Get Repairing wiring harnesses and connectors -> 2.6 Releasing and dismantling contact housings 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

– 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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Rep. gr.97 - Wiring

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Electrical System, General Information - Edition 07.2010

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

99

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

Electrical System, General Information - Edition 07.2010

– 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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Rep. gr.97 - Wiring

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

Electrical System, General Information - Edition 07.2010

– 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) .

2. Repairing wiring harnesses and connectors

101

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Electrical System, General Information - Edition 07.2010

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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Electrical System, General Information - Edition 07.2010

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

103

Repairing wiring harnesses and connectors -> 2.6 Releasing and dismantling contact housings for Your Volkswagen Sharan VAN First Generation (1995-2010)

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