Volkswagen Golf Service & Repair Manual: Repairs to contacts in contact housings

Volkswagen Golf Service & Repair Manual / Electrical system, general information / Wiring / Wiring harness and connector repairs / Repairs to contacts in contact housings

If necessary, first open or disengage the secondary locking mechanism of the contact housing → Chapter.

–	Disengage the contact (primary locking mechanism) using the appropriate release tool → Chapter.

–	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 position).

–	If necessary, unbind the wiring harness using the folding knife.

Repairs to contacts in contact housings

–	Push the new contact of the repair wire into the contact housing 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 → Chapter.

Repairs to contacts in contact housings

–	Trim the repair wire and the single wire of the vehicle's own wiring harness accordingly using wire strippers -VAS 1978/3-.

Repairs to contacts in contact housings

–	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” → Chapter.

Note

Repairs to contacts in contact housings

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 becoming 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 necessary, to prevent it from generating noise when the vehicle is in motion.

Repairs to contacts in contact housings

Notes on repairs to contact housings and connectors

Note Observe the general notes on repairs to the vehicle electrical system → Chapter. Allocation of the a ...

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 compartmen ...

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