Volkswagen Golf Service & Repair Manual: Preparing fibre optic cable

Special tools and workshop equipment required

Fibre optic cable repair kit -VAS 6223A-

Cutting pliers -VAS 6228-

Vehicle diagnostic tester

Caution

Do not excessively bend fibre optic cables. Minimum radius for bends is 25 mm.

Do not route fibre optic cables over sharp edges.

Make sure that the ends of fibre optic cables are not dirty and do not grasp them with your bare hands.

Do not expose fibre optic cables to heat.

It is not permissible to twist 2 fibre optic cables together or one fibre optic cable with a copper wire. Protect connectors and connecting cables against dust. Use protective caps from the case.

Fit tool adapter for fibre optic cable pliers -VAS 6223/1-.

Press locking pins -arrows- out.
Fit tool adapter onto pliers -arrow- and press locking pins back in.

Cutting fibre optic cable to size.

Determine required length of fibre optic cable.
Open fibre optic cable pliers and insert length of fibre optic cable -1- to be cut.
To cut the fibre optic cable to size, close fibre optic cable pliers.

Stripping off insulation

Open fibre optic cable pliers -VAS 6223/1-.
Push down the stripping lever -arrow-.
Insert fibre optic cable into the stripping hole.

The fibre optic cable must be flush with the rear of the cutting pliers.

Close fibre optic cable pliers as far possible and hold closed.
Push the stripping lever upwards -arrow- and remove fibre optic cable.

Cut precisely (making a clean optic surface at end of cable).

Insert fibre optic cable -1- into the cutting hole.

The insulation must be lying against the stop of the cutting station.

Close fibre optic cable pliers -VAS 6223/1- and remove cable.
Visually inspect cable-1- to make sure that it has been cut correctly and that there are no burrs on the cross-cut surface at end of cable.

Note Place the fibre optic cable only on surface or material that is absolutely clean or keep it in your hand. Use protective caps if there is a danger that the cross-cut surface at the ends of the fibre optic cable will be soiled.

Fit brass pin contact to fibre optic cable.

Change tool adapter -arrow-.
Move safety catch on fibre optic cable pliers-arrow- so that the word “Pin” can be seen.

Insert a brass pin contact -1- into the hole.
Close locking lever on fibre optic cable pliers-arrow-.

Push fibre optic cable into brass pin contact -arrow- as far as spring-cushioned stop and close fibre optic cable pliers.
Open fibre optic cable pliers and remove fibre optic cable together with brass pin contact.

Caution

Do not kink or excessively bend fibre optic cables (min. bending radius 25 mm).

Check that the brass pin contact -2- is correctly attached to fibre optic cable -1-.

4 crimping points must be visible on the brass connecting pin.

Make sure that the brass pin contact cannot be pulled off fibre optic cable by hand. The cross-cut end surface of the fibre optic cable is 0.01 … 0.1 mm behind the brass pin contact (visual inspection). Note There are plug-in connectors that are used to connect fibre optic cables → Electronic parts catalogue. Installation of the new fibre optic cable in the cable harness connector → Chapter.

Fitting corrugated tube onto fibre optic cable.

Cut corrugated tube to a suitable length.

Use cutting pliers -VAS 6228- or a sharp knife for cutting.

Do not cut the corrugated tube with a paper cutter.

The corrugated tube must be cut at a crest -arrow- not in a trough.

When the corrugated tube is installed, it must engage audibly in the housing of the fibre optic cable.

Insert fibre optic cable into pliers for fitting the corrugated tube -VAS 6223/10- as shown in the illustration.
Position pliers in place on the groove of the corrugated tube.
Push pliers in groove along the circumference of the corrugated tube. This causes the fibre optic cable to be inserted in the corrugated tube.

Preparing fibre optic cable