Get Repairing wiring harnesses and connectors -> 2.5 Repairs to contact housings and connectors 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

– 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.

lk

– 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

93

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

Electrical System, General Information - Edition 07.2010

– 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

lk

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 .

94

Rep. gr.97 - Wiring

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

Electrical System, General Information - Edition 07.2010

lk

– 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

95

lk

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

Electrical System, General Information - Edition 07.2010

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- .

96

Rep. gr.97 - Wiring

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

Electrical System, General Information - Edition 07.2010

– 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.

lk

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

97

Repairing wiring harnesses and connectors -> 2.5 Repairs to contact housings and connectors for Your Volkswagen Sharan VAN First Generation (1995-2010)

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Repairing wiring harnesses and connectors

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