VW Polo manuals

Volkswagen Polo Service & Repair Manual: Fiber-Optic Cable, Assembling

Special tools and workshop equipment required
Fiber-Optic Conductor Repair Set -VAS6223A-
Hose Cutting Pliers -VAS6228-
Vehicle Diagnostic Tester
It is very difficult to find the exact location of the problem. Replace the damaged fiber-optic cable and lay a new wire parallel to the defective fiber-optic cable.
  Note
Select the damaged fiber-optic cable components with the “Guided Fault Finding” or “Guided Functions” from the Vehicle Diagnostic Tester menu options.
A fiber-optic cable that needs repair is represented by a “yellow” color.
Procedure
–  Choose “Guided Fault Finding” or “Guided Functions” in the Vehicle Diagnostic Tester. Refer to Vehicle Diagnostic Tester.
–  Assemble the fiber-optic cable. Refer to → Chapter „Fiber-Optic Cable, Assembling“.
  Caution
Do not bend the fiber-optic cable too much. The bending radius must be no less than 25 mm.
Fiber optic cables must not be routed over sharp edges.
The fiber-optic cable must not be dirty or touched with bare fingers.
Fiber optic cables may not be heated.
It is not permitted to twist together 2 fiber optic cables or one fiber optic cable with a copper wire.
Protect the connector and the connection box from dust. Place the cap on the trunk.
  Caution
Do not bend the fiber-optic cable too much. The bending radius must be no less than 25 mm.
Fiber optic cables must not be routed over sharp edges.
The fiber-optic cable must not be dirty or touched with bare fingers.
Fiber optic cables may not be heated.
It is not permitted to twist together 2 fiber optic cables or one fiber optic cable with a copper wire.
Protect the connector and the connection box from dust. Place the cap on the trunk.
   
Mount the Tool Head for the Fiber-Optic Repair Set - Pliers -VAS6223/1-.
 

Fiber-Optic Cable, Assembling

–  Remove the locking pin -arrows-.
–  Remove the tool set -arrow- and pull the locking pin back.
 

Fiber-Optic Cable, Assembling

Fiber Optic Cable, Cutting to Length
–  Establish length of fiber optic cable required.
–  Open the Fiber-Optic Repair Set - Pliers -VAS6223/1- and lay the fiber-optic cable -1- in the mount.
–  Close the Fiber-Optic Repair Set - Pliers -VAS6223/1- to cut the fiber-optic cable lengths.
 

Fiber-Optic Cable, Assembling

Stripping
–  Open the Fiber-Optic Repair Set - Pliers -VAS6223/1-.
–  Position the wire stripper in the lower position -arrow-.
–  Insert fiber-optic cable into the stripping station.
The end of the fiber-optic cable must be flush with the rear side of the cutting pliers.
 

Fiber-Optic Cable, Assembling

–  Close the Fiber-Optic Repair Set - Pliers -VAS6223/1- until the stop and keep closed.
–  Bend the wire stripper upward -arrow- and remove the fiber-optic cable.
 

Fiber-Optic Cable, Assembling

Precision Cutting (Production of Optical End Face)
–  Push the fiber-optic cable -1- into the cutting station.
Insulation must make contact with cutting point stop.
 

Fiber-Optic Cable, Assembling

–  Close the Fiber-Optic Repair Set - Pliers -VAS6223/1- and remove the wire.
–  Visually inspect the wire -1- to make sure that it was cut correctly and that there are no burrs on the front surface.
  Note
Fiber-optic cable is only to be placed on an absolutely clean surface or held in hand.
Use the cap if there is a risk of the fiber-optic cable surface becoming dirty.
 

Fiber-Optic Cable, Assembling

Attaching Brass Pin Contact to Fiber-Optic Cable
 

Fiber-Optic Cable, Assembling

–  Change tool head -arrow-.
–  Slide the safeguard on the Fiber-Optic Repair Set - Pliers -VAS6223/1- in direction of -arrow- so that the word “Stift” (pin) is legible.
 

Fiber-Optic Cable, Assembling

–  Insert a brass pin contact -1- in the mount.
–  Close the securing lever on the Fiber-Optic Repair Set - Pliers -VAS6223/1- in direction of -arrow-.
 

Fiber-Optic Cable, Assembling

–  Insert the fiber-optic cable into the brass pin contact -arrow- all the way up to the threaded stop and then close the Fiber-Optic Repair Set - Pliers -VAS6223/1-.
–  Open the fiber-optic cable pliers and remove the fiber-optic cable along with the brass contact pin.
  Caution
Do not excessively bend or kink the fiber-optic cables (minimum bending radius 25 mm).
 

Fiber-Optic Cable, Assembling

–  Make sure the brass pin contact -2- is secured properly on the fiber-optic cable -1-.
4 crimped points must be visible on the brass connecting pin.
The brass pin contact must not be able to be removed by hand from fiber-optic cable.
The front surface of the fiber-optic cable is 0.01 to 0.1 mm behind the brass pin contact (visual check).
  Note
Connector couplings are available for connecting the fiber-optic cables. Refer to Parts Catalog.
To install the new fiber optic cable in wiring harness connector. Refer to → Chapter „Fiber-Optic Cable, Disconnecting from Wiring Harness Connector“.
 

Fiber-Optic Cable, Assembling

Corrugated Tube, Install on Fiber Optic Cable
–  Cut corrugated tube to appropriate length.
Use the Hose Cutting Pliers -VAS6228- or a sharp knife for cutting.
The corrugated tube must not be cut through using a side cutter under any circumstances
The corrugated tube must be cut on the wave peak -arrow-, not in the wave trough.
The corrugated tube must audibly engage in the fiber-optic cable housing when installing.
 

Fiber-Optic Cable, Assembling

–  Guide the fiber-optic cable into the Fiber-Optic Repair Set - Tube Tool -VAS6223/10- as shown.
–  Position corrugated tube assembly pliers on slot on the tube.
–  Position crimping pliers for fiber-optic cable at slot of corrugated tube. The fiber optic cable is then routed in the corrugated tube.
 

Fiber-Optic Cable, Assembling

Fiber-Optic Cables, Repairing
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Fiber-Optic Cable, Disconnecting from Wiring Harness Connector
Removing –  Unplug connector for fiber optic cable from appropriate control unit. –  Release the loc ...

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