Volkswagen Golf Variant / Jetta. Manual - part 489

 

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Volkswagen Golf Variant / Jetta. Manual - part 489

 

 

single wire as needed 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”.

3.2.4

Connector Housing with Insulation Dis‐

placement Connections, Repairing

Note

For technical reasons, the connector housing for the wire ter‐

minals can be supplied only with the contacts pushed in.

These contacts can be removed at every other connector

housing in the event they are not required.

Repair wires which have already been equipped with corre‐

sponding contacts crimped on are available. Refer to the Parts

Catalog.

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116

Contact Surfaces, Cleaning

⇒ “4.1  Contact Surface Cleaning Set VAS6410 ”, page 117

4.1

Contact Surface Cleaning Set -

VAS6410-

⇒ “4.1.1 Using Contact Surface Cleaning Set VAS6410 ”,

page 117
⇒ “4.1.2 Wiring Eyelets, Repairing”, page 117
⇒ “4.1.3 Threaded Connections, Repairing”, page 119
⇒ “4.1.4 Battery Clamps and Battery Terminals, Cleaning”,

page 120
⇒ “4.1.5 Protecting”, page 121

4.1.1

Using Contact Surface Cleaning Set -

VAS6410-

The Contact Surface Cleaning Set - VAS6410- makes optimal

repair quality possible in the realm of vehicle electronics. Using

the tools, service work can be performed in the area of the contact

sensor on the threaded connection wiring harnesses in the high

current circuit (starter and charging current). The Contact Surface

Cleaning Set - VAS6410- is adapted to the vehicle structural

measurements and ensures correct servicing and a comfortable

procedure.

Note

The illustrations of the service work only serve as examples.

Contact Surface Cleaning Set - VAS6410-

4.1.2

Wiring Eyelets, Repairing

Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-

Note

Do not use rust remover, contact spray or grease because the

lack of friction will cause the torque to be exceeded when in‐

stalling and this will lead to the threaded connection breaking.

The gray sanding pads are for slight contamination and suit‐

able for "soft surfaces". The red sanding pads are for heavy

contamination and suitable for "hard surfaces".

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

4. Contact Surfaces, Cleaning    

117

Risk of injury. Follow all warning messages and safety pre‐

cautions. 

Refer 

to

⇒ “1.3 Warnings and Safety Precautions”, page 3

 .

Procedure
– Disconnect the Battery - A- . Refer to ⇒  Electrical Equipment;

Rep. Gr.  27 ; Battery; Battery, Disconnecting and Connecting .

– Loosen the cap nut and remove the wiring eyelet from the

threaded connection.

– Check the wiring eyelet for corrosion and dirt.
– Select the corresponding adapter and the corresponding

sanding pad.

Note

The sanding block can be used instead.

Caution

Make sure the tin layer is not worn down too much and the

copper is not visible. A galvanic element can form from this,

destroying the metal and causing incorrect repairs.

Note

Due to the different thicknesses of the tin layer, the cleaning proc‐

ess must be performed in several steps and a visual inspection

of the wiring eyelet between steps is necessary.

– Insert the adapter in the wiring eyelet and sand off the corro‐

sion and contamination with circular motions.

– Check the wiring eyelet and sand it again.

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118

tion. Refer to ⇒  Electrical Equipment; Rep. Gr.  97 ; Compo‐

nent Location Overview - Relay Carriers, Fuse Panels and E-

Boxes or ⇒  Electrical Equipment; Rep. Gr.  27 ; Overview -

Battery .

– Protect the connection with the corresponding protection ma‐

terial. Refer to 

⇒ “4.1.5 Protecting”, page 121

 .

– Connect the Battery - A- . Refer to ⇒  Electrical Equipment;

Rep. Gr.  27 ; Battery; Battery, Disconnecting and Connecting .

WARNING

Risk of injury. Follow all warning messages and safety pre‐

cautions. 

Refer 

to

⇒ “1.3 Warnings and Safety Precautions”, page 3

 .

4.1.3

Threaded Connections, Repairing

Special tools and workshop equipment required
♦ Torque Wrench 1331 5-50Nm - VAG1331-

Note

Do not use rust remover, contact spray or grease because the

lack of friction will cause the torque to be exceeded when in‐

stalling and this will lead to the threaded connection breaking.

The gray sanding pads are for slight contamination and suit‐

able for "soft surfaces". The red sanding pads are for heavy

contamination and suitable for "hard surfaces".

WARNING

Risk of injury. Follow all warning messages and safety pre‐

cautions. 

Refer 

to

⇒ “1.3 Warnings and Safety Precautions”, page 3

 .

Procedure
– Disconnect the Battery - A- . Refer to ⇒  Electrical Equipment;

Rep. Gr.  27 ; Battery; Battery, Disconnecting and Connecting .

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

4. Contact Surfaces, Cleaning    

119

 

 

 

 

 

 

 

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