Volkswagen Polo Service & Repair Manual: Wire Break with Single Repair Point
| Repair point with single crimp connection |
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Free up wire intended for repair (approximately 20 cm to
both sides of repair point). |
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If required, remove wiring harness wrapping using a folding
knife. |
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Cut out the damaged section of wire using the Wiring Harness
Repair Set - Wire Strippers -VAS1978/3-. |
 Note
| If, by cutting out the damaged wire section, both ends of
the vehicle-specific single wire are too short for a repair
using a single crimp connection, insert a repair wire section of
matching length with two crimp connections. Refer to
→ Chapter „Wire Break with Dual Repair Point“. |
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Strip the wire ends using the 6 - 7 mm wire stripper. |
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Slide crimp connection onto both stripped wire ends of
vehicle-specific single wire and crimp them using crimp pliers. |
Note
| Always be sure to use the correct crimping slot for the
crimping connection used. Refer to
→ Chapter „Crimping Pliers with Insert“. |
| Do not crimp wire insulation. |
| After crimping, crimp connections must be heat-shrunk using
hot air gun to prevent moisture penetration. |
| – |
Place the Wiring Harness Repair - Blower - Shrink Element
-VAS1978/15A- on the Wiring Harness Repair Set - Hot Air Blower
-VAS1978/14A-. |
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| 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. |
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Special tools and workshop equipment
required
Crimping Pliers - .35-2.5mm -VAS1978/1A-
Wiring Harness Repair - Cri ...
Repair point with intermediate wire section
–
Free up wire intended for repair at two points
(approximately 20 cm to both sides of resp ...
Other materials:
Single Wire Seal Assembly Tools
Assembly tools serve the purpose of allowing the single wire
seals to be slid without damage into terminal housing up to
stop, this achieves a complete seal between single wire and
terminal housing.
Four assembly tools for single wire se ...
Run-Flat Tire, Overview of a PAX Tire
PAX tires involve specially developed system that exhibits
the following differences in comparison to conventional tires:
Pax Tires with Supporting Ring
–
-I- PAX tires with air
...
Wheel, Mounting, Volkswagen Assembly Instructions
Vehicles With Tire Pressure Monitoring Sensor.
If wheels are changed (for example, change from summer to
winter tires), wheel electronics send data as soon as speed of
new wheels exceeds 25 km/h (15.53 mph) The control module
automatical ...
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Caution
Wires with Cross Section up to 0.35 mm 2,
Repairing
Wire Break with Dual Repair Point