Procedure
- 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.
- Cut out the damaged section of wire using the Wiring Harness Repair Set - Wire Strippers -VAS1978/3-.
Note
If, by cutting out the damaged wire section, both ends of the vehicle-specific single wire are too short for a repair using a single crimp connector, insert a repair wire section of matching length with two crimp connections. Refer to → Chapter "Repair a wiring 0.35 mm 2 or greater with intermediate wire section".
- Adjust the sliding stop in the Wiring Harness Repair Set - Wire Strippers -VAS1978/3- pliers jaws to 6 to 7 mm for the wire to be stripped.
- Insert wire end from front up to stop into jaws of pliers and squeeze the pliers completely.
- Open pliers again and remove the stripped wire end.
- For the repair, use a suitable crimp connector from the Wiring Harness Repair Set -VAS1978B-.
Note
- Use the Wiring Harness Repair - Crimping Plier - Base Tool -VAS1978/1-2- to press the crimp connector.
The following exchangeable heads are available for the Wiring Harness Repair - Crimping Plier - Base Tool -VAS1978/1-2-:
- Slide crimp connection onto both stripped wire ends of vehicle-specific single wire and crimp them using crimp pliers.
Note
Do not crimp wire insulation.
After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.
- Insert the Wiring Harness Repair - Blower - Shrink Element -VAS1978/15A- on the Wiring Harness Repair Set - Hot Air Blower -VAS1978/14A-.
Caution
Risk of damaging surrounding components.
- Heat crimp connection using the hot air blower lengthwise from center outward until it is sealed completely and adhesive comes out the ends.
Note
Repairing a 0.22 mm 2 Wire with Intermediate Wire Section
Note
For repairing a 0.222 a repair wire can be used as the intermediate wire with a cross section of 0.35-mm2 or 0.5-mm2.
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.
Expose wrapped wiring harnesses carefully.
- If necessary, removing the wiring harness wrapping using a knife.
- Route the yellow repair wire next to the damaged wiring harness and cut the repair wire to the required length using the Wiring Harness Repair Set - Wire Strippers -VAS1978/3-.
- Cut damaged wire section from the vehicle-specific single wire.
- Adjust the sliding stop in the Wiring Harness Repair Set - Wire Strippers -VAS1978/3- pliers jaws to 12 to 14 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.
- Twist bare strands one-half turn.
- Repeat the procedure on the other end of the vehicle-specific individual wire.
- Adjust the sliding stop in the Wiring Harness Repair Set - Wire Strippers -VAS1978/3- pliers jaws to 6 to 7 mm for the wire to be stripped.
- Insert the yellow repair 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 this procedure on the other repair wire end.
- For the repair of a 0.22 mm 2 wire, use a small transparent crimp connector from the Wiring Harness Repair Set -VAS1978B-.
- Use die Wiring Harness Repair - Crimping Plier - Base Tool -VAS1978/1-2- with Wiring Harness Repair - Crimping Head - .35-2.5mm -VAS1978/1-1- from the Wiring Harness Repair Set -VAS1978B- to crimp the wire.
- Push the small transparent crimp connector on the side of the stripped, non-insulated wire ends of vehicle-specific single wire on the other side of the repair wire stripped wire ends.
- Crimp the crimp connection at both wire ends using crimp pliers.
- Repeat this procedure at the other repair wire end.
Note
Do not crimp wire insulation.
After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.
- Insert the Wiring Harness Repair - Blower - Shrink Element -VAS1978/15A- on the Wiring Harness Repair Set - Hot Air Blower -VAS1978/14A-.
Caution
Risk of damaging surrounding components.
- Heat crimp connection using the hot air blower lengthwise from center outward until it is sealed completely and adhesive comes out the ends.
Note
Repair a wiring 0.35 mm 2 or greater with intermediate wire section
Note
For the repair use repair wires with a cross section of 0.35 mm2 through 6.0-mm2.
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.
Expose wrapped wiring harnesses carefully.
- If necessary, removing the wiring harness wrapping using a knife.
- Route the yellow repair wire next to the damaged wiring harness and cut the repair wire to the required length using the Wiring Harness Repair Set - Wire Strippers -VAS1978/3-.
- Cut damaged wire section from the vehicle-specific single wire.
- Adjust the sliding stop in the Wiring Harness Repair Set - Wire Strippers -VAS1978/3- 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 from the Wiring Harness Repair Set -VAS1978B-.
Note
- Use the Wiring Harness Repair - Crimping Plier - Base Tool -VAS1978/1-2- to press the crimp connector.
The following exchangeable heads are available for the Wiring Harness Repair - Crimping Plier - Base Tool -VAS1978/1-2-:
- 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.
- Insert the Wiring Harness Repair - Blower - Shrink Element -VAS1978/15A- on the Wiring Harness Repair Set - Hot Air Blower -VAS1978/14A-.
Caution
Risk of damaging surrounding components.
- Heat crimp connection using the hot air blower lengthwise from center outward until it is sealed completely and adhesive comes out the ends.
Note
10 mm2- or 16 mm2 Wires with Separate Butt Connectors, Repairing
Special tools and workshop equipment required
Note
Procedure
- For the wire cross-section install the suitable crimp insert and crimp stamp as follows on the crimping pliers:
- Open the crimping pliers from the Wiring Harness Repair Set -VAS631003-.
- Remove the locking pin -1- all the way in the direction of -arrow A-.
- Open the adapter -2- in the direction of -arrow B-.
- Push in the crimp stamp -1- until it clicks into place in the mount -2- on the adapter -arrow A-.
- Push in the crimp insert -3- until it engages audibly in the mount -4- of the crimping pliers -arrow B-.
- Close the adapter -1- in the direction of -arrow A-.
- Push the locking pin -2- in the direction of -arrow- all the way.
- 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.
- Cut the damaged section of the wire with wire cutters from the Wiring Harness Repair Set -VAS631003-.
Note
- Adjust the sliding stop in the wire stripper pliers jaws from the Wiring Harness Repair Set -VAS631003- to the length for the wire to be stripped.
- Insert wire end from front up to stop into jaws of pliers and squeeze the pliers completely.
- Open pliers again and remove the stripped wire end.
- For the repair remove the corresponding butt connection and a heat-shrinkable tube from the Wiring Harness Repair Set -VAS631003-.
- Push the heat-shrinkable tube on one of the wires.
- Position the butt connection -1- with the first crimping position centered on the crimp insert -2-.
- Turn the quick feed lever -3- counter-clockwise -arrow- until the butt connection -1- is secured.
- Insert the wire -2- with the bare wire end all the way in the butt connection -1--arrow-.
- Completely close and open the crimping pliers several times, until the crimp insert goes downward by itself in its original position.
Note
The wire insulation must not be crimped at the same time.
- Repeat the wire crimping on the other side as described.
- Remove the securing pin in the direction of -arrow A- until it stops.
- Open the adapter in the direction of -arrow B-.
- Remove the crimped butt connectors.
Correct crimping results
A - 10 mm2, Star crimp
B - 16 mm2, B-Crimp
After crimping the heat-shrinkable tube must positioned over the butt connection and heat-shrunk with a hot air gun, to prevent moisture from entering.
- Insert the Wiring Harness Repair - Blower - Shrink Element -VAS1978/15A- on the Wiring Harness Repair Set - Hot Air Blower -VAS1978/14A-.
Caution
Risk of damaging surrounding components.
- Position the heat-shrinkable tube -1- by feeling the contours centered over the butt connection -2-.
- Heat the heat-shrinkable tube using the hot air blower lengthwise from center outward until it is sealed completely and adhesive comes out the ends.
Note
Early Release
- Push the lever -1- downward in direction of -arrow A-.
- Turn the quick feel lever -2- clockwise in direction of -arrow B- until the crimp insert is in its original position.
If releasing by hand is not possible then:
- Push the lever -1- downward in direction of -arrow A-.
- Place the socket from the Wiring Harness Repair Set -VAS 631 003- on the bolt -3- on the rear side.
- Turn the socket counter-clockwise in direction of -arrow C- until the crimp insert is in its original position,
Caution
Do not use the butt connectors after they are early released.
2.,5 mm2, 4 mm2 or 6 mm2 Aluminum Wires with Separate Butt Connectors, Repairing
Special tools and workshop equipment required
Note
Procedure
- Install the corresponding crimp insert, crimp stamp and contact positioner for the wire cross-section with the contact cross bar as follows on the crimping tool.
- Open the crimping tool from the Wiring Harness Repair Set -VAS 631 001-.
- Remove the locking pin -1- all the way in the direction of -arrow A-.
- Open the mount -2- in the direction of -arrow B-.
- Insert the crimp insert -1- in the crimping tool so that the crimp insert -1- is flush with the front of the clamps.
- Tighten the crimp insert with the pins -2- in direction of -arrow A- and the knurled screw hand tight.
- Insert the crimp stamp -3- that fits the crimp insert in the mount.
- Secure the crimp stamp with the pin -4- in direction of -arrow B- and the knurled screw hand-tight.
- Close the adapter -1- in the direction of -arrow A-.
- Push the locking pin -2- in the direction of -arrow- all the way.
- Insert the contact cross bar -1- in the contact positioner -2-.
- Position the contact positioner with the contact cross bar on the crimping tool -5- at the same time push the holes in the contact positioner -2- over the knurled screw -4-.
- Install the knurled bolt -3- and tighten hand-tight.
- 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.
- Cut the damaged section of the wire with wire stripper from the Wiring Harness Repair Set -VAS 631 001-.
Note
When both ends of the vehicle-specific single wire are too short after cutting out the damaged wire section for a repair with a separate butt connector, insert a corresponding long piece of yellow copper repair wire with two butt connectors.
- Insert the wire end from the front all the way in to the wire cross-section corresponding mount in the jaws of the pliers.
- Push the pliers completely together.
- Open pliers again and remove the stripped wire end.
- For the repair remove the corresponding butt connection with a heat-shrinkable tube from the Wiring Harness Repair Set -VAS 631 001-.
- Push the heat-shrinkable tube on one of the wires.
- Place the butt connection -1- in the contact positioner -2-.
- Push the contact cross bar -3- all the way in the direction of the -arrow B- and secure it with the butt clamp -1-.
- Insert the wire -2- with the bare wire end all the way in the butt connection -1--arrow-.
- Close the crimping tool completely until it reopens by itself.
- Push the contact cross bar -2- all the way in the direction of -arrow-.
- Remove the butt connection -1- from the contact positioner -3-.
- Turn the crimping tool for the second crimping.
- Repeat the wire crimping on the other side as described.
- Remove the securing pin -1- in the direction of -arrow A- until it stops.
- Open the mount -2- in the direction of -arrow B-.
- Remove the crimped butt connectors.
Correct crimping results
After crimping the heat-shrinkable tube must positioned over the butt connection and heat-shrunk with a hot air gun, to prevent moisture from entering.
- Insert the Wiring Harness Repair - Blower - Shrink Element -VAS 1978/15A- on the Wiring Harness Repair Set - Hot Air Blower -VAS 1978/14A-.
Caution
Risk of damaging surrounding components.
- Position the heat-shrinkable tube -1- centered over the butt connection -2-.
- Heat the heat-shrinkable tube using the hot air blower lengthwise from center outward until it is sealed completely and adhesive comes out the ends.
Note