Volkswagen Golf Variant / Jetta. Manual - part 488

 

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Volkswagen Golf Variant / Jetta. Manual - part 488

 

 

connector housing again.
Contacts without Retaining Tabs

– Insert release tool under retaining tab of the connector hous‐

ing.

– Push release tool through until it stops by gently lifting

-arrow-.

Contact is ejected from the connector housing.

3.2

Connector Housings and Connectors,

Repairing

⇒ “3.2.1 Connector Housings and Connectors, Repair Informa‐

tion”, page 112
⇒ “3.2.2 Contacts in Connector Housing, Repairing”, page 113
⇒ “3.2.3 Single Wire Seals, Installing”, page 114
⇒ “3.2.4 Connector Housing with Insulation Displacement Con‐

nections, Repairing”, page 116

3.2.1

Connector Housings and Connectors,

Repair Information

♦ Observe general notes for repairs on the vehicle electrical

system.

♦ Allocation of crimp contacts with correct fit to connector hous‐

ing is performed according to the part number stamped in on

the connector housing. Part numbers of connector housing are

listed in conjunction with the respective crimp contacts with

correct fit in plate 198 (electrical connecting elements) in the

Parts Catalog.

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

112

parts distributor.

3.2.2

Contacts in Connector Housing, Repair‐

ing

Procedure
– First open or release the secondary lock of the connector

housing.

– Release the contact (primary lock) using the appropriate re‐

lease tool.

– Pull contact at single wire out of the connector housing.
– Take the yellow repair wire with the correct contact out of the

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

pair Set - VAS1978A- / Wiring Harness Repair Set -

VAS1978B- .

– Free up repair point of vehicle-specific wiring harness (ap‐

proximately 20 cm to both sides of repair point).

– Remove wiring harness wrapping using a folding knife.

– Insert new contact of repair wire into connector housing until

it engages.

– Slide a single wire seal onto the repair wire.

Note

When doing this, the small diameter of the single seal must point

toward the connector housing.

– Slide the single wire seal into the connector housing using the

correct assembly tool. Refer to

⇒ “3.2.3 Single Wire Seals, Installing”, page 114

 .

– Shorten the repair wire and the vehicle-specific wiring harness

single wire using the Wiring Harness Repair Set - Wire Strip‐

pers - VAS1978/3- .

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

3. Connector Housings, Releasing and Disassembling    

113

wire 6 to 7 mm using the Wiring Harness Repair Set - Wire

Strippers - VAS1978/3- .

– Crimp the stripped ends of the repair wire and single wire of

vehicle-specific wiring harness using the Crimping Pliers - .

35-2.5mm - VAS1978/1A- and a crimp connector as described

in chapter “Open circuit with single repair point”.

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.

3.2.3

Single Wire Seals, Installing

Note

Single wire seals prevent the penetration of water and dirt into

the connector housing. They are installed in the engine com‐

partment and must be reinstalled after a repair.

Single wire seal is crimped on at the factory together with con‐

tact on the wire, this is not the case for repair wires. Single wire

seal must be slid onto wire first before crimping the repair wire.

Single wire seals must always fit with the repair wire cross-

section. Outer circumference of single wire seal is aligned

according to chamber circumference of the connector hous‐

ing. Perform assembly using only the assembly tool with cor‐

rect fit.

Assembling Single Wire Seal
– Release the contact lock using the appropriate release tool

-A- and then pull wire with single wire seal toward the rear

-arrow- out of the connector housing.

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114

specific wiring harness.

– Slide repair wire with the new contact into the corresponding

chamber of connector housing until it engages -arrow-.

– Put single wire seal -A- onto the free end of the repair wire.

Note

When doing this, the small diameter of the single wire seal must

point toward the connector housing.

– Slide single wire seal -A- on the repair wire up to the connector

housing -arrows-.

– Slide single wire seal -A- all the way into the connector housing

using the corresponding assembly tool -B-.

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

3. Connector Housings, Releasing and Disassembling    

115

 

 

 

 

 

 

 

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