VW Golf manuals

Volkswagen Golf Service & Repair Manual: 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 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 therefore 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 appropriate release tool -A- and then pull the wire with the single wire seal backwards -arrow- out of the contact housing.
 

Fitting single wire seals

–  Cut off the old contact with the single wire seal from the vehicle's own wiring harness.
 

Fitting single wire seals

–  Slide the repair wire with the new contact in the respective socket of the contact housing until it engages.
 

Fitting single wire seals

–  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.
 

Fitting single wire seals

–  Slide the single wire seal -A- using the respective assembly tool -B- fully into the contact housing.
 

Fitting single wire seals

–  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” → Chapter.
 

Fitting single wire seals

Repairs to contacts in contact housings
If necessary, first open or disengage the secondary locking mechanism of the contact housing → Chapter.     ...

Repairs to contact housings using cut and clamp technique
  Note     For technical reasons, the contact housings for cut and clamp technique can only be supplied with the cut ...

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