Handling Components and Connectors

Harness Connectors
The harness connectors used throughout the vehicle are designed to positively lock into place.

Harness Connector:

Typical wiring harness connector. Push on wire lock (arrow) and gently pull on connector to release.

CAUTION: To disconnect, pull only on the connector body. Never pull on the wires themselves.

Making Test Connections
Many electrical troubleshooting tests will require hooking up to wiring harness connectors, or socket connectors on electrical components. Test connections made carelessly or without proper tools can easily damage the connectors, causing poor connections and future problems.

Alligator-clip Test Leads With Flat Connectors:

To avoid connector damage, test connections to wiring harness connectors must be made using small, flat-blade terminals which will mate properly with the connectors. The Special Tools recommended include special adapters which can be used to make test connections safely and prevent connector damage. See Tools and Equipment.
All test connections to harness connectors should be made using the proper adapter or correct size flat connectors that will not deform the connector cavities.

Wiring Harness Repairs

W-Type Crimp Connection:

When repairing wiring harnesses, use only high-quality electrical connectors suitable for use with electronic components.

Wire Crimping Pliers, For Making W-Type Crimps:

Wire Crimping Pliers, Not Suitable For W-Type Crimps:

To make connections, use crimping pliers that make a "W"-type crimp. Only this type of crimp provides the necessary mechanical strength.
Connector repair kits, connectors and the correct crimping pliers are available through your authorized dealer Parts Department.

Wiring Harness Repair Kit VAS 1978

Wire Harness Repair Kit, VAS 1978:

Wiring Harness Repair Kit VAS 1978 was developed to simplify wiring harness repairs by using factory pre-crimped replacement wires thus elimination numerous repair kits and crimping fixtures. All of the tools and parts are conveniently located in one case and are easy to use. VAS 1978 kit reduces the total repair steps needed to effect repair.