VW Polo manuals

Volkswagen Polo Service & Repair Manual: Contacts in Contact Housing, Repairing

First, open or release if necessary the secondary lock of the contact housing. Refer to → Chapter „Contact Housings, Releasing and Disassembling“.
   
–  Release contact (primary lock) using the appropriate release tool. Refer to → Chapter „Contact Housings, Releasing and Disassembling“.
–  Pull contact at single wire out of contact housing.
–  Take the yellow repair wire with the correct contact out of the Wiring Harness Repair Set -VAS1978-.
–  Free up repair point of vehicle-specific wiring harness (approximately 20 cm to both sides of repair point).
–  If required, remove wiring harness wrapping using a folding knife.
 

Contacts in Contact Housing, Repairing

–  Insert new contact of repair wire into contact housing until it engages.
–  Slide a single wire seal onto the repair wire.
  Note
When doing this, small diameter of single seal must point toward contact housing.
–  Slide single wire seal into contact housing using the correct assembly tool. Refer to → Chapter „Single Wire Seals, Installing“.
 

Contacts in Contact Housing, Repairing

–  Shorten the repair wire and the vehicle-specific wiring harness single wire as needed using the Wiring Harness Repair Set - Wire Strippers -VAS1978/3-.
 

Contacts in Contact Housing, Repairing

–  Strip ends of repair wire and of vehicle-specific single wire using 6 - 7 mm wire stripper.
–  Crimp the stripped ends of repair wire and single wire of vehicle-specific wiring harness using crimp pliers and a crimp connection as described in chapter “Wire break with single repair point”. Refer to → Chapter „Wire Break with Single Repair Point“.
  Note
 

Contacts in Contact Housing, Repairing

Make sure that crimp connections do not lie directly next to each other when several wires need to be repaired. Arrange the crimp connectors at a slight offset so that the circumference of the wiring harness does not become too large.
In the event the repair point was previous taped, this point must be taped anew with yellow insulating tape after repairs.
Secure the repaired wiring harness if necessary with a cable tie to prevent flapping noises while driving.
 

Contacts in Contact Housing, Repairing

Contact Housings and Connectors, Repair Information
  Note Observe general notes for repairs on the vehicle electrical system. Refer to → Chapter „Vehicle Electrical System, General Repa ...

Single Wire Seals, Installing
  Note Single wire seals prevent the penetration of water and dirt into the contact housing. They are installed, for example, in the engine compart ...

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