10 Mm2- Or 16 Mm2 Wires With Separate Butt Connectors, Repairing

Special tools and workshop equipment required

Wiring Harness Repair Set - Hot Air Blower :VAS1978/14A from the Wiring Harness Repair Set :VAS1978B
Wiring Harness Repair - Blower - Shrink Element :VAS1978/15A from the Wiring Harness Repair Set :VAS1978B
Wiring Harness Repair Set VAS631 003:VAS631003

NOTE:

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

For the repair there are repair wires with a 10mm² or 16mm² cross section.

There are also separate repair wires with a crimped on/connected contact available for the repair.

Procedure

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-- 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 :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 in direction of -arrow A-.

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-- 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-.

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-- 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.

-- Cut the damaged section of the wire with wire cutters from the :VAS631003 .

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 repair wire with two butt connectors.

When repairing the single wire with crimped on/connected contact place the yellow repair wire near the damaged vehicle-specific single wire and cut to the required length.

-- Adjust the sliding stop in the wire stripper pliers jaws from the :VAS631003 to the length for the wire to be stripped.

Fig 1: Identifying Stripping Pliers To Strip Wiring Insulation

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10 mm² wires: 14 mm
16 mm² wires: 16.5 mm

-- 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.

The insolation must be cut cleanly and remove from the wires.
No insolation can remain on bare wires.
The single wires must not be damaged.

-- For the repair remove the corresponding butt connection and a heat-shrinkable tube from the :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-.

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The dimension -a- must be the same on both sides

-- 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-.

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All single wires must be pushed into the butt connection.

-- 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.

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-- Open the adapter in the direction of -arrow B-.

-- Remove the crimped butt connectors.

Correct crimping results

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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.

Fig 2: 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 the heat-shrinkable tube, 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.

-- Position the heat-shrinkable tube -1- by feeling the contours centered over the butt connection -2-.

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The dimension -a- must be approximately the same on both sides

-- 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.

The completed repair location -3- must look like so.

NOTE:

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

Fig 3: Identifying Offset Positions Of Crimped Connections

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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.

Early Release

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-- 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 :VAS631 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.