Lighting - Headlamp Connector Damage Repair

Group: 94

Number: 03-04

Date: Oct. 6, 2003

Subject:
Headlight Electrical Connection, Repair

Model(s):
New Jetta, Jetta Wagon 1999 --> 2003
New Golf

Supersedes T.B. Group 94 number 99-01 dated Dec. 8, 1999 in part due to addition of Models, Model Year and Labor Operation change to 8 digits.

Service

If service or accident damage necessitates headlight harness repair or connector replacement, perform the following:





- Always use VAS 1978 Wire Harness Repair Kit.

^ If connector and/or wiring cannot be repaired using procedure and materials contained in VAS 1978, then wire harness must be replaced.

^ No other procedure or materials, other than those in VAS 1978, may be used for wire harness repairs, specifically soldering, wire nuts, generic repair kits, etc.

CAUTION!
Review and follow Safety Precautions in VAS 1978 Instruction Manual prior to performing any wiring harness repairs.





CAUTION!
Shielded wiring for components such as speed sensors or knock sensors, may not be repaired, but must ALWAYS be replaced, DO NOT use solder wire when repairing a wiring harness. Or ply use approved methods and materials if wiring harness repairs are required.

- Remove headlight assembly. Refer to Repair Manual, Electrical Equipment, Repair Group 94.

- Cut off damaged connector and damaged wiring at appropriate distance so all original wire colors are still identifiable.

1 - White

2 - Brown

3 - Yellow

- Using Wire Stripper VAS 1978/3, cut three pre-terminated wires (Part No. 000 979 126) approximately 25 mm (1 inch) longer than the wires cut on the damaged connector.

CAUTION!
Part numbers are for reference only.

Always check with your Parts Dept. for the latest parts information.

- Strip insulation on all wire ends approximately 6-7 mm (1/4 inch).

- Twist wire strands.

- Insert butt connector (P/N 111 971 940 A) into Crimp Tool VAS 1978/1. Use red dot crimp.





Note:
Collar side of crimp must face wire to be crimped as shown.

- Insert wire into butt connector.

- Crimp together on both sides using crimping tool.





- Apply Electric Hot Air Blower VAS 1978/14 and Adapter for Heat Gun VAS 1978/15 to shrink and seal butt connector.

Note:
Connector must be heated by moving adapter tip from center outward until fully sealed.

- Allow connector to cool off before proceeding.

- Insert terminals into new hard shell connector (Part Number 1EO 941 165).





- Make sure wires are in correct position.

1 - White (Cavity 1)

2 - Brown (Cavity 2)

3 - Yellow (Cavity 3)

Note:

^ Make sure glass bulb is not handled with bare hands to avoid "hot spotting".

^ Do not use high intensity light bulbs in this application.

^ Use only original VW spare part 12V/60W

- Install headlight bulb for functional testing. Refer to Repair Manual, Electrical Equipment, Repair Group 94.

- Install headlight assembly. Refer to Repair Manual, Electrical Equipment, Repair Group 94.

- Check (and adjust if necessary) headlights to 0.7 VOL using the VAS 5107 (Hella Universal Beamsetter Series IV aiming equipment) according to instructions in Repair Manual - Repair Group - Maintenance.





When repair is made under the New Vehicle Limited Warranty, use the table.