Volkswagen Golf Variant / Jetta. Manual - part 625

 

  Index      Volkswagen     Volkswagen Golf Variant (2007), Jetta (2005) - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  623  624  625  626   ..

 

 

Volkswagen Golf Variant / Jetta. Manual - part 625

 

 

Note

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

face the contact to be crimped on.

– Open the crimping pliers (base tool) -VAS 1978/1-2- and insert

the end of the repair wire in the opening of the crimping pliers

(base tool) -VAS 1978/1-2- .

– Close the crimping pliers (base tool) -VAS 1978/1-2- com‐

pletely.

– Open the crimping pliers (base tool) -VAS 1978/1-2- and re‐

move the stripped wire end.

– Push the single wire seal towards the stripped wire end until it

is flush with the wiring insulation.

2. Repairs to wiring harnesses and connectors    

97

pliers (base tool) -VAS 1978/1-2- .

– Insert the stripped wire end with the positioned single wire seal

in the crimp contact until it comes into contact with the “wire

stop”.

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

crimping pliers (base tool) -VAS 1978/1-2- fully.

– Open the crimping pliers (base tool) -VAS 1978/1-2- again and

remove the successfully crimped contact.

Successful crimping can be identified by clean and equal appli‐

cation of pressure on the wire and single wire seal in the contact

and by a stamp on the rear that indicates the correct tool was used

in the correct manner to carry out the crimping process.

2.4.7

Wiring open circuit with one repair posi‐

tion

Repair position with single crimp connector
– Place the wire to be repaired to one side (about 20 cm either

side of the repair position).

– If necessary, unbind the wiring harness using the folding knife.

98

VAS 1978/3- .

Note

If, after the damaged wire has been cut out, both ends of the ve‐

hicle's own wiring are too short for a repair using single crimp

connectors, use a piece of repair wire of the appropriate length

with two crimp connectors 

⇒ page 100

 .

– Strip the wire ends of insulation by 6 to 7 mm using the wire

strippers -VAS 1978/3- .

– Push the crimp connector on both stripped wire ends of the

vehicle's own single wire and crimp it on using the crimping

pliers (base tool) -VAS 1978/1A- .

Note

Ensure without fail that the correct crimp recess is chosen for

the crimp connectors being used 

⇒ page 86

 .

The insulation on the wires must not be crimped.

After crimping, the crimp connector has to be shrink fitted using

the hot air blower, 220 V/50 Hz -VAS 1978/14- in order to prevent

any ingress of moisture.
– Place shrink element for hot air blower -VAS 1978/15- on hot

air blower, 220 V/50 Hz -VAS 1978/14- .

– Heat up the crimp connector using the hot air blower -VAS

1978/14- along a straight line, working from the middle out‐

wards, until it is sealed completely and the adhesive escapes

from the ends.

Caution

When shrink-fitting, take care not to damage any other wiring,

plastic parts or insulating material with the hot air blower, 220

V/50 Hz -VAS 1978/14- .
Observe ⇒  Operating instructions for hot air blower, 220 V/50

Hz -VAS 1978/14- .

2. Repairs to wiring harnesses and connectors    

99

Ensure that, where several wires have to be repaired, the

crimp connectors are not directly adjacent to each other. To

prevent the circumference of the wiring harness from becom‐

ing to great, position the crimp connectors so they are offset

slightly.

If the repair position was already wrapped, this section has to

be wrapped again with yellow insulation tape once the repair

has been carried out.

Attach the repaired wiring harness with a cable tie to prevent

it from generating noise when the vehicle is in motion.

2.4.8

Wiring open circuit with two repair posi‐

tions

Repair position with interlinked wire.
– Place the wire to be repaired to the side at two points (about

20 cm to both sides of the relevant repair position).

– Unbind the wiring harness using the folding knife.

– Place the yellow repair wire next to the damage wiring harness

and, using wire strippers -VAS 1978/3- , cut the repair wire to

the required length.

– Cut the damaged section of wire out of the vehicle's own single

wire.

– Strip the wire ends of insulation by 6 to 7 mm using the wire

strippers -VAS 1978/3- .

– Push the crimp connector onto one side of the vehicle's own

single wire and on the other side onto the repair wire.

100

 

 

 

 

 

 

 

Content   ..  623  624  625  626   ..