Volkswagen Workshop Service and Repair Manuals

Wiring open circuit with two repair positions

Repair position with interlinked wire. –  Place the wire to be repaired to the side at two points (about 20 cm to both sides of the relevant repair position). –  If necessary, unbind the wiring harness using the folding knife.

–  Place the yellow repair wire next to the damage wiring harness and, using wire strippers -VAS 1978/3-, cut the repair wire to the required length. –  Cut the damaged section of wire out of the vehicle's own single wire.

–  Strip the wire ends of insulation by 6 - 7 mm using the wire strippers. –  Push the crimp connector onto one side of the vehicle's own single wire and on the other side onto the repair wire.

–  Crimp the connector using the crimping pliers to both wire ends. –  Repeat this procedure on the other end of the repair wire.   Note t  Ensure without fail that the correct crimp recess is chosen for the crimp connectors being used → Chapter. t  The insulation on the wires must not be crimped. After crimping, the crimp connector has to be shrink fitted using the hot air blower in order to prevent any ingress of moisture. –  Place shrink element for hot air blower -VAS 1978/15- on hot air blower, 220 V / 50 Hz -VAS 1978/14-.

–  Heat up the crimp connector using the hot air blower along a straight line, working from the middle outwards, until it is sealed completely and the adhesive escapes from the ends.   Caution When shrink-fitting, take care not to damage any other wiring, plastic parts or insulating material with the hot air blower. Observe the operating instructions of the hot air blower without fail!   Note

t  Ensure that, where several wires have to be repaired, the crimp connectors are not directly adjacent to each other. To prevent the circumference of the wiring harness from becoming to great, position the crimp connectors so they are offset slightly. t  If the repair position was already wrapped, this section has to be wrapped again with yellow insulation tape once the repair has been carried out. t  Attach the repaired wiring harness with a cable tie, if necessary, to prevent it from generating noise when the vehicle is in motion.