Repairs Using Crimp Connectors

Various kits are available for repairing the wiring harness.





Example: Repair set A for contact sleeves on fan connectors.





Select repair set and remove following parts:
1 Prepackaged end of cable with requisite wire cross section
2 Crimp connector for selected wire cross section
3 Shrink-fit hose





Unlock housing and eject damaged contact (4).

Mark damaged contact (4) with socket number of housing and press it out of housing using relevant special tool contained in special tool kit 61 1 150.





Cut off wire with faulty contact (5) at point which is easily accessible.

Caution!
Check maximum length of repair cable!

NOTE: If more than one wire has to be repaired, cuts of wire ends must be arranged offset so that wiring harness will not be too thick at repaired point.





Strip wiring-harness wire end (6).





Cut prepackaged end of cable (7) to length and strip insulation.





Crimp connector onto prepackaged end of cable.





Install shrink-on sleeve (8) on unused wire end.





Crimp unused wire end to butt connector.





Pull shrink-on sleeve over buff connector.





With hot air blower, shrink the shrink-on sleeve on both sides (9) of shrink-fit hose until cement emerges uniformly all round.

Caution!
Do not burn shrink-on sleeve.
Install contact in housing.