VW Golf manuals

Volkswagen Golf Service & Repair Manual: General notes concerning repairs to vehicle electrical system

  Caution
When batteries are disconnected and reconnected, the procedure described in the workshop manual must be strictly observed.
  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.
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, defective electrical components, corrosion, etc.).
For additional information, e.g. removal and installation of individual components, please refer to the relevant workshop manual.
   
Soldering is not permitted for repairs to vehicle wiring.
 

General notes concerning repairs to vehicle electrical system

Wiring harness and connector repairs to vehicle electrical system 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.
 

General notes concerning repairs to vehicle electrical system

Crimp connectors may never be repaired. If necessary, lay wiring parallel to the defective wiring. After crimping, the crimp connector has to be shrink fitted using the hot air blower in order to prevent any ingress of moisture.
It is essential that the supplementary information is observed regarding repairs to wiring harnesses in airbag and belt tensioner systems, fibre optic cables, CAN bus lines, aerial cables and wiring with cross sections up to 0.35 mm2 → Chapter.
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.
 

General notes concerning repairs to vehicle electrical system

If possible, do not loosen any earth wires from the body (danger of corrosion).
 

General notes concerning repairs to vehicle electrical system

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 can be repaired. Wiring for camera systems are the exception. If damaged they must be replaced complete.
Heat resistant wiring can be found in various places in the vehicle, 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.
 

General notes concerning repairs to vehicle electrical system

Wiring harness and connector repairs
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Wiring harness repair set -VAS 1978
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