Wire break with repairs in two places (VW Passat B6)

Release the wire that needs to be repaired in two places (approximately 20 cm on both sides of the corresponding repair site).

If necessary, remove the wiring harness wrap with a pocket knife.

Place the yellow repair wire next to the damaged wire and use wire strippers to cut the repair wire to the required length.

Cut out the damaged section of wire.



Strip 6-7 mm of insulation from the ends of the wire using wire strippers (fig. 7.132).

Place the crimping sleeve on one side of the wire in the car, and on the other side of the repair wire.



Crimp the crimping sleeve with crimping pliers to both ends of the wires (fig. 7.133).

[The original article is available at VWManual]



Repeat the same on the other end of the repair wire.

Note: Make sure to use the correct tip for the used crimping sleeve.

Note: Wire insulation must not be crimped.

After crimping, the crimping sleeve must be seated to prevent moisture from getting inside it.

Attach the attachment to an industrial hair dryer, 220 V/50 Hz.



Heat the crimping sleeve with a hair dryer in the longitudinal direction from the middle to the edges until it is completely compressed and glue appears at the ends (fig. 7.134).

Caution: When shrinking crimp connections, be careful not to damage other wires, plastic parts or insulation with the hot nozzle of the hair dryer.

Follow the instructions in the hair dryer manual.

Note: If it is necessary to repair several wires, a certain distance must be maintained between the crimping sleeves. To prevent the wire bundle from being too thick in circumference after repair, install the crimping sleeves with some offset relative to each other.

Note: If the repaired area was initially wrapped with electrical tape, then after the repair it should be wrapped with yellow electrical tape.

Note: After repairing the wiring harness, if necessary, secure it with a wire tie to avoid any extraneous noise while driving.