Get Repairing wiring harnesses and connectors -> 2.2 Tool descriptions Guide for Volkswagen Sharan VAN First Generation (1995-2010)

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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

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

Electrical System, General Information - Edition 07.2010

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

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

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

Electrical System, General Information - Edition 07.2010

– Cut the wire if necessary with the cutting part on the upper side

of the wire strippers.

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- :

♦

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

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

mm ⇒ page 91 .

Interchanging head adapter:

– Open up the crimping pliers fully.

Rep. gr.97 - Wiring

Repairing wiring harnesses and connectors -> 2.2 Tool descriptions for Your Volkswagen Sharan VAN First Generation (1995-2010)

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