my-gti.com » Housings and Pins http://www.my-gti.com Wed, 25 Jan 2012 05:48:04 +0000 en hourly 1 http://wordpress.org/?v=3.3.1 Purchasing terminal kits or tools for your Volkswagen / Audi / Skoda http://www.my-gti.com/1801/purchasing-terminal-kits-or-tools-for-your-volkswagen-audi-skoda http://www.my-gti.com/1801/purchasing-terminal-kits-or-tools-for-your-volkswagen-audi-skoda#comments Sat, 30 Jan 2010 15:38:04 +0000 Maverick http://www.my-gti.com/?p=1801 website: www.schwabenparts.com

Schwaben Terminal Removal Tool Set

Available from ECS Tuning for USD $69.95

Laser Tools

website: www.lasertools.co.uk

Laser 4329 Terminal Tool Set

Appears to be the same as the Schwaben  kit above and both are similar dollars.

Volkswagen Terminal Tools

website: tools.vw.com Dealership spare parts department can order these in for you.

Volkswagen 8197A Terminal Kit

This kit contains 6680,6742,6807,6932, 6934 [...]]]> Schwaben Parts

website: www.schwabenparts.com

Schwaben Terminal Removal Tool Set

Available from ECS Tuning for USD $69.95

volkswagen_terminal_tools_schwaben_ce-70-2_2

volkswagen_terminal_tools_schwaben_ce-70-2_1 volkswagen_terminal_tools_schwaben_ce-70-2_3 volkswagen_terminal_tools_schwaben_ce-70-2_4

volkswagen_terminal_tools_schwaben_ce-70-2_5 volkswagen_terminal_tools_schwaben_ce-70-2_6 volkswagen_terminal_tools_schwaben_ce-70-2_7

Laser Tools

website: www.lasertools.co.uk

Laser 4329 Terminal Tool Set

Appears to be the same as the Schwaben  kit above and both are similar dollars.

volkswagen_terminal_tools_laser_4329_1

Volkswagen Terminal Tools

website: tools.vw.com
Dealership spare parts department can order these in for you.

Volkswagen 8197A Terminal Kit

volkswagen_terminal_tools_volkswagen_8197A_1

This kit contains 6680,6742,6807,6932, 6934 & 8638

Volkswagen VAS1978/35-19

Price: around USD $30.00

volkswagen_terminal_tools_volkswagen_VAS1978-35-19_1

Terminal Removal Tool used to remove Airbag Control Module Flat Contact in Housing part number 1K0 973 100 D.

Volkswagen VAS 1978/18

volkswagen_terminal_tools_volkswagen_VAS1978-18_1

Release tool VAS 1978/18 for flat contacts with two locking tabs, contact width 2.8 and 5.8mm.

Replacement part from wiring harness repair set VAS 1978A / VAS 1978B.

Volkswagen VAS 1978/7A

volkswagen_terminal_tools_volkswagen_VAS1978-7A_1

Release tool VAS 1978/7A for flat contacts with two locking tabs, contact width 1.5mm. Replacement part from wiring harness repair set VAS 1978A / VAS 1978B.

ASSENMACHER SPECIALTY TOOLS

website: www.asttool.com

AST S 1553 N

This tool is used to remove flat terminals with one release tang from the connector plug.

volkswagen_terminal_tools_ast_1553_1

This tool is used to remove flat terminals with one release tang from the connector plug.

AST S 1556 N

volkswagen_terminal_tools_ast_1556_1

This tool is used to remove flat terminals with two release tangs from the connector plug (1mm Wide, 2.5mm Apart and 12.15mm long).

AST S 1591 N

volkswagen_terminal_tools_ast_1591_1

This tool is used to remove flat terminals with two release tangs from the connector plug. Comparable to VW number VAS1978/18. (1.65mm Wide, 2.8mm Apart and 18mm long)

]]> http://www.my-gti.com/1801/purchasing-terminal-kits-or-tools-for-your-volkswagen-audi-skoda/feed 7 Releasing and dismantling contact housings http://www.my-gti.com/1707/releasing-and-dismantling-contact-housings http://www.my-gti.com/1707/releasing-and-dismantling-contact-housings#comments Wed, 18 Nov 2009 15:09:15 +0000 Maverick http://www.my-gti.com/?p=1707 The secondary locking mechanism is a housing catch (second line locking mechanism) that secures all the wires in one contact housing. If a secondary locking mechanism is fitted to a contact housing, this must always be opened or removed using the appropriate tool before releasing and pulling out individual crimp contacts. The secondary locking mechanism [...]]]> Secondary locking element

The secondary locking mechanism is a housing catch (second line locking mechanism) that secures all the wires in one contact housing. If a secondary locking mechanism is fitted to a contact housing, this must always be opened or removed using the appropriate tool before releasing and pulling out individual crimp contacts.
The secondary locking mechanism is different in colour from the rest of the contact housing. This makes it easier to identify the secondary locking mechanism and clarifies its intended function.
The types of contact housing shown here are just a few examples to show the different functions of secondary locking mechanism.

Example 1:

The housing catch is disengaged by removing a “toothed element”-arrow-.

vw_contact_housing_secondary_1

Example 2:

The housing catch is disengaged by opening a “flap”-arrow-.

vw_contact_housing_secondary_2

Example 3:

The housing catch can be disengaged by detaching a “slide”-arrow-.

vw_contact_housing_secondary_3

Primary locking element

The primary locking mechanism is what fixes an individual crimp contact in the contact housing.
If necessary, any housing catches in place (secondary locking mechanisms) must be released or removed prior to disengaging the contacts using the prescribed tool.
The types of primary locking mechanisms shown as follows are just a few examples to show the different functions of primary locking mechanism.

Round connector systems

If necessary, any housing catches in place (secondary locking mechanisms) must be released or removed prior to disengaging the contacts using the prescribed tool.

  • Insert the release tool appropriate for the contact housing in the release port of the contact housing.
  • Grab hold of the contact by the wire and push it lightly into the contact housing -arrow-.

vw_contact_housing_primary_round_1

Note: By pushing the contact in the direction of the contact housing, the locking tabs of the contact are lifted up by the housing edge and can be disengaged using the release tool.

  • At the same time, push the release tool in the direction of the contact housing -arrow- and pull out the released contact from the contact housing.
  • The release tool can be pulled out of the contact housing again once the contact has been removed.

vw_contact_housing_primary_round_2

Flat connector systems

If necessary, any housing catches in place (secondary locking mechanisms) must be released or removed prior to disengaging the contacts using the prescribed tool.

Flat connector with one locking tab:

  • Insert the release tool appropriate for the contact housing in the release port of the contact housing.
  • Grab hold of the contact by the wire and push it lightly into the contact housing -arrow-.

vw_contact_housing_primary_flat_1

Note: By pushing the contact in the direction of the contact housing, the locking tab of the contact is lifted up by the housing edge and can be disengaged using the release tool.

vw_contact_housing_primary_flat_2

  • At the same time, push the release tool in the direction of the contact housing and pull out the released contact from the contact housing -arrow-.
  • The release tool can be pulled out of the contact housing again once the contact has been removed.

Flat connector with two locking tabs:

  • Insert the release tool appropriate for the contact housing in the release port of the contact housing.
  • Grab hold of the contact by the wire and push it fully into the contact housing -arrow-.

vw_contact_housing_primary_flat_3

Note: By pushing the contact in the direction of the contact housing, the locking tabs of the contact are lifted up by the housing edge and can be disengaged using the release tool.

vw_contact_housing_primary_flat_4

  • At the same time, push the release tool in the direction of the contact housing and pull out the released contact from the contact housing -arrow-.
  • The release tool can be pulled out of the contact housing again once the contact has been removed.

Asymmetrical:

  • Insert the release tool appropriate for the contact housing in the release port of the contact housing.
  • Grab hold of the contact by the wire and push it lightly into the contact housing -arrow-.

vw_contact_housing_primary_flat_5

Note: By pushing the contact in the direction of the contact housing, the locking tabs of the contact are lifted up by the housing edge and can be disengaged using the release tool.

vw_contact_housing_primary_flat_6

  • At the same time, push the release tool in the direction of the contact housing and pull out the released contact from the contact housing -arrow-.
  • The release tool can be pulled out of the contact housing again once the contact has been removed.

Special connector systems

If necessary, any housing catches in place (secondary locking mechanisms) must be released or removed prior to disengaging the contacts using the prescribed tool.

Faston contacts:

  • Insert the release tool appropriate for the contact housing in the release port of the contact housing.
  • Grab hold of the contact by the wire and push it lightly into the contact housing.

vw_contact_housing_primary_special_1

Note: By pushing the contact in the direction of the contact housing, the locking tabs of the contact are lifted up by the housing edge and can be disengaged using the release tool.

vw_contact_housing_primary_special_2

  • At the same time, push the release tool in the direction of the contact housing and pull out the released contact from the contact housing -arrow-.
  • The release tool can be pulled out of the contact housing again once the contact has been removed.

GT 150/280 contacts:

  • Insert the release tool appropriate for the contact housing under the locking tab into the contact housing.
  • Push the tool onto the limit stop -arrow- in the contact housing.

vw_contact_housing_primary_special_3

The contact is ejected from the contact housing.

vw_contact_housing_primary_special_4

  • The release tool can be pulled out of the contact housing again once the contact has been ejected.

Contacts without locking tabs:

  • Insert the release tool under the locking tab of the contact housing.
  • Push through the release tool with a light upward movement -arrow- onto the limit stop.

vw_contact_housing_primary_special_5

The contact is ejected from the contact housing.

vw_contact_housing_primary_special_6

]]> http://www.my-gti.com/1707/releasing-and-dismantling-contact-housings/feed 0 Addition of extra circuits to the Volkswagen Golf / Jetta / Passat / EOS / Scirocco / Rabbit fuse box http://www.my-gti.com/601/addition-of-extra-circuits-to-the-volkswagen-golf-jetta-passat-eos-scirocco-rabbit-fuse-box http://www.my-gti.com/601/addition-of-extra-circuits-to-the-volkswagen-golf-jetta-passat-eos-scirocco-rabbit-fuse-box#comments Sun, 20 Sep 2009 07:04:07 +0000 Maverick http://www.my-gti.com/?p=601 Adding new circuits to your Volkswagen Golf / Jetta / Passat / EOS / Scirocco /Passat fuse box is reasonably straight forward, allow 2 hours for the first time and 1 hour for each time after that.

(Golf 1K1 /1K5, Golf Plus 5M1, Passat 3C2/3C5, Passat CC 357, EOS 1F7, Scirocco 137)

There are two sizes used in the interior fuse [...]]]> Adding new circuits to your Volkswagen Golf / Jetta / Passat / EOS / Scirocco /Passat fuse box is reasonably straight forward, allow 2 hours for the first time and 1 hour for each time after that.

(Golf 1K1 /1K5, Golf Plus 5M1, Passat 3C2/3C5, Passat CC 357, EOS 1F7, Scirocco 137)

There are two sizes used in the interior fuse box, ATM and ATO size. These are commonly referred to as Mini and Standard. In the main fuse box there is an additional type called ATX but commonly referred to as Maxi.

Repair Wire or Terminals for additional circuits

To install new circuits you require either repair wire (two terminals on the end of one short cable, cut the cable in the middle and join the two cables to the new circuits) or terminals (not recommended see below for details).

The small fuses in the fusebox use the 2.8mm terminals. The terminals are the same size but the repair wires are different sizes. I used the 1.0mm wire size for this guide.

  • 000 979 021 (000979021): 0.5mm wire
  • 000 979 133 (000979133): 1.0mm wire (used for this guide)
  • 000 979 225 (000979225): 2.5mm wire

Crimp on pins are available as well but I recommend the repair wires unless you’re familiar with the crimping process:

  • N 906 844 05 (N90684405): for 1.0mm wire
  • N 906 845 05 (N90684505): for 2.5mm wire

The large fuses in the fusebox use the 4.8mm terminals. The terminals are the same size but the repair wires are different sizes. These were not installed in this guide but the process is identical.

  • 000 979 023 (000979023): 0.5mm wire
  • 000 979 135 (000979135): 1.0mm wire
  • 000 979 227 (000979227): 2.5mm wire
  • 000 979 306 (000979306): 4.0mm wire

Crimp on pins are available as well but I recommend the repair wires unless you’re familiar with the crimping process:

  • N 907 326 03 (N90732603): for 1.0mm wire
  • N 907 327 03 (N90732703): for 2.5mm wire
  • N 906 966 03 (N90696603): for 4.0mm wire
  • N 904 221 02 (N90422102): for 6.0mm wire

Fuses available and their colours are listed at the end of this guide.

Using repair wire to connect to your new circuits.

Cut the repair wire in two as shown, I recommend unequal length so the two soldering joints are not adjacent to one another.

volkswagen_fuse_box_repair_wire_1

Twist the connectors together and solder as shown keeping the joins as small as possible. Ensure that you have installed the heatshrink tubing on the cable before you solder!

volkswagen_fuse_box_repair_wire_2

The finished product should look like this.

volkswagen_fuse_box_repair_wire_3

Installation of new circuits

This guide is for RHD Volkswagen Golfs, the LHD fuse box removal is easier and does not require the removal of trim.

Important: Make sure all the doors are unlocked, the key is not in the ignition and disconnect the car battery.

Start by removing the cover over the fusebox,  a small notch is visible 2/3rds of the way down on the side where you can place the ignition key and lever this off. Once this has been removed you will see the fuse box.

volkswagen_fuse_box_before

Next remove the two clips as indicated, these can be pushed out from behind with your finger.

volkswagen_fuse_box_before_main

Remove the headlight switch by pushing the knob inwards when on Auto and turning it around to the off position.

volkswagen_fuse_box_trim_headlight_switch_1 volkswagen_fuse_box_trim_headlight_switch_3

This will allow the locking tab to withdraw.

volkswagen_fuse_box_trim_headlight_switch_2 volkswagen_fuse_box_trim_headlight_switch_4

Remove the screw at the rear top.

volkswagen_fuse_box_trim_headlight_switch_remove_screw

Remove the drivers side drawer by opening it and pressing the sides together at the back to release it and once open you can remove the drawer by unclipping the hinge. Remove the two screws at the bottom and the one at the top.

volkswagen_fuse_box_trim_storage_box_1 volkswagen_fuse_box_trim_storage_box_2

Pop the trim above the steering column by using a trim removal tool, be careful not to scratch the trip around the instruments as there is a metal clip on the rear of this trim.

volkswagen_fuse_box_trim_above_steering_column_1 volkswagen_fuse_box_trim_above_steering_column_2 volkswagen_fuse_box_trim_above_steering_column_3

Remove the screw and sit the trim back in place.

volkswagen_fuse_box_trim_above_steering_column_4

The trim panel can now be removed and the fuse box can be loosened by undoing the screw on the top and bottom of the fuse box.

volkswagen_fuse_box_before

The fuse box is now loose.

volkswagen_fuse_box_open_1

Pull the label forward (don’t remove it) to uncover one of the three sets of clips holding the cover on.

volkswagen_fuse_box_open_2

Gently unclip the three clips around the cover.

volkswagen_fuse_box_open_3

Remove the fuse box cover and expose the rear of the fuse box.

volkswagen_fuse_box_open_4

The next step requires removing all your fuses, as nearly every fuse box is different it is essential you document the fuse layout, at the very least take photos and even write them down.

volkswagen_fuse_box_open_5

These are the two locations where we will be installing our connectors and creating our new circuits.

volkswagen_fuse_box_open_6

Insert a small flat head screwdriver where indicated and move the carrier downwards as indicated to enable the connectors to be unlocked.

volkswagen_fuse_box_open_7

Insert the repair connectors as shown.

volkswagen_fuse_box_open_8

The carrier has been slid back into place to lock the connectors.

volkswagen_fuse_box_open_9

The new circuits have been run in along the same path as the factory loom.

volkswagen_fuse_box_open_10

Snap the cover back into place.

volkswagen_fuse_box_open_11

Refasten the fuse box into place.

volkswagen_fuse_box_open_12

Reinstall the fuses including the new fuse(s) if the circuits are connected or have been isolated.

volkswagen_fuse_box_open_13

Reinstall the trim following the removal instructions in reverse and place the cover back over the fuse box and reconnect the car battery.

Fuses available and their colours.

ATM Type Mini Fuse

  • 7.5 Amp – Brown
  • 10 Amp – Red
  • 15 Amp – Blue
  • 20 Amp – Yellow
  • 25 Amp – White
  • 30 Amp – Green

ATO Type Standard Fuse

  • 5 Amp – Orange
  • 7.5 Amp – Brown
  • 10 Amp – Red
  • 15 Amp – Blue
  • 20 Amp – Yellow
  • 25 Amp – White
  • 30 Amp – Green

ATX Type Maxi Fuse

  • 20 Amp – Yellow
  • 30 Amp – Green
  • 40 Amp – Orange
  • 50 Amp – Red
  • 60 Amp – Blue
]]> http://www.my-gti.com/601/addition-of-extra-circuits-to-the-volkswagen-golf-jetta-passat-eos-scirocco-rabbit-fuse-box/feed 12 Volkswagen / Skoda Bluetooth Housings and Pins http://www.my-gti.com/1300/volkswagen-skoda-bluetooth-housings-and-pins http://www.my-gti.com/1300/volkswagen-skoda-bluetooth-housings-and-pins#comments Sun, 30 Aug 2009 10:55:27 +0000 Maverick http://www.my-gti.com/?p=1300 Main Connector - 54-pin (18×3) – blue- 4E0 972 144 (4E0972144)

Pins – N/A Repair Wire 0.5mm – 000 979 010 (000979010) Repair Wire 1.0mm – N/A Repair Wire 2.5mm – N/A

Male

Pins – N/A Repair Wire 0.5mm – N/A Repair Wire 1.0mm – N/A Repair Wire 2.5mm – N/A

Microphone - 2-pin (2×1) [...]]]> Bluetooth Connector – use by Volkswagen, Skoda, Seat and Audi.

Main Connector - 54-pin (18×3) – blue- 4E0 972 144 (4E0972144)

  • Pins – N/A
  • Repair Wire 0.5mm – 000 979 010 (000979010)
  • Repair Wire 1.0mm – N/A
  • Repair Wire 2.5mm – N/A

Male

  • Pins – N/A
  • Repair Wire 0.5mm – N/A
  • Repair Wire 1.0mm – N/A
  • Repair Wire 2.5mm – N/A

Microphone - 2-pin (2×1) – microphone

  • Pins – N/A
  • Repair Wire 0.5mm – 000 979 018 (000979018)
  • Repair Wire 1.0mm – N/A
  • Repair Wire 2.5mm – N/A

Male – 8D0 972 643 (8D0972643)

  • Pins – N/A
  • Repair Wire 0.5mm – 000 979 017 (000979017)
  • Repair Wire 1.0mm – N/A
  • Repair Wire 2.5mm – N/A
]]> http://www.my-gti.com/1300/volkswagen-skoda-bluetooth-housings-and-pins/feed 2 Volkswagen Head Unit Housings and Pins http://www.my-gti.com/1294/volkswagen-head-unit-housings-and-pins http://www.my-gti.com/1294/volkswagen-head-unit-housings-and-pins#comments Sun, 30 Aug 2009 10:32:27 +0000 Maverick http://www.my-gti.com/?p=1294

Connector 1 – 8-pin (4×2) – brown – 3B7 035 447 (3B7035447)

Pins – N 906 844 05 (N90684405) Repair Wire 0.5mm – 000 979 021 (000979021) Repair Wire 1.0mm – 000 979 133 (000979133) Repair Wire 2.5mm – 000 979 225 (000979225)

Male

Pins – N [...]]]> Quad Lock – All recent Volkswagen, Skoda, Seat and Audi vehicles use this connector.

connectors_rns_510_main_N91-10928

Connector 1 – 8-pin (4×2) – brown – 3B7 035 447 (3B7035447)

  • Pins – N 906 844 05 (N90684405)
  • Repair Wire 0.5mm – 000 979 021 (000979021)
  • Repair Wire 1.0mm – 000 979 133 (000979133)
  • Repair Wire 2.5mm – 000 979 225 (000979225)

Male

  • Pins – N 103 189 05 (N10318905)
  • Repair Wire 0.5mm – 000 979 022 (000 979 022)
  • Repair Wire 1.0mm – 000 979 134 (000979134)
  • Repair Wire 2.5mm – 000 979 226 (000979226)

Connector 2 – 8-pin (4×2) – plus quadlock – 3B7 035 444 (3B7035444)

  • Pins – N 906 844 05 (N90684405)
  • Repair Wire 0.5mm – 000 979 021 (000979021)
  • Repair Wire 1.0mm – 000 979 133 (000979133)
  • Repair Wire 2.5mm – 000 979 225 (000979225)

Male

  • Pins – N 103 189 05 (N10318905)
  • Repair Wire 0.5mm – 000 979 022 (000979022)
  • Repair Wire 1.0mm – 000 979 134 (000979134)
  • Repair Wire 2.5mm – 000 979 226 (000979226)

Connector 3- 12-pin (6×2) – green- 3B7 035 447 B (3B7035447B) – telephone

  • Pins – N/A
  • Repair Wire 0.5mm – 000 979 009 (000979009)
  • Repair Wire 1.0mm – N/A
  • Repair Wire 2.5mm – N/A

Male

  • Pins – N/A
  • Repair Wire 0.5mm – 000 979 012 (000979012)
  • Repair Wire 1.0mm – N/A
  • Repair Wire 2.5mm – N/A

Connector 4- 12-pin (6×2) – blue- 3B7 035 447 A (3B7035447A) – cdc

  • Pins – N/A
  • Repair Wire 0.5mm – 000 979 009 (000979009)
  • Repair Wire 1.0mm – N/A
  • Repair Wire 2.5mm – N/A

Male

  • Pins – N/A
  • Repair Wire 0.5mm – 000 979 012 (000979012)
  • Repair Wire 1.0mm – N/A
  • Repair Wire 2.5mm – N/A

Audio Visual Input – used by Volkswagen RNS 510 and AUDI RNS-E

connectors_rns_510_av_N91-10930

Connector - 32-pin (16×2) – grey- 1J0 972 977 G (1J0972977G)

  • Pins – N/A
  • Repair Wire 0.5mm – 000 979 009 (000979009)
  • Repair Wire 1.0mm – N/A
  • Repair Wire 2.5mm – N/A

Male

  • Pins – N/A
  • Repair Wire 0.5mm – 000 979 012 (000979012)
  • Repair Wire 1.0mm – N/A
  • Repair Wire 2.5mm – N/A
]]> http://www.my-gti.com/1294/volkswagen-head-unit-housings-and-pins/feed 4