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“. |
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Release contact (primary lock) using the appropriate release
tool. Refer to
→ Chapter „Contact Housings, Releasing and Disassembling“. |
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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). |
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If required, remove wiring harness wrapping using a folding
knife. |
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Insert new contact of repair wire into contact housing until
it engages. |
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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“. |
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Shorten the repair wire and the vehicle-specific wiring
harness single wire as needed using the Wiring Harness Repair
Set - Wire Strippers -VAS1978/3-. |
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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
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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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Note
Observe general notes for repairs on the vehicle electrical
system. Refer to
→ Chapter „Vehicle Electrical System, General Repa ...
Note
Single wire seals prevent the penetration of water and dirt
into the contact housing. They are installed, for example, in
the engine compart ...
Other materials:
Maximum permitted gross combination weight
First read and observe the introductory information
and safety warnings
All data in the official vehicle documents take precedence over these data. All
data in this manual apply to the basic model. The vehicle data sticker in the service
schedule and the official vehicle documents show which ...
Crimping Pliers with Insert
The Crimping Pliers without Insert -VAS1978/1- with Crimping
Pliers - Insert 2 -VAS1978/2- is a component of the Wiring
Harness Repair Set -VAS1978- and is used to crimp the connector
during the wiring harness repair.
...
Battery, Charging
Requirements
WARNING
Batteries that have a light yellow visual indicator
do not have to be tested or charged. Jump starting must
not be used!
There is a risk ...
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Contact Housings and Connectors, Repair Information
Single Wire Seals, Installing