Volkswagen Golf Service & Repair Manual: Repairs to contacts in contact housings
| If necessary, first open or disengage the secondary locking
mechanism of the contact housing
→ Chapter. |
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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. |
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| – |
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. |
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| – |
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”
→ Chapter. |
Note
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| 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. |
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Note
Observe the general notes on repairs to the vehicle
electrical system
→ Chapter.
Allocation of the a ...
Note
Single wire seals prevent the ingress of moisture and dirt
in the contact housing. They are installed, for example, in the
engine compartmen ...
Other materials:
Removing and installing thermostat for large cooling circuit
Special tools and workshop equipment
required
Hose clip pliers -VAS 6362-
Special wrench -T10508-
R ...
Checklist
In some countries, special safety standards and emissions-related
legislation apply that may differ from the construction of the vehicle. Volkswagen
recommends that you visit your Volkswagen dealership before travelling abroad
to find out about any legal requirements and the following is ...
Assembly tools for single wire seals
The assembly tools serve as a means of sliding the single
wire seals fully into the contact housing without damage and
thereby assure complete sealing between single wire and contact
housing.
Four assembly tools for single wire seals are ...
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Notes on repairs to contact housings and connectors
Fitting single wire seals