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!

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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.

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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.

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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.

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3. Connector Housings, Releasing and Disassembling    

107