Category Archives: Housings and Pins

Purchasing terminal kits or tools for your Volkswagen / Audi / Skoda

Schwaben Parts

website: www.schwabenparts.com

Schwaben Terminal Removal Tool Set

Available from ECS Tuning for USD $69.95

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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

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

Volkswagen VAS 1978/18

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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

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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.

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

AST S 1556 N

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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

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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)

Releasing and dismantling contact housings

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-.

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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.

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The contact is ejected from the contact housing.

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  • 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.

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Addition of extra circuits to the Volkswagen Golf / Jetta / Passat / EOS / Scirocco / Rabbit fuse box

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!

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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.

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This will allow the locking tab to withdraw.

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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.

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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.

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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.

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The fuse box is now loose.

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

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Gently unclip the three clips around the cover.

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

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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.

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

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

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Insert the repair connectors as shown.

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

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

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Snap the cover back into place.

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Refasten the fuse box into place.

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

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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

Volkswagen / Skoda Bluetooth Housings and Pins

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

Volkswagen Head Unit Housings and Pins

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