Volkswagen Golf Variant / Jetta. Manual - part 486

 

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Volkswagen Golf Variant / Jetta. Manual - part 486

 

 

Repair Set - Wire Strippers - VAS1978/3- .

Note

If, by cutting out the damaged wire section, both ends of the ve‐

hicle-specific single wire are too short for a repair using a single

crimp connector, insert a repair wire section of matching length

with two crimp connectors. Refer to

⇒ “2.3.6 Wire Break with Dual Repair Point”, page 105

 .

– Strip the wire ends 6 to 7 mm using the Wiring Harness Repair

Set - Wire Strippers - VAS1978/3- .

– Slide the crimp connector onto both stripped wire ends of the

vehicle-specific single wire and crimp them using the Crimping

Pliers - .35-2.5mm - VAS1978/1A- .

Note

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

connection used.

Do not crimp wire insulation.

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

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

to prevent moisture penetration.
– Place the Wiring Harness Repair - Blower - Shrink Element -

VAS1978/15A- on the Wiring Harness Repair Set - Hot Air

Blower - VAS1978/14A- .

– Heat the crimp connector using the Wiring Harness Repair Set

- Hot Air Blower - VAS1978/14A- lengthwise from the center

outward until it is sealed completely and the adhesive comes

out at the ends.

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!

Beetle 2012 ➤ , Golf 2015 ➤ , Golf Variant 2007 ➤ , Golf Variant 2010 ➤ ...

104

Make sure that crimp connections do not lie directly next to

each other when several wires need to be repaired. Arrange

the crimp connectors at a slight offset so that the circumfer‐

ence of the wiring harness does not become too large.

In the event the repair point was previous taped, this point

must be taped anew with yellow insulating tape after repairs.

Secure the repaired wiring harness with a cable tie to prevent

flapping noises while driving.

2.3.6

Wire Break with Dual Repair Point

Repair Point with Intermediate Wire Section
– Free up the wire to be repaired at two places (approximately

20 cm on both sides of the respective repair point).

– Remove wiring harness wrapping using a folding knife.

– Place the yellow repair wire next to the damaged wiring har‐

ness and cut the repair wire to the required length using the

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

– Cut damaged wire section from the vehicle-specific single

wire.

– Strip the wire ends 6 to 7 mm using the Wiring Harness Repair

Set - Wire Strippers - VAS1978/3- .

– Slide crimp connection onto vehicle-specific single wire at one

side and onto repair wire at the other side.

Beetle 2012 ➤ , Golf 2015 ➤ , Golf Variant 2007 ➤ , Golf Variant 2010 ➤ ...

2. Connectors    

105

ing Pliers - .35-2.5mm - VAS1978/1A- .

– Repeat this procedure at the other repair wire end.

Note

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

connection used.

Do not crimp wire insulation.

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

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

to prevent moisture penetration.
– Place the Wiring Harness Repair - Blower - Shrink Element -

VAS1978/15A- on the Wiring Harness Repair Set - Hot Air

Blower - VAS1978/14A- .

– Heat the crimp connector using the Wiring Harness Repair Set

- Hot Air Blower - VAS1978/14A- lengthwise from the center

outward until it is sealed completely and the adhesive comes

out at the ends.

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!

Note

Make sure that crimp connections do not lie directly next to

each other when several wires need to be repaired. Arrange

the crimp connectors at a slight offset so that the circumfer‐

ence of the wiring harness does not become too large.

In the event the repair point was previous taped, this point

must be taped anew with yellow insulating tape after repairs.

Secure the repaired wiring harness with a cable tie to prevent

flapping noises while driving.

Beetle 2012 ➤ , Golf 2015 ➤ , Golf Variant 2007 ➤ , Golf Variant 2010 ➤ ...

106

Connector Housings, Releasing and

Disassembling

⇒ “3.1 Connector Housings, Releasing and Disassembling”, page

107
⇒ “3.2 Connector Housings and Connectors, Repairing”,

page 112

3.1

Connector Housings, Releasing and

Disassembling

⇒ “3.1.1 Information on Releasing and Disassembling Connector

Housings”, page 107
⇒ “3.1.2 Secondary Lock”, page 107
⇒ “3.1.3 Primary Lock”, page 108
⇒ “3.1.4 Round Connector Systems”, page 109
⇒ “3.1.5 Flat Connector Systems”, page 109
⇒ “3.1.6 Special Connector Systems”, page 111

3.1.1

Information on Releasing and Disas‐

sembling Connector Housings

♦ Observe general notes for repairs on the vehicle electrical

system.

♦ Always use the release tools intended for the releasing proc‐

ess. Under no circumstances may terminals be pulled force‐

fully out of connector housings.

♦ Damaged connector housings must be replaced. New con‐

nector housings may be ordered via the replacement parts

distributor.

♦ Small screwdrivers may be used as an aid to release the sec‐

ondary locks.

♦ The chamber/connector assignment is partially stamped on

the secondary lock or the rear side of the connector housing.

♦ Detailed information on component locations of harness con‐

nectors. Refer to ⇒ Wiring diagrams, Troubleshooting & Com‐

ponent locations.

The allocation of the correct release tools to the respective locking

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

VAS1978/35- Operating Instructions.

3.1.2

Secondary Lock

The secondary lock is a housing securing mechanism (second

locking mechanism) that secures all wires in one connector hous‐

ing. If a secondary lock is installed at a connector housing, it must

always be opened or removed using specified tool before releas‐

ing and pulling out individual crimp contacts.
Secondary lock is distinguished by a different color from the rest

of the connector housing. It simplifies recognizing the secondary

lock and clarifies its function.

Beetle 2012 ➤ , Golf 2015 ➤ , Golf Variant 2007 ➤ , Golf Variant 2010 ➤ ...

3. Connector Housings, Releasing and Disassembling    

107

 

 

 

 

 

 

 

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