Repairing A Wire 0.35 Mm 2 Or Greater With Individual Crimp Connector

Special tools and workshop equipment required

Wiring Harness Repair Set :VAS1978B
Wiring Harness Repair - Crimping Head -.35-2.5mm :VAS1978/1-1
Wiring Harness Repair - Crimping Plier - Base Tool :VAS1978/1-2
Wiring Harness Repair - Crimping Head -.35-2.5mm :VAS1978/1-1
Wiring Harness Repair Set - Crimping Head - 4-6mm :VAS1978/2A
Wiring Harness Repair Set - Hot Air Blower :VAS1978/14A
Wiring Harness Repair - Blower - Shrink Element :VAS1978/15A

NOTE:

Observe general notes for repairs on the vehicle electrical system. Refer to VEHICLE ELECTRICAL SYSTEM, GENERAL REPAIR INFORMATION .

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.

-- Cut out the damaged section of wire using the :VAS1978/3 .

Fig 1: Cutting Wire

Courtesy of AUDI OF AMERICA, LLC

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 REPAIR A WIRING 0.35 MM .

-- Adjust the sliding stop in the :VAS1978/3 pliers jaws to 6 to 7 mm for the wire to be stripped.

Fig 2: Identifying Stripping Pliers To Strip Wiring Insulation

Courtesy of AUDI OF AMERICA, LLC

-- 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 :VAS1978B .

NOTE:

Always be sure to use the corresponding crimp connector and the correct crimping slot for the crimping connection used. Refer to CRIMPING PLIERS WITH INSERT .

Do not crimp wire insulation.

-- Use the :VAS1978/1-2 to press the crimp connector.

Fig 3: Crimping Pliers

Courtesy of AUDI OF AMERICA, LLC

The following exchangeable heads are available for the :VAS1978/1-2 :

:VAS1978/1-1
:VAS1978/2A

-- Slide crimp connection onto both stripped wire ends of vehicle-specific single wire and crimp them using crimp pliers.

Fig 4: Crimping A Single Break Point

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Do not crimp wire insulation.

After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.

Fig 5: Heating Crimp Connection Using Hot Air Gun

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-- Insert the :VAS1978/15A on the :VAS1978/14A .

CAUTION:

Risk of damaging surrounding components.

When heat-shrinking crimp connections, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the hot air blower.
Always observe operating instructions of heat gun.

-- Heat crimp connection using the hot air blower lengthwise from center outward until it is sealed completely and adhesive comes out the ends.

Fig 6: Identifying Single Crimp Connection

Courtesy of AUDI OF AMERICA, LLC

This is how the completed repair location with individual crimp connector should appear.

NOTE:

Make sure that crimp connections do not lie directly next to each other when several wires need to be repaired. Arrange the crimp connectors at a slight offset so that the circumference of the wiring harness does not become too large.

Fig 7: Identifying Offset Positions Of Crimped Connections

Courtesy of AUDI OF AMERICA, LLC

If the repair point was previous taped, this point must be taped again with yellow insulating tape after repairs.

Secure the repaired wiring harness if necessary with a cable tie to prevent flapping noises while driving.