VW Polo manuals

Volkswagen Polo Service & Repair Manual: 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 compartment and must be reinstalled after a repair.
Single wire seal is crimped on at the factory together with contact on the wire, this is not the case for repair wires. Single wire seal must be slid onto wire first before crimping the repair wire.
Single wire seals must always fit with the repair wire cross-section. Outer circumference of single wire seal is aligned according to chamber circumference of the contact housing. Perform assembly using only the assembly tool with correct fit.
Assembling Single Wire Seal
   
–  Release contact lock using assembly tool with correct fit -A- and then pull wire with single wire seal toward rear -arrow- out of contact housing.
 

Single Wire Seals, Installing

–  Cut off the old contact with single wire seal from the vehicle-specific wiring harness.
 

Single Wire Seals, Installing

–  Slide repair wire with new contact into corresponding chamber of contact housing until it engages.
 

Single Wire Seals, Installing

–  Put single wire seal -A- onto free end of repair wire.
  Note
When doing this, small diameter of single wire seal must point toward contact housing.
–  Slide single wire seal -A- onto repair wire up to the contact housing.
 

Single Wire Seals, Installing

–  Slide single wire seal -A- into contact housing until it stops using the corresponding assembly tool -B-.
 

Single Wire Seals, Installing

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

Single Wire Seals, Installing

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“. ...

Contact Housings, Repairing Wire Terminals
  Note     For technical reasons, the contact housing for the wire terminals can be supplied only with the contacts p ...

Other materials:

Warranty Test, Performing
  WARNING Do not check or charge batteries that have a visual indicator that is bright yellow. Jump starting must not be used! There is a risk of explosion during testing, cha ...

Tire Sidewall Swelling
A swelling in the flank of the tire indicates that the substructure of the carcass has been damaged.     Typical causes for such damage include, for example, driving over curbs at a sharp angle. ...

Wear Spots
  A wear spot is a flat spot on the tread of the tires that can be caused by extreme braking maneuvers on subsurface such as asphalt. At the same time a tire during the braking maneuver is rubbed at selective points which ...

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