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1995-2010 Volkswagen Sharan VAN Wiring User Manual

MY CAR USER MANUAL

Wiring for Your Volkswagen Sharan VAN First Generation (1995-2010)

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Electrical System, General Information - Edition 07.2010  
97 – Wiring  
1
Vehicle diagnostic, testing and infor‐  
mation systems  
WARNING  
♦ During testing or measuring operations using a vehicle di‐  
agnostic information system, there is a risk of serious or  
even fatal injury!  
♦ If the vehicle diagnostic information system is lodged in  
the activity area of an airbag during a testing or measuring  
operation, a triggered airbag can result in serious or even  
fatal injury!  
♦ During testing and measuring operations, work with a per‐  
son who can operate the vehicle diagnostic and informa‐  
tion system from one of the back seats.  
lk  
Note  
♦ All the operations described, e.g. adaptation, coding, etc. can  
be performed using the vehicle diagnostic tester .  
♦ All work procedures can be found in „guided fault finding“ and  
„guided functions“ modes.  
♦ Additional information  
⇒ Self-study programme No. 202 ; Vehicle diagnostic, testing  
and information system VAS 5051  
⇒ Self-study programme No. 256 ; VAS 5052  
⇒ Self-study programme No. 294 ; Online connection of VAS  
5051  
– Connecting vehicle diagnostic tester ⇒ page 78  
1.1  
Connecting vehicle diagnostic tester  
Note  
Observe the latest operating instructions for vehicle diagnostic  
tester , which are displayed after selecting the „Administration“  
and „Operating Manual“ keys.  
Special tools and workshop equipment required  
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Electrical System, General Information - Edition 07.2010  
♦ Vehicle diagnostic tester  
♦ Diagnostic cable -VAS 5051/6A- (5 m)  
♦ Diagnostic cable -VAS 5051/5A- (3 m)  
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Note  
Only these cables are to be used for diagnosis, as they are the  
only ones fitted with CAN wiring and therefore allowing CAN di‐  
agnosis and/or CAN communication.  
Connecting vehicle diagnostic tester :  
– Apply handbrake.  
– Vehicles with automatic gearbox, move selector lever to posi‐  
tion „P“ or „N“.  
– Vehicles with manual gearbox, move gearstick to neutral po‐  
sition.  
– With ignition switched off, connect vehicle diagnostic tester  
using diagnostic cable -VAS 5051/6A- to diagnostic interface  
-arrow- in vehicle.  
– Switch on ignition.  
– Switch off all electrical consumers.  
Note  
All other and the following vehicle diagnostic, testing and infor‐  
mation systems or vehicle diagnostic and service information  
systems are connected accordingly in the sequence described  
above.  
1. Vehicle diagnostic, testing and information systems  
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Electrical System, General Information - Edition 07.2010  
1.2  
Connecting vehicle diagnostic tester  
Golf Model Year 1998 - 2003  
– Apply handbrake.  
– Vehicles with automatic gearbox, move selector lever to posi‐  
tion „P“ or „N“.  
– Vehicles with manual gearbox, move gear lever to neutral po‐  
sition.  
– Pull out trim -1- in direction of arrow.  
– With ignition switched off, connect vehicle diagnostic tester  
using diagnostic cable to diagnostic interface -arrow- in vehi‐  
cle.  
– Switch on ignition.  
– Switch off all electrical consumers.  
Note  
All other and the following vehicle diagnosis, testing and informa‐  
tion systems or vehicle diagnostic and service information sys‐  
tems are connected accordingly in the sequence described  
above.  
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2
Repairing wiring harnesses and con‐  
nectors  
2.1  
Wiring harness repair set  
2.1.1  
Wiring harness repair set -VAS 1978-  
Wiring harness repair set -VAS 1978- allows optimal repair quality  
lk  
to be achieved in the area of vehicle electrics. Using the tools,  
repairs to connectors and wiring open circuits can be carried out.  
To do this, complete repair wire sections with contacts already  
crimped on are used and joined to the vehicle's own wiring har‐  
ness with the aid of crimp connectors. A special set of pliers with  
three different crimp recesses and a hot air blower for shrinking  
the crimp connectors make a perfect electrical connection.  
Note  
Additional information:  
⇒ Operating instructions Wiring harness repair set -VAS 1978-  
2.1.2  
Upgrade kit -VAS 1978/50-  
Upgrade kit -VAS 1978/50- is required to bring the „old“ wiring  
harness repair set -VAS 1978- up to the latest standard of wiring  
harness repair set -VAS 1978A- . The upgrade kit comprises of 4  
assembly and 10 release tools, a new set of crimping pliers for  
2
crimp connectors with head adapter 0.35 - 2.5 mm -VAS  
2
1978/1-1- , 4.0 - 6.0 mm -VAS 1978/2 A- and head adapter for  
JPT contacts -VAS 1978/9-1- . Also included are new stickers, a  
new set of operating instructions, crimp connectors for 0.35  
2
mm cable cross-section and a roll of black felt adhesive tape.  
2.1.3  
Wiring harness repair set -VAS 1978A-  
The new wiring harness repair set -VAS 1978A- allows optimal  
repair quality to be achieved in the area of vehicle electrics. Using  
the new pliers, repairs to connectors and wiring open circuits can  
be carried out. To do this, complete repair wire sections with con‐  
tacts already crimped on are used and joined to the vehicle's own  
wiring harness with the aid of four different types of crimp con‐  
nectors. A new set of crimping pliers with head adapters and a  
hot air blower for shrinking the crimp connectors make a perfect  
electrical connection.  
Note  
Additional information:  
⇒ Operating instructions Wiring harness repair set -VAS 1978A-  
2. Repairing wiring harnesses and connectors  
81  
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2.1.4  
Release tool set -VAS 1978/35-  
Release tool set -VAS 1978/35- serves as a means of releasing  
various primary and secondary locking devices in Group vehicles.  
The set comprises of 26 different tools with which, for example,  
round connector systems, flat contacts with one or two fasteners  
and also single wire seals can be released or fitted.  
Allocation of the correct release tool to the respective locking de‐  
vices can be gleaned from the table in the ⇒ operating instruc‐  
tions of -VAS 1978/35- .  
2.2  
Tool descriptions  
2.2.1  
Special pliers with insert  
The special pliers without insert -VAS 1978/1- with insert for spe‐  
cial pliers -VAS 1978/2- is part of the wiring harness repair set -  
VAS 1978- and is used to crimp connectors during wiring harness  
repairs.  
Colour of crimp  
connector  
Colour of crimp re‐ Wiring cross section  
cess  
2
Yellow  
Red  
Blue  
Yellow.  
Red.  
Blue  
0.35 mm  
2
2
2
2
0.5 mm - 1.0 mm  
1.5 mm - 2.5 mm  
4.0 mm - 6.0 mm  
2
2
Yellow.  
Yellow.  
Note  
♦ As an alternative, the connectors can also be crimped with  
crimping pliers (base tool) -VAS 1978/1-2- in conjunction with  
head adapters -VAS 1978/1-1- or -VAS 1978/2A-  
⇒ page 84 .  
♦ Ensure without fail that the correct crimp recess is chosen for  
the crimp connectors being used.  
♦ The insulation on the wires must not be crimped.  
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2.2.2  
Release tools for contacts  
The various release tools serve as a means of detaching the dif‐  
ferent contacts from the contact housings without damage.  
A selection of release tools is included in wiring harness repair  
set -VAS 1978- and wiring harness repair set -VAS 1978A- . The  
complete set of release tools is included in release tool set -VAS  
1978/35- ⇒ page 82 .  
WARNING  
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Some tools are equipped with a tool safety device. This must  
be pushed over the tip of the tool after use in order to protect  
the tip and prevent personal injury.  
Releasing and dismantling contact housings ⇒ page 102 .  
2.2.3  
Assembly tools for single wire seals  
The assembly tools serve as a means of sliding the single wire  
seals fully into the contact housing without damage and thereby  
assure complete sealing between single wire and contact hous‐  
ing.  
Four assembly tools for single wire seals are included in each  
wiring harness repair set -VAS 1978 B- and previous versions.  
Assembling single wire seals ⇒ page 99 .  
2.2.4  
Wire strippers -VAS 1978/3-  
Wire strippers -VAS 1978/3- serve as a means of stripping insu‐  
lation off wires and cutting wires in the correct manner.  
Wire strippers -VAS 1978/3- are included in wiring harness repair  
set -VAS 1978 B- and previous versions.  
The wire strippers have an adjustable limit stop within the pliers  
jaws, with which the desired length of insulation to be removed  
can be adjusted.  
Stripping:  
– Adjust the sliding limit stop in the pliers jaws to the desired  
length of insulation to be removed.  
– Insert the end of the wire from the front fully into the pliers jaws  
and squeeze the pliers together completely.  
– Open the pliers and removed the stripped wire end.  
2. Repairing wiring harnesses and connectors  
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– Cut the wire if necessary with the cutting part on the upper side  
of the wire strippers.  
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2.2.5  
Hot air blower, 220 V / 50 Hz -VAS  
1978/14-  
Caution  
When shrink-fitting, take care not to damage any other wiring,  
plastic parts or insulating material with the hot air blower.  
Observe the operating instructions of the hot air blower without  
fail!  
The hot air blower, 220 V / 50 Hz -VAS 1978/14- is used in con‐  
junction with shrink element for hot air blower -VAS 1978/15- to  
shrink fit the crimp connectors. After crimping, the crimp connec‐  
tor has to be shrink fitted using the hot air blower in order to  
prevent any ingress of moisture.  
Hot air blower, 220 V/50 Hz -VAS 1978/14- is included in wiring  
harness repair set -VAS 1978 B- and previous versions.  
Shrink fitting crimp connectors using hot air blower, 220 V / 50 Hz  
-VAS 1978/14- ⇒ page 94 , or ⇒ page 96 .  
2.2.6  
Crimping pliers -VAS 1978/1A-  
Crimping pliers -VAS 1978/1A- or crimping pliers (base tool) -VAS  
1978/1-2- together with head adapter 0.35 - 2.5 mm² -VAS  
1978/1-1- or head adapter 4.0 - 6.0 mm² -VAS 1978/2A- are used  
to squeeze together crimp connectors from the wiring harness  
repair sets.  
Crimping connectors using crimping pliers -VAS 1978/1A-  
⇒ page 96 .  
The following heads adapters are available for crimping pliers  
(base tool) -VAS 1978/1-2- :  
2
2
♦
♦
Head adapter 0.35 mm - 2.5 mm -VAS 1978/1-1-  
2
2
Head adapter 4.0 mm - 6.0 mm -VAS 1978/2A-  
♦ Head adapter for JPT contacts -VAS 1978/9-1-  
In conjunction with head adapter for JPT contacts -VAS  
1978/9-1- , the crimping pliers are used to crimp contacts to single  
wires during repairs to wiring with cross sections up to 0.35  
2
mm ⇒ page 91 .  
Interchanging head adapter:  
– Open up the crimping pliers fully.  
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– Unclip both locking pins -arrows- from the body of the crimping  
pliers.  
– Insert the required head adapter from above -arrow- in the  
body of the crimping pliers.  
– Lock the head adapter by engaging the pins -arrows- in the  
body of the crimping pliers.  
2.3  
General notes concerning repairs to ve‐  
hicle electrical system  
Caution  
When batteries are disconnected and reconnected, the proce‐  
dure described in the workshop manual must be strictly ob‐  
served.  
WARNING  
Some tools are equipped with a tool safety device. This must  
be pushed over the tip of the tool after use in order to protect  
the tip and prevent personal injury.  
2. Repairing wiring harnesses and connectors  
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♦ Observe the latest notes in the respective workshop manual  
when carrying out repairs.  
♦ Observe country-specific regulations.  
♦ Always disconnect the battery earth strap before working on  
the electrical system. Disconnecting the battery earth strap  
(open circuit) provides a safe working environment for repairs  
to the electrical system. The battery positive wire need only be  
disconnected for removal of the battery.  
♦ Before starting a repair, it is important to identify and rectify  
the cause of damage (e.g. sharp edges on body panels, de‐  
fective electrical components, corrosion, etc.).  
♦ For additional information, e.g. removal and installation of in‐  
dividual components, please refer to the relevant workshop  
manual.  
♦ Soldering is not permitted for repairs to vehicle wiring.  
♦ Wiring harness and connector repairs to vehicle electrical sys‐  
tem should be carried out using wiring harness repair set -VAS  
1978 B- and previous versions only. Only use yellow wires  
from wiring harness repair set -VAS 1978 B- .  
♦ Wiring harness repairs may not be integrated in the vehicle's  
own wiring harness and must be marked with the use of yellow  
adhesive tape. This indicates a previous repair.  
♦ Crimp connectors may never be repaired. If necessary, lay  
wiring parallel to the defective wiring. After crimping, crimp  
connectors must to be shrink fitted using the hot air blower in  
order to prevent any ingress of moisture.  
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♦ It is essential that the supplementary information is observed  
regarding repairs to wiring harnesses in airbag and belt ten‐  
sioner systems, fibre optic cables, CAN bus lines, aerial cables  
2
and wiring with cross sections up to 0.35 mm ⇒ page 91 .  
♦ Carry out a function test after every repair. It may be necessary  
for the fault memory to be interrogated, erased and/or for the  
systems to be reset.  
♦ If possible, do not loosen any earth wires from the body (dan‐  
ger of corrosion).  
♦ Wiring harness repair set -VAS 1978 B- and previous versions  
do not cover all wiring cross sections that occur in the vehicle.  
If the required wiring cross section is not available, the next  
largest one should be used.  
♦ Screened wires must not be repaired. If damaged they must  
be replaced complete.  
♦ Heat resistant wiring can be found in various places in the ve‐  
hicle, mainly in the engine compartment. Heat resistant wiring  
can be identified by its slightly matt and softer insulation. To  
repair these wires, only heat resistant wiring may be used.  
2.4  
Repairs to wiring harnesses  
Note  
Observe the general notes on repairs to the vehicle electrical  
system ⇒ page 85 .  
Notes on repairs to airbag and belt tensioner wiring ⇒ page 88  
Notes on repairs to fibre optic cables ⇒ page 89  
2. Repairing wiring harnesses and connectors  
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Notes on repairs to CAN bus wiring ⇒ page 90  
Notes on replacement of aerial cables ⇒ page 90  
2
Notes on repairs to wiring with cross sections up to 0.35 mm  
⇒ page 91  
Notes on repair of wiring open circuit with one repair position  
⇒ page 94  
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Notes on repair of wiring open circuit with two repair positions  
⇒ page 96  
2.4.1  
Notes on repairs to airbag and belt ten‐  
sioner wiring  
In addition to the general notes on repairs to wiring harnesses,  
the following instructions must be observed on how to repair wir‐  
ing in airbag and belt tensioner systems:  
WARNING  
♦ Airbag and seat belt tensioner can fail.  
♦ Faulty repairs to the airbag and seat belt tensioning sys‐  
tem can cause malfunctions in the passenger protection  
system.  
♦ For repairs to airbag and belt tensioner wiring harnesses,  
only contacts, connectors and wiring designed specifically  
for this purpose may be used ⇒ Electronic parts catalogue  
(ETKA) .  
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Note  
♦ Wires from airbag and belt tensioner wiring harness are only  
allowed to be repaired using wiring harness repair set -VAS  
1978 B- and previous versions.  
♦ Observe the general notes on repairs to the vehicle electrical  
system ⇒ page 85 .  
♦ Observe vehicle stickers indicating high voltage components.  
Before carrying out repairs, discharge residual voltage ⇒  
General body repairs, interior; Rep. gr. 69 ; Occupant safety .  
♦ For repairs to wiring in the airbag and belt tensioner system,  
a maximum of two positions may be repaired. The more the  
repairs there are in the wiring, the greater the resistance and  
this can trigger faults in the self-diagnosis of the system.  
♦ To avoid corrosion, the crimp connectors are always to be  
shrink-fitted when performing airbag or belt tensioner wiring  
harness repairs.  
♦ Do not incorporate the repaired wiring back in the vehicle's  
own wiring harness and mark the area of repair clearly with  
yellow insulating tape.  
lk  
♦ Repairs in the area of the airbag or belt tensioner should not  
be more than 30 cm from the next contact housing. Together  
with the yellow insulating tape, this gives a clear indication of  
repairs that have already been carried out.  
♦ The wires to the triggering units (airbags) are entwined as  
standard with a twine spacing of 20 mm ± 5. This spacing is  
assured for series production via industrial standard numbers  
for wiring pairs and it is essential that it is adhered to on the  
repair lengths of entwined wiring.  
♦ During repairs, the wiring to the triggering units (airbags) must  
have the same length. When wires -1- and -2- are entwined,  
the twine spacing of A = 20 mm ± 5 must be adhered to without  
fail.  
♦ There must not be any section of wiring, for example in the  
vicinity of crimp connectors -arrow-, longer than B = 100 mm  
with the wires not twisted.  
2.4.2  
Fibre optic cables (FOC)  
There is no provision for fibre optic cable repairs at Volkswagen.  
In the event of repairs, the entire fibre optic wiring harness must  
be replaced. To do this, the following safety precautions must be  
observed:  
Note  
♦ Avoid sharp bends in the fibre optic cable; the bend radius  
should be no tighter than 25 mm.  
♦ Do not route fibre optic cables over sharp edges.  
♦ The end pieces (lenses) must not be made dirty or touched  
with bare hands.  
♦ Do not expose fibre optic cables to heat.  
♦ Entwining two fibre optic cables or a fibre optic cable with a  
copper wire is not permissible.  
2. Repairing wiring harnesses and connectors  
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2.4.3  
Repairs to CAN bus wiring  
♦ An unshielded two-wire line -1- and -2- with a cross section of  
2
2
0.35 mm or 0.5 mm is used for CAN bus wiring.  
♦ The colour codes of the CAN bus wiring can be gleaned from  
the following table:  
Powertrain CAN, high wire  
Convenience CAN, high wire  
Infotainment CAN, high  
CAN low wire, (all)  
Orange/black  
Orange/green  
Orange/violet  
Orange/brown  
♦ Repairs to CAN bus wiring can be carried out either with sec‐  
tions of repair wiring with the correct cross section or with  
entwined wires „green/yellow“ or „white/yellow“ from the elec‐  
tronic parts catalogue (ETKA) ⇒ Electronic parts catalogue  
(ETKA) .  
♦ When repairs are performed, both bus wires must have the  
same length. When twisting the wires -1- and -2- together, the  
length of each complete twist must be A = 20 mm.  
♦ There must not be any section of wiring, for example in the  
vicinity of crimp connectors -arrow-, longer than B = 50 mm  
with the wires not twisted.  
♦ Mark the area of repair with yellow insulation tape to make it  
easy to identify.  
2.4.4  
Renewal of aerial wiring  
A new repair concept has been developed for repair work on aer‐  
ial wires. Now connecting wires in different lengths and various  
adapter cables are available as replacement parts instead of a  
complete aerial wire.  
General description:  
♦ Aerial wires must not be repaired, but if repair is required, they  
must be replaced only by connecting wires and adapter cables  
offered as genuine parts.  
♦ Replacement parts can be found in the ⇒ Parts catalogue  
(ETKA): Special catalogue; Electrical connections; Genuine  
accessories; Subgroup 35 from illustration No. 035-20 .  
♦ These genuine parts are suitable for all aerial wires and wire  
diameters which may need to be replaced.  
♦ The connector housings for aerial wires are only available as  
genuine parts in one colour. However, they can be used for all  
colours of aerial connector.  
♦ No provision has been made for replacement of individual  
aerial connectors in the event of repair.  
♦ The wires can be used retroactively for all VW models, with all  
installed aerial wire diameters.  
♦ All adapter and connection wires are suitable for all transmitter  
and receiver signals.  
♦ This repair method can also be used for testing or retrofitting.  
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Assembly overview of aerial cable:  
Example: aerial wire between radio and aerial is defective. The  
following wires are required for the repair:  
1 - Adapter cable, to radio connection. Length approx. 30 cm.  
lk  
2 - Connecting wire, available in different lengths.  
3 - Adapter cable, to aerial connection. Length approx. 30 cm.  
Installing a new aerial cable:  
Note  
Note that the total length of an aerial wire, depending on vehicle  
equipment level, can be divided into sections by aerial diversity  
control unit, traffic information control unit or aerial amplifier. Only  
the defective section of aerial wire must be replaced.  
– Pull defective aerial wire connections off units.  
– Determine the routing of the defective aerial wire in vehicle  
and measure the total length of the aerial connecting wire to  
be replaced.  
The total length of aerial connecting wire is the sum of the length  
of adapter cables required -1- and -3- and the connecting wire  
-2-.  
– To determine the length of connecting wire required, subtract  
60 cm from the measured total length of aerial connecting wire  
-2-.  
– Procure the required adapter cables -1- and -3- and connect‐  
ing wire -2- at length calculated as genuine part from the  
Electronic parts catalogue (ETKA).  
– Cut off connectors of defective aerial wire.  
The remainder of the defective aerial wire remains in the vehicle.  
– Connect adapter cables -1- and -3- to equipment in vehicle.  
– Route and attach the connection line -2- in the immediate vi‐  
cinity of the factory routing.  
Note  
Do not kink or excessively bend aerial wires! The bending radius  
must not be below 50 mm.  
– Connect connecting wire to adapter cables.  
– Perform functional test.  
2.4.5  
Repairs to wiring with cross sections up  
to 0.35 mm2  
Special tools and workshop equipment required  
♦ Crimping pliers, complete -VAS 1978/1 A-  
2. Repairing wiring harnesses and connectors  
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♦ Head adapter 0.35 mm² - 2.5 mm² -VAS 1978/1-1-  
2
For repairs to wiring with cross sections up to 0.35 mm , it is es‐  
sential that contacts are crimped on using crimping pliers for JPT  
contacts -VAS 1978/9A- or crimping pliers (base tool) -VAS  
1978/1-2- with attached head adapter for JPT contacts -VAS  
1978/9-1- . Due to the low current strength of these wires in the  
micro and thousandths range, incorrectly crimped contacts cause  
electrical resistances and result in faults or failure in the respec‐  
tive system. The most common applications of these contacts are:  
♦ Lambda probe  
♦ Engine speed sender  
♦ Air mass meter  
With the use of crimping pliers for JPT contacts -VAS 1978/9A-  
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or crimping pliers (base tool) -VAS 1978/1-2- with attached head  
adapter for JPT contacts -VAS 1978/9-1- , the correct connection  
between crimp contact, wire and single wire seal is assured. The  
tool is only to be used for the application described.  
Note  
Crimped to the repair wiring are normal contacts and gold-plated  
contacts. The repair contact must always be the same type as the  
contact installed in the factory.  
Crimping on new contact with single wire seal  
– Insert head adapter for JPT contacts -VAS 1978/9-1- in crimp‐  
ing pliers (base tool) -VAS 1978/1-2- ⇒ page 84 .  
– Attach the single wire seal to the repair wire.  
Note  
When doing this, the small diameter of the single wire seal must  
face the contact to be crimped on.  
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– Open the crimping pliers and insert the end of the repair wire  
in the opening of the crimping pliers for wire stripping.  
– Close the crimping pliers fully.  
– Open the crimping pliers again and removed the stripped wire  
end.  
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– Push the single wire seal towards the stripped wire end until it  
is flush with the wiring insulation.  
– Insert the new crimp contact in the mounting of the crimping  
pliers.  
2. Repairing wiring harnesses and connectors  
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Electrical System, General Information - Edition 07.2010  
– 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 fully.  
– Open the crimping pliers 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  
lk  
in the correct manner to carry out the crimping process.  
2.4.6  
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.  
– Cut out the damaged piece of wiring using the wire strippers -  
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 96 .  
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– Strip the wire ends of insulation by 6 - 7 mm using the wire  
strippers.  
– Push the crimp connector on both stripped wire ends of the  
vehicle's own single wire and crimp it on using the crimping  
pliers.  
Note  
♦ Ensure without fail that the correct crimp recess is chosen for  
the crimp connectors being used ⇒ page 82 .  
♦ The insulation on the wires must not be crimped.  
After crimping, the crimp connector has to be shrink fitted using  
the hot air blower 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 along a  
straight line, working from the middle outwards, 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.  
Observe the operating instructions of the hot air blower without  
fail!  
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, if neces‐  
sary, to prevent it from generating noise when the vehicle is in  
motion.  
2. Repairing wiring harnesses and connectors  
95  
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2.4.7  
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).  
– If necessary, 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 - 7 mm using the wire  
strippers.  
– Push the crimp connector onto one side of the vehicle's own  
single wire and on the other side onto the repair wire.  
– Crimp the connector using the crimping pliers 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 82 .  
♦ The insulation on the wires must not be crimped.  
After crimping, the crimp connector has to be shrink fitted using  
the hot air blower 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- .  
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– Heat up the crimp connector using the hot air blower along a  
straight line, working from the middle outwards, 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.  
lk  
Observe the operating instructions of the hot air blower without  
fail!  
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, if neces‐  
sary, 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  
Note  
♦ Observe the general notes on repairs to the vehicle electrical  
system ⇒ page 85 .  
♦ 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  
numbers for the contact housings in conjunction with the as‐  
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  
– If necessary, first open or disengage the secondary locking  
mechanism of the contact housing ⇒ page 102 .  
2. Repairing wiring harnesses and connectors  
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– Disengage the contact (primary locking mechanism) using the  
appropriate release tool ⇒ page 102 .  
– 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 .  
– 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 99 .  
– Trim the repair wire and the single wire of the vehicle's own  
wiring harness accordingly using wire strippers -VAS 1978/3- .  
lk  
– Strip the 6 - 7 mm of insulation from the end of the repair wire  
and the vehicle's own single wire using the wire strippers.  
– Crimp the stripped ends of the repair wire and single wire of  
the vehicle's own wiring harness using the crimping pliers and  
a crimp connector, as described in the chapter entitled „Wiring  
open circuits with one repair position“ ⇒ page 94 .  
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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, if neces‐  
sary, 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, for example, in the  
lk  
engine compartment 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.  
Assembling 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. Repairing wiring harnesses and connectors  
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– Cut off the old contact with the single wire seal from the vehi‐  
cle's own wiring harness.  
– Slide the repair wire with the new contact in the respective  
socket of the contact housing until it engages.  
lk  
– 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.  
– Slide the single wire seal -A- using the respective assembly  
tool -B- fully into the contact housing.  
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– Trim the repair wire and the single wire of the vehicle's own  
wiring harness accordingly using 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 and  
a crimp connector, as described in the chapter entitled „Wiring  
open circuits with one repair position“ ⇒ page 94 .  
2.5.4  
Repairs to contact housings using cut  
and clamp technique  
Note  
♦ For technical reasons, the contact housings for cut and clamp  
lk  
technique can only be supplied with the cut and clamp con‐  
tacts inserted.  
♦ These contacts can be removed just like any other contact  
housing if they are not needed.  
♦ Repair wires can be supplied that already have the appropriate  
contacts crimped on ⇒ Electronics parts catalogue (ETKA) .  
2. Repairing wiring harnesses and connectors  
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2.6  
Releasing and dismantling contact  
housings  
lk  
2.6.1  
Notes on releasing and dismantling con‐  
tact housings  
Note  
♦ Observe the general notes on repairs to the vehicle electrical  
system ⇒ page 85 .  
♦ To release, always use the correct release tools. Under no  
circumstances should the contacts be pulled out of the contact  
housings with force.  
♦ Damaged contact housings must always be replaced. New  
contact housings can be ordered from the OTC in Kassel.  
♦ As an aid to disengage the secondary locking mechanisms, a  
small screwdriver can be used.  
♦ The socket/pin assignment can be found stamped on the sec‐  
ondary locking mechanism or on the rear of the contact hous‐  
ing.  
♦ For more detailed information about the locations of connec‐  
tors, see ⇒ Current flow diagrams, Electrical fault finding and  
Fitting locations.  
Allocation of the correct release tool to the respective locking de‐  
vices can be gleaned from the table in the ⇒ operating instruc‐  
tions of -VAS 1978/35- .  
2.6.2  
Secondary locking element  
The secondary locking mechanism is a housing catch (second  
line locking mechanism) that secures all the wires in one contact  
housing. If a secondary locking mechanism is fitted to a contact  
housing, this must always be opened or removed using the ap‐  
propriate tool before releasing and pulling out individual crimp  
contacts.  
The secondary locking mechanism is different in colour from the  
rest of the contact housing. This makes it easier to identify the  
secondary locking mechanism and clarifies its intended function.  
The types of contact housing shown here are just a few examples  
to show the different functions of secondary locking mechanism.  
Example 1:  
The housing catch is disengaged by removing a „toothed ele‐  
ment“ -arrow-.  
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Example 2:  
The housing catch is disengaged by opening a „flap“ -arrow-.  
Example 3:  
The housing catch can be disengaged by detaching a „slide“  
-arrow-.  
lk  
2.6.3  
Primary locking element  
The primary locking mechanism is what fixes an individual crimp  
contact in the contact housing.  
If necessary, any housing catches in place (secondary locking  
mechanisms) must be released or removed prior to disengaging  
the contacts using the prescribed tool ⇒ page 102 .  
The types of primary locking mechanisms shown as follows are  
just a few examples to show the different functions of primary  
locking mechanism.  
♦ Round connector systems ⇒ page 103  
♦ Flat connector systems ⇒ page 104  
♦ Special connector systems ⇒ page 106  
Allocation of the correct release tool to the respective locking de‐  
vice can be gleaned from the table in the ⇒ operating instructions  
of -VAS 1978/35- .  
2.6.4  
Round connector systems  
Note  
If necessary, any housing catches in place (secondary locking  
mechanisms) must be released or removed prior to disengaging  
the contacts using the prescribed tool ⇒ page 102 .  
2. Repairing wiring harnesses and connectors  
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– Insert the release tool appropriate for the contact housing in  
the release port of the contact housing.  
– Grab hold of the contact by the wire and push it lightly into the  
contact housing -arrow-.  
Note  
By pushing the contact in the direction of the contact housing, the  
locking tabs of the contact are lifted up by the housing edge and  
disengaged using the release tool.  
– At the same time, push the release tool in the direction of the  
contact housing -arrow- and pull out the released contact from  
the contact housing.  
– The release tool can be pulled out of the contact housing again  
once the contact has been removed.  
lk  
2.6.5  
Flat connector systems  
Note  
If necessary, any housing catches in place (secondary locking  
mechanisms) must be released or removed prior to disengaging  
the contacts using the prescribed tool ⇒ page 102 .  
Flat connector with one locking tab:  
– Insert the release tool appropriate for the contact housing in  
the release port of the contact housing.  
– Grab hold of the contact by the wire and push it lightly into the  
contact housing -arrow-.  
Note  
By pushing the contact in the direction of the contact housing, the  
locking tab of the contact is lifted up by the housing edge and can  
be disengaged using the release tool.  
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– At the same time, push the release tool in the direction of the  
contact housing and pull out the released contact from the  
contact housing -arrow-.  
– The release tool can be pulled out of the contact housing again  
once the contact has been removed.  
Flat connector with two locking tabs:  
– Insert the release tool appropriate for the contact housing in  
the release port of the contact housing.  
– Grab hold of the contact by the wire and push it fully into the  
contact housing -arrow-.  
Note  
By pushing the contact in the direction of the contact housing, the  
locking tabs of the contact are lifted up by the housing edge and  
disengaged using the release tool.  
– At the same time, push the release tool in the direction of the  
contact housing and pull out the released contact from the  
contact housing -arrow-.  
– The release tool can be pulled out of the contact housing again  
once the contact has been removed.  
Asymmetrical:  
– Insert the release tool appropriate for the contact housing in  
the release port of the contact housing.  
– Grab hold of the contact by the wire and push it lightly into the  
contact housing -arrow-.  
Note  
By pushing the contact in the direction of the contact housing, the  
locking tabs of the contact are lifted up by the housing edge and  
disengaged using the release tool.  
2. Repairing wiring harnesses and connectors  
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– At the same time, push the release tool in the direction of the  
contact housing and pull out the released contact from the  
contact housing -arrow-.  
– The release tool can be pulled out of the contact housing again  
once the contact has been removed.  
2.6.6  
Special connector systems  
lk  
Note  
If necessary, any housing catches in place (secondary locking  
mechanisms) must be released or removed prior to disengaging  
the contacts using the prescribed tool ⇒ page 102 .  
Faston contacts:  
– Insert the release tool appropriate for the contact housing in  
the release port of the contact housing.  
– Grab hold of the contact by the wire and push it lightly into the  
contact housing.  
Note  
By pushing the contact in the direction of the contact housing, the  
locking tabs of the contact are lifted up by the housing edge and  
disengaged using the release tool.  
– At the same time, push the release tool in the direction of the  
contact housing and pull out the released contact from the  
contact housing -arrow-.  
– The release tool can be pulled out of the contact housing again  
once the contact has been removed.  
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GT 150/280 contacts:  
– Insert the release tool appropriate for the contact housing un‐  
der the locking tab into the contact housing.  
– Push the tool onto the limit stop -arrow- in the contact housing.  
lk  
The contact is ejected from the contact housing.  
– The release tool can be pulled out of the contact housing again  
once the contact has been ejected.  
Contacts without locking tabs:  
– Insert the release tool under the locking tab of the contact  
housing.  
– Push through the release tool with a light upward movement  
-arrow- onto the limit stop.  
The contact is ejected from the contact housing.  
2. Repairing wiring harnesses and connectors  
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3
Contact surface cleaning set -VAS  
6410-  
3.1  
Using contact surface cleaning set -VAS  
6410-  
The contact surface cleaning set -VAS 6410- allows optimal repair  
quality to be achieved in the area of vehicle electrics. The tools  
allow performing repair work in the area of the sensor in wiring  
harnesses for threaded connections in the high-current circuit  
(starting and charging current). The contact surface cleaning set  
lk  
-VAS 6410- is adapted to the structural conditions of vehicles and  
ensures the process security of repair work as well as a comfort‐  
able procedure.  
Note  
The illustrations shown here are just a few examples of repair  
work.  
Contact surface cleaning set VAS 6410  
3.1.1  
Repairing ring terminals  
Special tools and workshop equipment required  
♦ VAG 1331  
Note  
♦ The use of penetrating fluid, contact spray or grease etc. is  
prohibited since the missing adhesion in the threads may  
cause a torque excess and, therefore, the break of the threa‐  
ded connection.  
♦ The grey sanding pads are suitable for light dirt and "soft sur‐  
faces". The red sanding pads are suitable for heavy dirt and  
"hard surfaces".  
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WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
– Disconnect battery.  
– Loosen cap nut and remove ring terminal from threaded con‐  
nection.  
– Check ring terminal for corrosion, dirt etc.  
– Select suitable adapter and suitable sanding pad.  
Note  
As an alternative, the sanding block may also be used.  
Caution  
Take care not to abrade excessively the tin coating and ensure  
that the copper does not appear. This could produce a galvanic  
cell which destroys metal and causes faulty repair.  
lk  
Note  
As the thickness of the tin coating may differ according to the de‐  
sign, the cleaning process must be performed step by step and a  
visual check of the ring terminal is necessary between the steps.  
– Insert adapter into ring terminal and grind off corrosion and dirt  
with circular movements.  
– Check ring terminal and regrind if necessary.  
3. Contact surface cleaning set VAS 6410  
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– Loosen cap nut and remove ring terminal from threaded con‐  
nection.  
– Check threaded connection for corrosion, dirt etc.  
– Select suitable adapter and suitable sanding pad for threaded  
connection.  
Caution  
Take care not to abrade excessively the tin coating and ensure  
that the copper does not appear. This could produce a galvanic  
cell which destroys metal and causes faulty repair.  
Note  
As the thickness of the tin coating may differ according to the de‐  
sign, the cleaning process must be performed step by step and a  
visual check of the ring terminal is necessary between the steps.  
– Set adapter on threaded connection and grind off corrosion  
and dirt with circular movements.  
– Check threaded connection and regrind if necessary.  
– Tighten connection and, if necessary, locating element again  
to specified torque ⇒ Current flow diagrams, Electrical fault  
finding and Fitting locations.  
Note  
Optimum contact is ensured when the components to be secured  
are tightened to the specified torque after cleaning.  
lk  
– Apply suitable anti-corrosion treatment to threaded connection  
⇒ page 113 .  
– Reconnect battery.  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
– Teach in electric windows again, enter radio code, set clock  
and, if necessary, recode control units which emit code sig‐  
nals.  
3.1.3  
Cleaning battery clamp and battery ter‐  
minal  
Special tools and workshop equipment required  
3. Contact surface cleaning set VAS 6410  
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♦ VAG 1331  
Note  
lk  
The use of penetrating fluid, contact spray or grease etc. is pro‐  
hibited since the missing adhesion in the threads may cause a  
torque excess and, therefore, the break of the threaded connec‐  
tion.  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
tions ⇒ page 2 !  
– Disconnect battery.  
– Check battery clamp and battery terminal for corrosion or dirt.  
– Clean battery clamp using wire brush of battery terminal clean‐  
er with circular movements.  
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– Clean battery terminal using underside of battery terminal  
cleaner with circular movements.  
WARNING  
Danger of injury! Observe warning notices and safety regula‐  
lk  
tions ⇒ page 2 !  
– Reconnect battery and tighten battery terminals to specified  
torque.  
Note  
Optimum contact is ensured when the components to be secured  
are tightened to the specified torque after cleaning.  
3.1.4  
Anti-corrosion treatment  
Caution  
Missing anti-corrosion treatment results in damage to the on‐  
board supply.  
Note  
♦ All threaded connections must be tightened to specified tor‐  
que.  
♦ Always use hose supplied with anticorrosive agent tin.  
♦ Use protection wax for cold area.  
♦ Use cavity sealing agent for warm area.  
♦ The sealing agent independently reaches the respective  
points through capillary action.  
– Hold injector below ring terminal and spray pin all around.  
3. Contact surface cleaning set VAS 6410  
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– Hold injector above ring terminal and spray pin and wiring eye  
all around.  
lk  
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4
Renewing Lambda probe  
Note  
♦ Do not repair lambda probe wires, since this can result in mal‐  
functions.  
♦ If necessary, replace attachment parts, cable ties or marking  
rings to match the uniform probe to the defective probe as  
specified.  
♦ Identify the lambda probe by way of the protective tube as re‐  
quired ⇒ page 117 .  
4.1  
Renewing LSF Lambda probe (4-pin)  
Note  
♦ If necessary, replace attachment parts, cable ties or marking  
rings to match the uniform probe to the defective probe as  
specified.  
♦ Do not repair lambda probe wires, since this can result in mal‐  
functions.  
– Remove the defective Lambda probe.  
– Place both Lambda probes next to each other so that the sen‐  
sor housings are at the same height.  
lk  
4. Renewing Lambda probe  
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– Tie back any excess in the uniform probe length (approx. 50 -  
250 mm) to the size of the defective probe and secure with  
cable ties -1-.  
– Check that the connector housing of the Lambda probe is  
compatible with the onboard supply side.  
– If necessary, replace the onboard supply system connector  
with the Lambda probe connector housing supplied  
⇒ page 97  
Note  
♦ The connector housing should only be replaced on older ve‐  
hicles. On new vehicles, the connector housing coding match‐  
es.  
♦ Observe pin assignment. For reasons of clarity, respective  
pins in new connector housing have a colour marking.  
♦ Further notes can be found in the leaflet of the new lambda  
probe.  
– Install the new Lambda probe in the vehicle.  
4.2  
Renewing LSU Lambda probe (6-pin)  
Note  
lk  
♦ If necessary, replace attachment parts, cable ties or marking  
rings to match the uniform probe to the defective probe as  
specified.  
♦ The wires should not be crimped or cut as otherwise the func‐  
tion of the Lambda probe will be impaired.  
– Remove the old Lambda probe.  
– Place both Lambda probes next to each other so that the sen‐  
sor housings are at the same height.  
116  
Rep. gr.97 - Wiring  
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...  
Electrical System, General Information - Edition 07.2010  
– Tie back any excess in the uniform probe length (approx. 50 -  
250 mm) to the size of the defective probe and secure with  
cable ties -1-.  
– Install the new Lambda probe in the vehicle.  
lk  
4.3  
Types of protective tube on uniform  
Lambda probes  
Note  
In addition to identifying by way of the part number, the protective  
tube can also be used as a means of identification.  
Type D1, 6 openings at 3.5 mm each  
Only used on 4-pin LSF Lambda probes.  
Type D2, 6 openings at 2 mm each  
Only used on 4-pin LSF Lambda probes and 6-pin LSU Lambda  
probes.  
Type D4, 12 openings at 1.4 mm each  
4. Renewing Lambda probe  
117  
Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...  
Electrical System, General Information - Edition 07.2010  
Only used on 4-pin LSF Lambda probes and 6-pin LSU Lambda  
probes.  
lk  
118  
Rep. gr.97 - Wiring  

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