Repair of connectors terminals — VW

🧭 Before you start

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• The smallest diameter of the sheath shall point to the connector.

📋 Procedure

1. If necessary, first open or unlock the secondary lock device of the connectors' terminals .
2. Unlock the terminal (primary unlock device) with a proper unlock tool .
3. Pull the terminal on the single cable and remove it from the connector.
4. Select the yellow repair cable with the proper terminal from Wiring harness repair setVAS 1978 or Wiring harness repair setVAS 1978A.
5. Loosen the repair region of the original cable (approx. 20 cm to both sides of the repair region).

6. If necessary, remove the cable sheath with a pocket knife.
7. Fit the new terminal of the repair cable on the connector until it locks.
8. If necessary, insert single cable lining (A) with the respective assembly tool (B) bolts to the connector stanchion. [Note: The smallest diameter of the sheath shall point to the connector.]
9. Shorten the repair cable and the original single cable according as necessary with Wire stripperVAS 1978/3.
10. Strip 6 to 7 mm of the repair cable ends and of the original single cable with Wire stripperVAS 1978/3.
11. Compress the original harness' repair cable and single cable stripped tips with the crimping pliers and a pressure connection, as described in chapter "“Interruption on cables with one repair region”". [Note: In case more there is more than one cable be repaired, make sure that the connections by pressure are not placed together. In order to prevent that cable regions occupy too much space, position the connection by pressure slightly displaced.In case the repair region was covered, cover it again with yellow adhesive tape after repair.If necessary, fix the repaired cables with a clamp, thus avoiding further noises when driving the vehicle.]

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