Connector Housings and Connectors, Repairing

Connector Housings and Connectors, Repairing

=> [ Connector Housings and Connectors, Repair Information ]

=> [ Contacts in Connector Housing, Repairing ]

=> [ Single Wire Seals, Installing ]

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

Connector Housings and Connectors, Repair Information

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

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

• Damaged connector housings must always be replaced.

Contacts in Connector Housing, Repairing

Procedure





- First, open or release if necessary the secondary lock of the connector housing. Refer to => [ Contact Housings, Releasing and Disassembling ] Contact Housings, Releasing and Disassembling.

- Release the contact (primary lock) using the appropriate release tool - A -. Refer to => [ Contact Housings, Releasing and Disassembling ] Contact Housings, Releasing and Disassembling.

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

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





- Take the yellow repair wire with the correct contact out of the wiring harness repair set (VAS 1978 B).

- Free up the wire to be repaired approximately 20 cm on both sides of the repair point.

CAUTION!
Risk of damaging the electrical wires.

• Expose wrapped wiring harnesses carefully.

- If necessary, removing the wiring harness wrapping using a knife.

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





- If necessary, install the single wire seal on the repair wire.

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





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

Single Wire Seals, Installing

Procedure

• Single wire seals prevent the penetration of water and dirt into the connector housing. They are installed, for example 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 connector housing. Perform assembly using only the assembly tool with correct fit.

- Put single wire seal - A - onto free end of repair wire.





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

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





Connector Housings with Insulation Displacement Terminal, Repairing

• For technical reasons, connector housings with insulation displacement can be supplied only with the insulation displacement contacts pushed in.





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

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