Volkswagen Golf Variant / Jetta. Manual - part 484

 

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Volkswagen Golf Variant / Jetta. Manual - part 484

 

 

Repair - Crimping Plier - Base Tool - VAS1978/1-2- .

– Insert the required exchangeable head into the Wiring Har‐

ness Repair - Crimping Plier - Base Tool - VAS1978/1-2- from

above -arrow-.

– Lock the exchangeable head by pressing the pins -arrows- into

the Wiring Harness Repair - Crimping Plier - Base Tool -

VAS1978/1-2- .

2.2

Vehicle Electrical System, General Re‐

pair Information

Caution

When disconnecting and connecting the Battery - A- , the pro‐

cedure must be followed as described in the repair manual.

Disconnecting and Connecting .

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.

♦ When performing repairs, always heed any notes, cautions

and warnings found in the applicable repair manual.

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96

system. Refer to ⇒  Electrical Equipment; Rep. Gr.  27 ; Bat‐

tery; Battery, Disconnecting and Connecting . By disconnect‐

ing the Battery - a- (current disruption), the electrical system

is guaranteed to be safe to work on. Disconnecting the positive

battery cable is only required when removing the Battery - A- .

♦ Before beginning repair work, always eliminate any cause of

damage (sharp body edges, faulty electrical components, cor‐

rosion).

♦ Further information, for example, installing and removing the

individual components, can be found in the appropriate repair

manual.

♦ Soldering is not permissible for repairs to the vehicle electrical

system.

♦ Wiring harness and connector repairs to vehicle electrical sys‐

tem may only be performed using the Wiring Harness Repair

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

Wiring Harness Repair Set - VAS1978B- .

♦ Wiring harness repairs are only to be done using yellow wires.
♦ Wiring harness repairs may not be performed again in the

wrapping of the vehicle-specific wiring harness and are to be

marked with yellow adhesive tape.

♦ These yellow wires and every location on wiring harness wrap‐

ped in yellow insulating tape indicates a previous repair.

♦ Crimp connections must never be repaired. Route a wire par‐

allel to the faulty wire.

♦ After crimping, the crimp connectors must be heat-shrunk us‐

ing the Wiring Harness Repair Set - Hot Air Blower -

VAS1978/14A- to prevent moisture penetration.

♦ Always observe the supplementary notes also for repairing

wiring harnesses on airbag-system and belt tensioners, fiber

optic cables, CAN-Bus wires, antenna wires and wires with

cross-sections up to 0.35 mm 

2

. Refer to

⇒ “2.3.4 Wires with Cross Section up to 0.35 mm 2, Repairing”,

page 101

 .

♦ A function test must be performed after every repair. If nec‐

essary, check DTC memory, erase and/or bring systems into

basic setting.

♦ If possible, do not loosen ground (GND) straps from body

(danger of corrosion).

♦ Not all wire cross-sections in the vehicle are contained in the

Wiring Harness Repair Set - VAS1978B- and its previous ver‐

sions. If the required wire cross-section is not present, the next

greater cross-section must be used.

♦ Shielded harnesses may not be repaired. If faulty, the entire

harness must be replaced.

♦ Heat-resistant wires have been installed in the vehicle at var‐

ious locations, mainly in the engine compartment. Heat-resist‐

ant wires can be recognized by their somewhat duller and

softer insulation. Only heat-resistant wires may be used to re‐

pair these wires.

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2. Connectors    

97

Wiring Harnesses, Repairing

⇒ “2.3.1 Wiring Harnesses, Repair Information”, page 98
⇒ “2.3.2 Airbag and Belt Tensioner Wire Repair Information”,

page 98
⇒ “2.3.3 CAN Bus Lines Repair Information”, page 100
⇒ “2.3.4 Wires with Cross Section up to 0.35 mm 2, Repairing”,

page 101
⇒ “2.3.5 Wire Break with Single Repair Point”, page 103
⇒ “2.3.6 Wire Break with Dual Repair Point”, page 105

2.3.1

Wiring Harnesses, Repair Information

♦ Observe general notes for repairs on the vehicle electrical

system. Refer to

⇒ “2.2 Vehicle Electrical System, General Repair Information”,

page 96

 .

♦ Not all wire cross-sections in the vehicle are contained in the

Wiring Harness Repair Set - VAS1978- / Wiring Harness Re‐

pair Set - VAS1978A- . If the required wire cross-section is not

present, the next greater cross-section must be used.

♦ Wiring harness and connector repairs to vehicle electrical sys‐

tem must only be performed using the Wiring Harness Repair

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

♦ Soldering is not permissible for repairs to the vehicle electrical

system.

♦ Wiring harness repairs are only to be done using yellow wires.
♦ Wiring harness repairs may not be performed again in the

wrapping of the vehicle-specific wiring harness and are to be

marked with yellow adhesive tape.

♦ These yellow wires and every location on wiring harness wrap‐

ped in yellow insulating tape indicates a previous repair.

♦ Crimp connections must never be repaired. Route a wire par‐

allel to the faulty wire.

♦ After crimping, the crimp connectors must be heat-shrunk us‐

ing the Wiring Harness Repair Set - Hot Air Blower -

VAS1978/14A- to prevent moisture penetration.

♦ Shielded harnesses may not be repaired. If faulty, the entire

harness must be replaced.

♦ Heat-resistant wires have been installed in the vehicle at var‐

ious locations, mainly in the engine compartment. Heat-resist‐

ant wires can be recognized by their somewhat duller and

softer insulation. Only heat-resistant wires may be used to re‐

pair these wires.

♦ Always observe also the supplementary notes for repairing

wiring harnesses on airbag- and seat belt tensioner systems,

fiber optic cables, CAN bus lines, antenna wires and wires with

cross-sections up to 0.35 mm 

2

.

2.3.2

Airbag and Belt Tensioner Wire Repair

Information

In addition to the general repairs on wiring harnesses, the follow‐

ing methods and instructions must be observed for repairs on

wiring harnesses for airbag systems and belt tensioners:

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98

♦ The airbag system and belt tensioner can fail.
♦ Faulty repairs performed on airbag and seat belt tensioner

system can lead to malfunction in passenger protection.

♦ When performing repairs on airbag and seat belt tensioner

wiring harness, use only terminals, connectors and wires

designated for it. Refer to the Parts Catalog.

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2. Connectors    

99

 

 

 

 

 

 

 

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