0.22 Mm 2 Wire, Repairing With Individual Crimp Connector

Special tools and workshop equipment required

Wiring Harness Repair Set :VAS1978B
Wiring Harness Repair Set - Wire Strippers :VAS1978/3
Wiring Harness Repair - Crimping Head -.35-2.5mm :VAS1978/1-1
Wiring Harness Repair - Crimping Plier - Base Tool :VAS1978/1-2
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 (7.87 in) 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

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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 REPAIRING A 0.22 MM .

-- Adjust the sliding stop in the :VAS1978/3 pliers jaws to 12 to 14 mm for the wire to be stripped.

Fig 2: Identifying Stripping Pliers To Strip Wiring Insulation

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-- 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.

-- Twist bare strands one-half turn.

-- For the repair of a 0.22 mm ² wire, use a small transparent crimp connector from the :VAS1978B .

-- To press the crimp connector, use the :VAS1978/1-2 with :VAS1978/1-1 .

Fig 3: Crimping Pliers

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-- Slide the small transparent crimp connector onto both stripped, non-insulated wire ends on the vehicle-specific single wire and crimp them using crimp pliers.

Fig 4: Crimping A Single Break Point

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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

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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

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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.