Get Repairing wiring harnesses and connectors -> 2.4 Repairs to wiring harnesses 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

♦ 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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Electrical System, General Information - Edition 07.2010

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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Rep. gr.97 - Wiring

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

Electrical System, General Information - Edition 07.2010

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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Electrical System, General Information - Edition 07.2010

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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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Rep. gr.97 - Wiring

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Electrical System, General Information - Edition 07.2010

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

Electrical System, General Information - Edition 07.2010

♦ 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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Rep. gr.97 - Wiring

Repairing wiring harnesses and connectors -> 2.4 Repairs to wiring harnesses for Your Volkswagen Sharan VAN First Generation (1995-2010)

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