Volkswagen Polo Service & Repair Manual: Wire Break with Single Repair Point
| Repair point with single crimp connection |
| – |
Free up wire intended for repair (approximately 20 cm to
both sides of repair point). |
| – |
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:
Two-Part Synthetic Adhesion Filler
Definition:
Two-Part Synthetic Adhesion Filler -LKF 696 009 A2-, white
Two-Part Synthetic Adhesion Filler -LKF 696 040 A2-, black
Edition 08/2013
Product Description
...
Performance figures
First read and observe the introductory information
and safety warnings
For reasons of vehicle registration and vehicle taxation, the power output and
performance of some engines may vary in some countries from the information given
in this booklet.
Petrol engines
...
Manual gearbox: selecting a gear
Fig. 110 Gear shift pattern of a 5 or 6-speed
manual gearbox
First read and observe the introductory information
and safety warnings The positions of the individual driving
gears are shown on the gearshift lever .
Fully depress and hold the clutch pedal.
Move the gear lever t ...
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Caution
Wires with Cross Section up to 0.35 mm 2,
Repairing
Wire Break with Dual Repair Point