Volkswagen Golf Variant / Jetta. Manual - part 483

 

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Volkswagen Golf Variant / Jetta. Manual - part 483

 

 

Upgrade Kit For VAS1978 -

VAS1978/50-

The Upgrade Kit For VAS1978 - VAS1978/50- is required in order

to bring the “old” Wiring Harness Repair Set - VAS1978- up to the

new standard of the Wiring Harness Repair Set - VAS1978A- .

The Upgrade Kit For VAS1978 - VAS1978/50- contains 4 assem‐

bly- and 10 release tools as well as the new Wiring Harness

Repair - Crimping Plier - Base Tool - VAS1978/1-2- for crimp

connectors with the Wiring Harness Repair - Crimping Head -

0.35-2.5 mm/2 - VAS1978/1-1- , Wiring Harness Repair Set -

Crimping Head - 4-6 mm/2 - VAS1978/2A- and the Wiring

Harness Repair Set - Crimping Head - JPT - VAS1978/9-1- . Fur‐

thermore it contains new stickers, a new set of user instructions,

crimp connections for 0.35 mm

2

-wire cross sections and a roll of

black felt adhesive tape.
Upgrade Kit For VAS1978 - VAS1978/50-

2.1.3

Wiring Harness Repair Set -

VAS1978A-

The new Wiring Harness Repair Set - VAS1978A- makes optimal

repair quality possible in the realm of vehicle electronics. Using

the new pliers, repairs affecting harness connectors and for

breaks in wiring can be performed. For this purpose, complete

repair wires with terminals already crimped on are used and can

be connected to vehicle-specific wiring harness by the use of the

4 different types of crimp connections. A new Wiring Harness Re‐

pair - Crimping Plier - Base Tool - VAS1978/1-2- with exchange‐

able Wiring Harness Repair - Crimping Head - .35-2.5mm -

VAS1978/1-1- or Wiring Harness Repair Set - Crimping Head -

4-6mm - VAS1978/2A- and a Wiring Harness Repair Set - Hot Air

Blower - VAS1978/14A- for shrinking the crimp connectors pro‐

vide a trouble-free electrical connection.
Wiring Harness Repair Set - VAS1978 A-
Additional information:
♦ Refer to Wiring Harness Repair Set - VAS1978A- Operating

Instructions.

The Wiring Harness Repair Set - VAS1978A- was replaced by the

Wiring Harness Repair Set - VAS1978B- .

2.1.4

Release Tool Set - VAS1978/35-

The Release Tool Set - VAS1978/35- is used to release the var‐

ious primary and secondary locking mechanisms on VW-group

vehicles. The set consists of 26 different tools with which round

connector systems, flat terminals with one or two locks as well as

single wire seals can be professionally released and assembled.
Release Tool Set - VAS1978/35-
The allocation of the correct release tools to the respective locking

mechanisms can be found in the table in Release Tool Set -

VAS1978/35- Operating Instructions.

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92

Crimping Pliers with Insert

The Crimping Pliers - VAS1978/1- , with the Crimping Pliers - In‐

sert 2 - VAS1978/2- , is a component of the Wiring Harness Repair

Set - VAS1978- / Wiring Harness Repair Set - VAS1978A- / Wiring

Harness Repair Set - VAS1978B- and is used to crimp the crimp

connectors during the wiring harness repair.

Color of crimp

connectors

Color of crimping

slot

Wire cross-section

yellow

yellow

             0.35 mm

2

Red

Red

0.5 mm

2

 through

1.0 mm

2

Blue

Blue

1.5 mm

2

 through

2.5 mm

2

yellow

yellow

4.0 mm

2

 through

6.0 mm

2

Note

The Wiring Harness Repair - Crimping Plier - Base Tool -

VAS1978/1-2- can also be used together with the Wiring Har‐

ness Repair - Crimping Head - .35-2.5mm - VAS1978/1-1- or

Wiring Harness Repair Set - Crimping Head - 4-6mm -

VAS1978/2A- to crimp the connections as an alternative.

Always be sure to use the correct crimping slot for the crimp

connector used.

Do not crimp wire insulation.

2.1.6

Contact Release Tools

Various release tools are used to remove the different terminals

from the connector housing without damage.
A selection of release tools is a component of the Wiring Harness

Repair Set - VAS1978- / Wiring Harness Repair Set -

VAS1978A- / Wiring Harness Repair Set - VAS1978B- . The

Release Tool Set - VAS1978/35- contains the entire set of release

tools.

WARNING

Some tools are supplied with a tool safety clip, which is slid

over the tool points after using the tool, in order to protect other

workers from injuries and tool points from damage.

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2. Connectors    

93

Single Wire Seal Assembly Tools

Assembly tools serve the purpose of allowing the single wire seals

to be slid without damage into the connector housing up to stop,

this achieves a complete seal between a single wire and connec‐

tor housing.
Four assembly tools for single wire seals are components of the

Wiring Harness Repair Set - VAS1978- / Wiring Harness Repair

Set - VAS1978A- / Wiring Harness Repair Set - VAS1978B- .

2.1.8

Wiring Harness Repair Set - Wire Strip‐

pers - VAS1978/3-

The Wiring Harness Repair Set - Wire Strippers - VAS1978/3- is

used for professional stripping and cutting of wires.
The Wiring Harness Repair Set - Wire Strippers - VAS1978/3- are

a component of the Wiring Harness Repair Set - VAS1978- / Wir‐

ing Harness Repair Set - VAS1978A- / Wiring Harness Repair Set

- VAS1978B- .
The Wiring Harness Repair Set - Wire Strippers - VAS1978/3-

have an adjustable stop in its pliers-jaws which can be set to the

desired length of wire insulation to be removed.
Stripping
– Set the slideable stop in pliers-jaws to the desired length di‐

mension to be stripped.

– Insert the wire end from the front up to the stop into the jaws

of pliers and squeeze the Wiring Harness Repair Set - Wire

Strippers - VAS1978/3- together completely.

– Reopen the Wiring Harness Repair Set - Wire Strippers -

VAS1978/3- and remove the stripped wire end.

– Cut the wires using the side-cutter function on the top of the

Wiring Harness Repair Set - Wire Strippers - VAS1978/3- .

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94

Wiring Harness Repair Set - Hot Air

Blower - VAS1978/14A-

Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A-

Caution

When heat-shrinking crimp connections, be careful not to dam‐

age any other wiring, plastic parts or insulating material with

the hot nozzle of the Wiring Harness Repair Set - Hot Air Blow‐

er - VAS1978/14A- .
Always follow the Wiring Harness Repair Set - Hot Air Blower

- VAS1978/14A- Operating Instructions!

The Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A-

is used together with the Wiring Harness Repair - Blower - Shrink

Element - VAS1978/15A- to heat-shrink the crimp connectors.

After crimping, the crimp connectors must be heat-shrunk using

the Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A-

to prevent moisture penetration.
The Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A-

is a component of the Wiring Harness Repair Set - VAS1978- /

Wiring Harness Repair Set - VAS1978A- / Wiring Harness Repair

Set - VAS1978B- .

2.1.10

Crimping Pliers - .35-2.5mm -

VAS1978/1A-

The Crimping Pliers - .35-2.5mm - VAS1978/1A- or the Wiring

Harness Repair - Crimping Plier - Base Tool - VAS1978/1-2- to‐

gether with the Wiring Harness Repair - Crimping Head - .

35-2.5mm - VAS1978/1-1- and the Wiring Harness Repair Set -

Crimping Head - 4-6mm - VAS1978/2A- from the wiring harness

repair set is used to compress the crimp connectors.
Crimp connectors, press using the Crimping Pliers - .35-2.5mm -

VAS1978/1A- .
The following crimping heads are available for the Wiring Harness

Repair - Crimping Plier - Base Tool - VAS1978/1-2- :
♦ Wiring Harness Repair - Crimping Head - .35-2.5mm -

VAS1978/1-1-

♦ Wiring Harness Repair Set - Crimping Head - 4-6mm -

VAS1978/2 A-

♦ Wiring Harness Repair Set - Crimping Head - JPT -

VAS1978/9-1-

In conjunction with Wiring Harness Repair Set - Crimping Head -

JPT - VAS1978/9-1- , crimping pliers are used to crimp terminals

onto individual wires when repairing wiring cross-sections up to

0.35 mm

2

 .

Changing Exchangeable Head
– Completely open the Wiring Harness Repair - Crimping Plier

- Base Tool - VAS1978/1-2- .

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2. Connectors    

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