Volkswagen Golf Variant / Jetta. Manual - part 626

 

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Volkswagen Golf Variant / Jetta. Manual - part 626

 

 

to both wire ends.

– Repeat this procedure on the other end of the repair wire.

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- .

Note

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.

2.5

Repairs to contact housings and con‐

nectors

2.5.1

Notes on repairs to contact housings

and connectors

♦ Observe the general notes on repairs to the vehicle electrical

system 

⇒ page 90

 .

♦ Allocation of the appropriate crimp contacts to the contact

housings is by way of the part number stamped on the contact

housing. Listed in illustration 198 (electrical connecting ele‐

ments) in ⇒  Electronic parts catalogue “(ETKA)” are the part

2. Repairs to wiring harnesses and connectors    

101

sociated crimp contacts.

♦ Damaged contact housings must always be replaced.
♦ New contact housings can be ordered from the OTC in Kassel.

2.5.2

Repairs to contacts in contact housings

Carry out following procedures:
– First, open or disengage the secondary locking mechanism of

the contact housing 

⇒ page 105

 .

– Disengage the contact (primary locking mechanism) using the

appropriate release tool 

⇒ page 105

 .

– Pull the contact by the single wire out of the contact housing.
– Select the yellow repair wire with the correct contact from the

wiring harness repair set -VAS 1978- / wiring harness repair

set -VAS 1978A- / wiring harness repair set -VAS 1978 B- .

– Place the wire to be repaired from the vehicle's own wiring

harness to one side (about 20 cm either side of the repair po‐

sition).

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

– Push the new contact of the repair wire into the contact hous‐

ing until it engages.

– Slide the single wire seal onto the repair wire.

Note

The small diameter of the single wire seal must face the contact

housing.

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

correct assembly tool 

⇒ page 103

 .

– Trim the repair wire and the single wire of the vehicle's own

wiring harness accordingly using wire strippers -VAS 1978/3- .

102

and the vehicle's own single wire using the wire strippers -VAS

1978/3- .

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

the vehicle's own wiring harness using the crimping pliers -

VAS 1978/1A- and a crimp connector, as described in the

chapter entitled “Wiring open circuit with one repair position”

⇒ page 98

 .

Note

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.

2.5.3

Fitting single wire seals

Note

Single wire seals prevent the ingress of moisture and dirt in

the contact housing. They are installed in the engine compart‐

ment and must always be reinstalled following repairs.

As standard, the single wire seal is crimped together with the

contact on the wire; this is not the case with the repair wires.

Before crimping the repair line, the single wire seal must there‐

fore first be pushed onto the wire.

It is essential that the single wire seals are of the correct size

to fit the cross section of the repair wire. The outer diameter

of the single wire seal is based on the socket diameter of the

contact housing. Only carry out the repair using the correct

assembly tool.

Installing the single wire seal
– Disengage the contact locking mechanism using the appro‐

priate release tool -A- and then pull the wire with the single

wire seal backwards -arrow- out of the contact housing.

2. Repairs to wiring harnesses and connectors    

103

cle's own wiring harness.

– Slide the repair wire with the new contact in the respective

socket of the contact housing until it engages -arrow-.

– Place the single wire seal -A- on the free end of the repair wire.

Note

The small diameter of the single wire seal must face the contact

housing.

– Slide the single wire seal -A- on the repair wire until it reaches

the contact housing -arrow-.

– Slide the single wire seal -A- using the respective assembly

tool -B- fully into the contact housing.

104

 

 

 

 

 

 

 

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