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Volkswagen Golf Variant / Jetta. Manual - part 622

Repairs to wiring harnesses and con‐

nectors

2.1

Wiring harness repair set

2.1.1

Wiring harness repair set -VAS 1978-

Wiring harness repair set -VAS 1978- allows optimal repair quality

to be achieved in the area of vehicle electrics. Using the tools,

repairs to connectors and wiring open circuits can be carried out.

To do this, complete repair wire sections with contacts already

crimped on are used and joined to the vehicle's own wiring har‐

ness with the aid of crimp connectors. A perfect electrical con‐

nection can be achieved using crimping pliers -VAS 1978/1- with

head adapter -VAS 1978/2- and three different crimp recesses as

well as a hot air blower, 220 V/50 Hz -VAS 1978/14- for shrink-

fitting crimp connectors.
Wiring harness repair set -VAS 1978-
Additional information:
♦ ⇒ Operating instructions Wiring harness repair set -VAS

1978-

2.1.2

Upgrade kit -VAS 1978/50-

Upgrade kit -VAS 1978/50- is required to bring the “old” wiring

harness repair set -VAS 1978- up to the latest standard of wiring

harness repair set -VAS 1978A- . The upgrade kit -VAS 1978/50-

consists of 4 assembly and 10 release tools, new crimping pliers

(base tool) -VAS 1978/1-2- for crimp connector with head adapter

0.35-2.5mm/2 -VAS 1978/1-1- , head adapter 4.0-6.0mm/2 -VAS

1978/2A- and head adapter for JPT contact -VAS 1978/9-1- . Also

included are new adhesive labels, a new set of operating instruc‐

tions, crimp connectors for 0.35 mm

wiring cross sections and a

roll of black felt adhesive tape.
Upgrade kit -VAS 1978/50-

2.1.3

Wiring harness repair set -VAS 1978A-

The new wiring harness repair set -VAS 1978A- allows optimal

repair quality to be achieved in the area of vehicle electrics. Using

the new pliers, repairs to connectors and wiring open circuits can

be carried out. To do this, complete repair wire sections with con‐

tacts already crimped on are used and joined to the vehicle's own

wiring harness with the aid of four different types of crimp con‐

nectors. A perfect electrical connection can be achieved using

new crimping pliers (base tool) -VAS 1978/1-2- with interchange‐

able head adapter 0.35-2.5mm/2 -VAS 1978/1-1- or head adapter

4.0-6.0mm/2 -VAS 1978/2A- and a hot air blower, 220 V/50 Hz -

VAS 1978/14- for shrink-fitting crimp connectors.
Wiring harness repair set -VAS 1978A-
Additional information:
♦ ⇒ Operating instructions Wiring harness repair set -VAS

1978A-

The wiring harness repair set -VAS 1978A- has been supple‐

mented with the wiring harness repair set -VAS 1978B- .

2. Repairs to wiring harnesses and connectors

Set of release tools -VAS 1978/35-

The set of release tools -VAS 1978/35- is used to release various

primary and secondary locking devices in Group vehicles. The set

comprises of 26 different tools with which, for example, round

connector systems, flat contacts with one or two locking devices

and also single wire seals can be released and fitted.
Release tool set -VAS 1978/35-
Which release tool belongs to which locking device is indicated in

the table in the ⇒ operating instructions of the set of release tools

-VAS 1978/35- .

2.2

Tool descriptions

2.2.1

Special pliers with insert

Crimping pliers -VAS 1978/1- with head adapter -VAS 1978/2- are

part of wiring harness repair set -VAS 1978- / wiring harness re‐

pair set -VAS 1978A- / wiring harness repair set -VAS 1978B- and

is used to crimp connectors during wiring harness repairs.

Colour of crimp

connector

Colour of crimp re‐

cess

Wiring cross section

Yellow.

0.35 mm

Red.

0.5 mm

to 1.0 mm

Blue

1.5 mm

to 2.5 mm

Yellow.

4.0 mm

to 6.0 mm

Note

♦

As an alternative, the connectors can also be crimped with

crimping pliers (base tool) -VAS 1978/1-2- in conjunction with

head adapters 0.35 - 2.5 mm/2 -VAS 1978/1-1- or 4.0 - 6.0

mm/2 -VAS 1978/2A-

⇒ page 89

♦

Ensure that the correct crimp recess is chosen for the crimp

connectors being used.

♦

The insulation on the wires must not be crimped.

Release tools for contacts

The various release tools serve as a means of detaching the dif‐

ferent contacts from the contact housings without damage.
A selection of release tools is included in wiring harness repair

set -VAS 1978- / wiring harness repair set -VAS 1978A- / wiring

harness repair set -VAS 1978B- . The complete set of release

tools is included in set of release tools -VAS 1978/35-

⇒ page 86

WARNING

Some tools are equipped with a tool safety device. This must

be pushed over the tip of the tool after use in order to protect

the tip and prevent personal injury.

Releasing and dismantling contact housings

⇒ page 105

2.2.3

Assembly tools for single wire seals

The assembly tools serve as a means of sliding the single wire

seals fully into the contact housing without damage and thereby

assure complete sealing between single wire and contact hous‐

ing.
Four assembly tools for single wire seals are included in wiring

harness repair set -VAS 1978- / wiring harness repair set -VAS

1978A- / wiring harness repair set -VAS 1978B- .
Assembling single wire seals

⇒ page 103

2.2.4

Wire strippers -VAS 1978/3-

Wire strippers -VAS 1978/3- serve as a means of stripping insu‐

lation off wires and cutting wires in the correct manner.
Wire strippers -VAS 1978/3- are included in wiring harness repair

set -VAS 1978- / wiring harness repair set -VAS 1978A- / wiring

harness repair set -VAS 1978B- .
Wire stripper -VAS 1978/3- has an adjustable limit stop within the

pliers jaws, with which the desired length of insulation to be re‐

moved can be adjusted.
Stripping
– Adjust the sliding limit stop in the pliers jaws to the desired

length of insulation to be removed.

2. Repairs to wiring harnesses and connectors

and squeeze wire stripper -VAS 1978/3- together completely.

– Open wire stripper -VAS 1978/3- and remove stripped wire

end.

– Cut wire, using cutter on upper side of wire stripper -VAS

1978/3- .

2.2.5

Hot air blower, 220 V / 50 Hz -VAS

1978/14-

Hot air blower, 220 V / 50 Hz -VAS 1978/14-

Caution

When shrink-fitting, take care not to damage any other wiring,

plastic parts or insulating material with the hot air blower, 220

V/50 Hz -VAS 1978/14- .
Observe ⇒ Operating instructions for hot air blower, 220 V/50

Hz -VAS 1978/14- .

The hot air blower, 220 V/50 Hz -VAS 1978/14- is used in con‐

junction with shrink element for hot air blower -VAS 1978/15- to

shrink fit the crimp connectors. After crimping, the crimp connec‐

tor has to be shrink fitted using the hot air blower, 220 V/50 Hz -

VAS 1978/14- in order to prevent any ingress of moisture.

The hot air blower, 220 V/ 50 Hz, -VAS 1978/14- is included in

wiring harness repair set -VAS 1978- / wiring harness repair set

-VAS 1978A- / wiring harness repair set -VAS 1978B- .
Shrink fitting crimp connectors using hot air blower, 220 V/50 Hz

-VAS 1978/14-

⇒ page 98

⇒ page 100

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