Volkswagen Golf Variant / Jetta. Manual - part 485

 

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Volkswagen Golf Variant / Jetta. Manual - part 485

 

 

may only be repaired using the Wiring Harness Repair Set -

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

Harness Repair Set - VAS1978B- .

♦ Pay attention to stickers on vehicle designating high voltage

components. When performing repairs, residual voltage must

Pyrotechnic Components Safety Precautions .

♦ A maximum of 2 repairs may be performed when repairing

wires of airbag- and seat belt tensioner system. Repairs in‐

crease the electrical resistance in the wire and may trigger

malfunctions in the system On Board Diagnostic (OBD).

♦ When repairing airbag or safety belt tensioner wiring, crimp

connectors must be shrunk to prevent corrosion.

♦ Wiring harness repairs may only be performed using yellow

wires.

♦ Do not wrap the repair point again into the vehicle-specific

wiring harness and mark the repair point very visibly with yel‐

low insulating tape.

♦ Repairs in the area of the airbag or seat belt tensioner should

be performed a maximum of 30 cm from the next connector

housing. Together with the identification via yellow insulating

tape, this procedure makes it possible to obtain a quick over‐

view of previously performed repairs.

♦ Wires to the deploying units (airbags) have a wire-twisting with

a length of lay of 20 mm ± 5 mm in series production. This

length of lay is guaranteed via the norm part numbers for wire

pairs in series production and must be observed strictly for the

repair lengths of twisted wires.

♦ During repair work, wires to deploying units (airbags) must

have the same length. When twisting together wires -1- and

-2-, length of lay of A = 20 mm ± 5 mm must be strictly ob‐

served.

♦ While doing this, no section of the wire also in area of crimp

connectors -arrow-, may be greater than B = 100 mm without

twisting of the wires.

2.3.3

CAN Bus Lines Repair Information

♦ Unshielded two-strand wiring -1- and -2- with a cross section

of 0.35 mm

2

 and/or 0.5 mm

2

 can be used as CAN bus wiring.

♦ The color coding of CAN bus lines can be found in the following

table:

Powertrain CAN high wire

Orange/black

Comfort CAN high wire

Orange/green

Infotainment CAN high wire

Orange/violet

CAN low wire (all)

Orange/brown

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with matching cross section, and also using twisted wires

“green/yellow” and “white/yellow” from the Parts Catalog.

♦ When repairing CAN bus lines, both wires must be same

length. When twisting together wires -1- and -2-, the lay length

of A = 20 mm must be observed.

♦ While doing this, no section of the wire also in area of crimp

connectors -arrow-, may be greater than B = 50 mm without

twisting of the wires.

♦ Wrap repair points with yellow adhesive tape to mark a per‐

formed repair.

2.3.4

Wires with Cross Section up to 0.35 mm

2

, Repairing

When repairing wires with a cross-section up to 0.35 mm

2

, new

contacts must always be crimped on using the Crimping Pliers -

JPT - VAS1978/9A- or the Wiring Harness Repair - Crimping Plier

- Base Tool - VAS1978/1-2- with the Wiring Harness Repair Set

- Crimping Head - JPT - VAS1978/9-1- installed. Due to the low

current strengths of these wires in the micro- to milli- range, con‐

tacts crimped on incorrectly lead to continuity resistances and

cause malfunctions or failure of the respective system. The most

frequent applications of these contacts are:
♦ Heated Oxygen Sensor
♦ RPM sensor
♦ Mass Airflow Sensor
By using the Crimping Pliers - JPT - VAS1978/9A- or the Wiring

Harness Repair - Crimping Plier - Base Tool - VAS1978/1-2- with

the Wiring Harness Repair Set - Crimping Head - JPT -

VAS1978/9-1- installed, the correct connection between crimp

contact, wire and single wire seal is guaranteed. The tool is to be

used only for the purpose described.

Note

Contacts in a normal and a gold-plated version are crimped onto

repair wires. The same version of the contact that was installed

at the factory must always be used for repairs.

Crimping A New Contact with Single Wire Seal
– Insert the Wiring Harness Repair Set - Crimping Head - JPT -

VAS1978/9-1- into the Wiring Harness Repair - Crimping Plier

- Base Tool - VAS1978/1-2- . Refer to

⇒ “2.1.10  Crimping Pliers - .35-2.5mm VAS1978/1A ”,

page 95

 .

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2. Connectors    

101

Note

When doing this, the smaller diameter of single wire seal must be

facing in the direction of the contact to be crimped on.

– Open the Wiring Harness Repair - Crimping Plier - Base Tool

- VAS1978/1-2- (green body) and insert the repair wire end

into the stripping slot of the Wiring Harness Repair - Crimping

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

– Close the Wiring Harness Repair - Crimping Plier - Base Tool

- VAS1978/1-2- completely.

– Reopen the Wiring Harness Repair - Crimping Plier - Base

Tool - VAS1978/1-2- and remove the stripped wire end.

– Slide single wire seal in direction of stripped wire end until it

rests flush with the wire insulation.

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

– Insert the stripped wire end with positioned single wire seal

into crimp contact until it makes contact on “Wire-Stop”.

– Crimp the contact, wire and single wire seal by completely

closing the Wiring Harness Repair - Crimping Plier - Base Tool

- VAS1978/1-2- .

– Reopen the Wiring Harness Repair - Crimping Plier - Base

Tool - VAS1978/1-2- and remove the finished crimped-on con‐

tact.

A correctly performed crimp is distinguished by a clean compres‐

sion of wire and single wire seal in the contact and has an

impression on the rear side which identifies that the crimp was

performed by a professional using the correct tool.

2.3.5

Wire Break with Single Repair Point

Repair Point with Single Crimp Connection
– Free up the wire to be repaired approximately 20 cm on both

sides of the repair point.

– If required, remove wiring harness wrapping using a folding

knife.

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2. Connectors    

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