Repair of contacts in connector housings (VW Passat B6)

First, open or unlock the secondary connector housing fastener if necessary.



Unblock the contact (primary fastening) with a suitable master key (fig. 7.135).

Remove the contact from the connector housing by pulling on the individual wire.

Take the yellow repair wire with the desired contact from the cable repair kit.

Release the wire that needs to be repaired (approximately 20 cm on both sides of the repair site).

If necessary, remove the wiring harness wrap with a pocket knife.



Insert the new contact of the repair wire into the connector body until it snaps into place (fig. 7.136).

Place the wire seal onto the repair wire.

Note: The smaller diameter of the seal must be on the side of the connector body.

Insert the seal into the connector body using a suitable installation tool.

Cut the repair and separate wire in the car to the required length with wire strippers.



Strip 6-7 mm of insulation from the ends of the wires using wire strippers (fig. 7.132).

Crimp the stripped ends of the wires using crimping pliers and a crimping sleeve as described in the chapter "Broken Wire in One Place".

Note: If it is necessary to repair several wires, a certain distance must be maintained between the crimping sleeves. To prevent the wire bundle from being too thick in circumference after repair, install the crimping sleeves with some offset relative to each other.

If the originally repaired area was wrapped with electrical tape, then after the repair it should be wrapped with yellow electrical tape.

The repaired wiring harness should then be secured with a wire tie if necessary to avoid extraneous noise while driving.

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