors must only be performed using the Wiring harness repair set (VAS 1978 B).

• Observe the country-specific requirements.

• Use of the Wiring harness repair set (VAS 1978 B) is described in detail in the attached operating instructions.

• Repairs on open circuits and faulty connectors are also explained using examples.

• Observe general notes for repairs on the vehicle electrical system. Refer to=> [ General Notes on Repairs on Vehicle Electrical System ] General Notes on Repairs on Vehicle Electrical System.

• Observe the notes on wiring harness and connector repairs. Refer to=> [ General Notes For Repairing Wiring Harnesses and Connectors ] General Notes For Repairing Wiring Harnesses and Connectors including identifying repair locations.

A two-layer wire - 1 and 2 - with a 0.35 mm 2 profile is used as a FlexRay wire.






• During repair work, both wires must have the same length.

• When twisting the wires - 1 and 2 - together, the - A - = 30 mm (1.2 in.) routing length must be maintained.

• While doing so, no section of wire may be greater than - B - = 50 mm (2 in.) without twisting the wires, for example, in the area of crimp connectors - arrow -.

• Maximum exposed wire length: - C - = 100 mm (4 in.)






• Protect the area being repairs from the environment. Use a crimp connector with heat-shrinkable tube over the untwisted location being repairs and waterproof insulation over the exposed wire.

• Mark the location of the repair with something suitable, for example, with yellow tape.

• Repairing both wires is identical to repair just one wire.

• Position both repaired location - arrows - - A - = 30 mm (1.2 in.) opposite each other.

• Crimp the cables with connectors.

1 Repair location in the area without insulation
2 Repair location with connectors
C Maximum exposed length = 100 mm (4 in.)