Volkswagen Polo Service & Repair Manual: Wires with Cross Section up to 0.35 mm 2,
Repairing
| Special tools and workshop equipment
required |
| Crimping Pliers - .35-2.5mm -VAS1978/1A- |
| Wiring Harness Repair - Crimping Head - .35-2.5mm
-VAS1978/1-1- |
| When repairing wires with a cross-section up to 0.35 mm2,
new contacts must always be crimped on using the Crimping Pliers
- JPT -VAS1978/9A- or the Wiring Harness Repair - Crimping Plier
- Base Tool -VAS1978/1-2- with the Wiring Harness Repair Set -
Crimping Head - JPT -VAS1978/9-1- installed. Due to the low
current strengths of these wires in the micro- to milli- range,
contacts crimped on incorrectly lead to continuity resistances
and cause malfunctions or failure of the respective system. The
most frequent applications of these contacts are |
| By using the Crimping Pliers - JPT -VAS1978/9A- or the
Wiring Harness Repair - Crimping Plier - Base Tool -VAS1978/1-2-
with the Wiring Harness Repair Set - Crimping Head - JPT
-VAS1978/9-1- installed, the correct connection between crimp
contact, wire and single wire seal is guaranteed. The tool is to
be used only for the purpose described. |
 Note
| Contacts in a normal and a gold-plated version are crimped
onto repair wires. The same version of the contact that was
installed at the factory must always be used for repairs. |
| Crimping A New Contact with Single Wire Seal |
| – |
Insert the Wiring Harness Repair Set - Crimping Head - JPT
-VAS1978/9-1- into the Wiring Harness Repair - Crimping Plier -
Base Tool -VAS1978/1-2-. Refer to
→ Chapter „Crimping Pliers - .35-2.5mm -VAS1978/1A-“. |
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Place the single wire seal onto the repair wire. |
Note
| When doing this, the smaller diameter of single wire seal
must be facing in the direction of the contact to be crimped on. |
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Open crimp pliers and place the repair wire end into
stripping slot of crimp pliers. |
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Close crimp pliers completely. |
| – |
Open crimp pliers again and remove the stripped wire end. |
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Slide single wire seal in direction of stripped wire end
until it rests flush with the wire insulation. |
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Place new crimp contact into mount on crimp pliers. |
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Insert the stripped wire end with positioned single wire
seal into crimp contact until it makes contact on “wire stop”. |
| – |
Crimp the contact, wire and single wire seal by closing
crimp pliers completely. |
| – |
Open crimp pliers again and remove the finished crimped-on
contact. |
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| A correctly performed crimp is distinguished by a clean
compression of wire and single wire seal in the contact and has
an impression on the rear side which identifies that the crimp
was performed by a professional using the correct tool. |
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A new repair concept has been developed for repairing
antenna wires. Refer to
→ Chapter „Antenna Wires, Repairing“.
Instead of a ...
Repair point with single crimp connection
–
Free up wire intended for repair (approximately 20 cm to
both sides of repair point).
...
Other materials:
Rear towing eye
Fig. 194 In the rear bumper on the
right-hand side: removal of the covers for the towing eye
Fig. 195 In the rear bumper:
removal of the covers for the towing eye
First read and observe the introductory
information and safety warnings
There is a fixed towing eye located underneath the rea ...
Switching lights on and off
Fig. 68 Next to the steering wheel: examples
of the various light switches
First read and observe the introductory information
and safety warnings
Observe any country-specific regulations when using vehicle lighting.
In vehicles with a factory-fitted towing bracket, the vehicle's
rear fog ...
Run-Flat Tire, General Information
Run-flat tires have a reinforced sidewall in comparison to
standard tires. This reduces the tendency for the sidewall to
roll when there is a loss of pressure and prevents the sides of
the tire from being pinched. This allows the vehicle to be
driven whi ...
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Antenna Wires, Replacing
Wire Break with Single Repair Point