Volkswagen Polo Service & Repair Manual: Wire Break with Dual Repair Point

Volkswagen Polo Service & Repair Manual / Wiring / Wiring Harness and Connector Repairs / Wiring Harnesses, Repairing / Wire Break with Dual Repair Point

Repair point with intermediate wire section

–	Free up wire intended for repair at two points (approximately 20 cm to both sides of respective repair points).

–	If required, remove wiring harness wrapping using a folding knife.

Wire Break with Dual Repair Point

–	Route the yellow repair wire next to the damaged wiring harness and cut the repair wire to the required length using the Wiring Harness Repair Set - Wire Strippers -VAS1978/3-.

–	Cut damaged wire section from the vehicle-specific single wire.

Wire Break with Dual Repair Point

–	Strip the wire ends using the 6 - 7 mm wire stripper.

–	Slide crimp connection onto vehicle-specific single wire at one side and onto repair wire at the other side.

Wire Break with Dual Repair Point

–	Crimp the crimp connection at both wire ends using crimp pliers.

–	Repeat this procedure at the other repair wire end.

Note

Always be sure to use the correct crimping slot for the crimping connection used. Refer to → Chapter „Crimping Pliers with Insert“.

Do not crimp wire insulation.

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

–	Place the Wiring Harness Repair - Blower - Shrink Element -VAS1978/15A- on the Wiring Harness Repair Set - Hot Air Blower -VAS1978/14A-.

Wire Break with Dual Repair Point

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

Caution

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 gun.

Always observe operating instructions of heat gun.

Note

Wire Break with Dual Repair Point

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.

In the event the repair point was previous taped, this point must be taped anew with yellow insulating tape after repairs.

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

Wire Break with Dual Repair Point

Wire Break with Single Repair Point

Repair point with single crimp connection – Free up wire intended for repair (approximately 20 cm to both sides of repair point). ...

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