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Adapter Cable, Installing

Special tools and workshop equipment required

Wiring Harness Repair Set VAS 1978/A VAS 1978 B

NOTE:

Applies to vehicles between July 4, 2005 and July 13, 2007.

If the generator -C- has to be replaced on these vehicles, then it is necessary to install an adapter cable between the blue connector/contact 16 on the instrument cluster and the brown/black wire, diode number 1Y0.970.082. The adapter wiring set contains a semiconductor diode.

Adapter wiring set:

Adapter wiring set number: 1Y0.970.082.

Perform the following work:

-- Remove the instrument cluster. Refer to INSTRUMENT CLUSTER .

-- Remove the connector housing -1- on the blue connector (T32a) -7-.

Fig 1: Identifying Connector Housing -1- On Blue Connector (T32a) -7-

GWWM90-10001

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove approximately 105 mm of insulation from the blue connector (T32a) on the wiring harness.

-- Remove the brown/black wire -6- on contact 16 approximately 65 mm from the contact housing -7-.

-- Remove 5 mm (0.2 inches) of insulation on the ends of the wires using the wire stripper VAS 1978/3 in the VAS 1978 B.

Fig 2: Identifying Stripping Pliers To Strip Wiring Insulation

GWWN97-0016

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Make the crimp connections between the wire ends -2-, -6- and the adapter cable -4-.

Fig 3: Identifying Connector Housing -1- On Blue Connector (T32a) -7-

GWWM90-10001

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Brown wire, adapter cable -5- with the brown/black wire -6- on the contact housing -7-
Brown/black wire, adapter cable -3- with the brown/black wire, wiring harness -2-

-- Use the crimp pliers (basic tool) VAS 1978/1-2 and exchangeable head, 0.35 mm² - 2.5 mm² VAS 1978/1-1.

Fig 4: Crimping Pliers

GWWN97-10491

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Crimp the connector with the VAS 1978/1-2.

Fig 5: Crimping Single Break Point

GWWN97-10490

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

After crimping, crimp connections must be heat-shrunk using hot air blower VAS 1978/14A to prevent moisture penetration.

-- Attach the shrink element for hot air blower VAS 1978/15A on the VAS 1978/14A and warm the crimp connector starting in the center and working outward until it is completely sealed and adhesive starts to run out.

Fig 6: Heating Crimp Connection Using Hot Air Gun

GWWN97-0013

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Assemble the contact housing -7- and the connector housing -1-.

Fig 7: Identifying Connector Housing -1- On Blue Connector (T32a) -7-

GWWM90-10001

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Wrap the wiring harness for the blue connector -1- with tape -3- until the wiring harness -4- is completely wrapped.

Fig 8: Wrapping Wiring Harness For Blue Connector -1- With Tape

GWWM90-10002

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Secure the wiring harness on the blue connector -1- using a cable tie -2-.

-- Install the instrument cluster.

-- Switch on ignition.

-- Operate the remote rear lid release switch -E188-.

The rear lid unlocked indicator lamp -K116- inside the instrument cluster must turn on. Refer to INSTRUMENT CLUSTER INDICATOR LAMPS .

If the rear lid unlocked indicator lamp does not turn on:

-- Check the crimp connections on the adapter wiring set and check for the correct diode polarity.

Brown cable, adapter wiring set to the brown/black cable, blue connector (PIN 16).
Brown / black cable, adapter wiring set to the brown/black cable, wiring harness.