Get Repairing wiring harnesses and connectors Guide for Volkswagen Sharan VAN First Generation (1995-2010)

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Electrical System, General Information - Edition 07.2010

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

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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

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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

0.5 mm - 1.0 mm

1.5 mm - 2.5 mm

4.0 mm - 6.0 mm

2

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

♦

Head adapter 0.35 mm - 2.5 mm -VAS 1978/1-1-

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.

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– 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.

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♦ 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

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.

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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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– 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

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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

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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.

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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- .

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– 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

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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.

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– 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

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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) .

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2.6

Releasing and dismantling contact

housings

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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-.

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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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Repairing wiring harnesses and connectors for Your Volkswagen Sharan VAN First Generation (1995-2010)

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