Volkswagen Golf Service & Repair Manual: Repairs to wiring with cross sections up to 0.35 mm2

Special tools and workshop equipment required

Crimping pliers, complete -VAS 1978/1 A-

Head adapter 0.35 mmІ - 2.5 mmІ -VAS 1978/1-1-

For repairs to wiring with cross sections up to 0.35 mm², it is essential that contacts are crimped on using crimping pliers for JPT contacts -VAS 1978/9A- or crimping pliers (base tool) -VAS 1978/1-2- with attached head adapter for JPT contacts -VAS 1978/9-1-. Due to the low current strength of these wires in the micro and thousandths range, incorrectly crimped contacts cause electrical resistances and result in faults or failure in the respective system. The most common applications of these contacts are:

Lambda probe

Engine speed sender

Air mass meter

With the use of crimping pliers for JPT contacts -VAS 1978/9A- or crimping pliers (base tool) -VAS 1978/1-2- with attached head adapter for JPT contacts -VAS 1978/9-1-, the correct connection between crimp contact, wire and single wire seal is assured. The tool is only to be used for the application described. Note Crimped to the repair wiring are normal contacts and gold-plated contacts. The repair contact must always be the same type as the contact installed in the factory.

Crimping on new contact with single wire seal

Insert head adapter for JPT contacts -VAS 1978/9-1- in crimping pliers (base tool) -VAS 1978/1-2- → Chapter.

Repairs to wiring with cross sections up to 0.35 mm2

Attach the single wire seal to the repair wire.

Note When doing this, the small diameter of the single wire seal must face the contact to be crimped on.

Open the crimping pliers and insert the end of the repair wire in the opening of the crimping pliers for wire stripping.

Close the crimping pliers fully.
Open the crimping pliers again and removed the stripped wire end.

Push the single wire seal towards the stripped wire end until it is flush with the wiring insulation.

Insert the new crimp contact in the mounting of the crimping pliers.

Insert the stripped wire end with the positioned single wire seal in the crimp contact until it comes into contact with the “wire stop”.
Crimp the contact, wire and single wire seal by closing the crimping pliers fully.
Open the crimping pliers again and remove the successfully crimped contact.

Successful crimping can be identified by clean and equal application of pressure on the wire and single wire seal in the contact and by a stamp on the rear that indicates the correct tool was used in the correct manner to carry out the crimping process.

Repairs to wiring with cross sections up to 0.35 mm2