Get Contact surface cleaning set VAS 640 Guide for Volkswagen Sharan VAN First Generation (1995-2010)

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

– 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.

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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.

104

Rep. gr.97 - Wiring

lk

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

– 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

105

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

– 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.

106

Rep. gr.97 - Wiring

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

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.

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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

107

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

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".

108

Rep. gr.97 - Wiring

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

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

109

Bora 1999 ➤ , Bora Variant 1999 ➤ , CC 2010 ➤ , Eos 2006 ➤ , Golf 199 ...

Electrical System, General Information - Edition 07.2010

– 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.

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– 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

111

Contact surface cleaning set VAS 640 for Your Volkswagen Sharan VAN First Generation (1995-2010)

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