Get Repairing wiring harnesses and connectors -> 2.1 Wiring harness repair set 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

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

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

crimp connectors with head adapter 0.35 - 2.5 mm -VAS

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

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

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

Electrical System, General Information - Edition 07.2010

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

Yellow

Red

Blue

Yellow.

Red.

Blue

0.35 mm

0.5 mm - 1.0 mm

1.5 mm - 2.5 mm

4.0 mm - 6.0 mm

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.

Rep. gr.97 - Wiring

Repairing wiring harnesses and connectors -> 2.1 Wiring harness repair set for Your Volkswagen Sharan VAN First Generation (1995-2010)

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