Volkswagen Touran Service Manual: Fiber-Optic Cable, Assembling

Volkswagen Touran Service Manual / Electrical System / Wiring / Wiring Harness and Connector Repairs / Fiber-Optic Cable, Assembling

Special tools and workshop equipment required

Fiber-Optic Conductor Repair Set -VAS6223A-

Hose Cutting Pliers -VAS6228-

Vehicle Diagnostic Tester

It is very difficult to find the exact location of the problem. Replace the damaged fiber-optic cable and lay a new wire parallel to the defective fiber-optic cable.

Note

Select the damaged fiber-optic cable components with the "Guided Fault Finding" or "Guided Functions" from the Vehicle Diagnostic Tester menu options.

A fiber-optic cable that needs repair is represented by a "yellow" color.

Procedure

Choose "Guided Fault Finding" or "Guided Functions" in the Vehicle Diagnostic Tester. Refer to Vehicle Diagnostic Tester.

Assemble the fiber-optic cable. Refer to → Chapter "Fiber-Optic Cable, Assembling".

Caution

Do not bend the fiber-optic cable too much. The bending radius must be no less than 25 mm.

Fiber optic cables must not be routed over sharp edges.

The fiber-optic cable must not be dirty or touched with bare fingers.

Fiber optic cables may not be heated.

It is not permitted to twist together 2 fiber optic cables or one fiber optic cable with a copper wire.

Protect the connector and the connection box from dust. Place the cap on the trunk.

Caution

Do not bend the fiber-optic cable too much. The bending radius must be no less than 25 mm.

Fiber optic cables must not be routed over sharp edges.

The fiber-optic cable must not be dirty or touched with bare fingers.

Fiber optic cables may not be heated.

It is not permitted to twist together 2 fiber optic cables or one fiber optic cable with a copper wire.

Protect the connector and the connection box from dust. Place the cap on the trunk.

Mount the Tool Head for the Fiber-Optic Repair Set - Pliers -VAS6223/1-.

Remove the locking pin -arrows-.

Remove the tool set -arrow- and pull the locking pin back.

Fiber Optic Cable, Cutting to Length

Establish length of fiber optic cable required.

Open the Fiber-Optic Repair Set - Pliers -VAS6223/1- and lay the fiber-optic cable -1- in the mount.

Close the Fiber-Optic Repair Set - Pliers -VAS6223/1- to cut the fiber-optic cable lengths.

Stripping

Open the Fiber-Optic Repair Set - Pliers -VAS6223/1-.

Position the wire stripper in the lower position -arrow-.

Insert fiber-optic cable into the stripping station.

The end of the fiber-optic cable must be flush with the rear side of the cutting pliers.

Close the Fiber-Optic Repair Set - Pliers -VAS6223/1- until the stop and keep closed.

Bend the wire stripper upward -arrow- and remove the fiber-optic cable.

Precision Cutting (Production of Optical End Face)

Push the fiber-optic cable -1- into the cutting station.

Insulation must make contact with cutting point stop.

Close the Fiber-Optic Repair Set - Pliers -VAS6223/1- and remove the wire.

Visually inspect the wire -1- to make sure that it was cut correctly and that there are no burrs on the front surface.

Note

Fiber-optic cable is only to be placed on an absolutely clean surface or held in hand.

Use the cap if there is a risk of the fiber-optic cable surface becoming dirty.

Attaching Brass Pin Contact to Fiber-Optic Cable

Change tool head -arrow-.

Slide the safeguard on the Fiber-Optic Repair Set - Pliers -VAS6223/1- in direction of -arrow- so that the word "Stift" (pin) is legible.

Insert a brass pin contact -1- in the mount.

Close the securing lever on the Fiber-Optic Repair Set - Pliers -VAS6223/1- in direction of -arrow-.

Insert the fiber-optic cable into the brass pin contact -arrow- all the way up to the threaded stop and then close the Fiber-Optic Repair Set - Pliers -VAS6223/1-.

Open the fiber-optic cable pliers and remove the fiber-optic cable along with the brass contact pin.

Caution

Do not excessively bend or kink the fiber-optic cables (minimum bending radius 25 mm).

Make sure the brass pin contact -2- is secured properly on the fiber-optic cable -1-.

4 crimped points must be visible on the brass connecting pin.

The brass pin contact must not be able to be removed by hand from fiber-optic cable.

The front surface of the fiber-optic cable is 0.01 to 0.1 mm behind the brass pin contact (visual check).

Note

Connector couplings are available for connecting the fiber-optic cables. Refer to Parts Catalog.

To install the new fiber optic cable in wiring harness connector. Refer to → Chapter "Fiber-Optic Cable, Disconnecting from Wiring Harness Connector".

Corrugated Tube, Install on Fiber Optic Cable

Cut corrugated tube to appropriate length.

Use the Hose Cutting Pliers -VAS6228- or a sharp knife for cutting.

The corrugated tube must not be cut through using a side cutter under any circumstances

The corrugated tube must be cut on the wave peak -arrow-, not in the wave trough.

The corrugated tube must audibly engage in the fiber-optic cable housing when installing.

Guide the fiber-optic cable into the Fiber-Optic Repair Set - Tube Tool -VAS6223/10- as shown.

Position corrugated tube assembly pliers on slot on the tube.

Position crimping pliers for fiber-optic cable at slot of corrugated tube. The fiber optic cable is then routed in the corrugated tube.

Wire Break with Dual Repair Point

Repair point with intermediate wire section Free up wire intended for repair at two points (approximately 20 cm to both sides of respect ...

Fiber-Optic Cable, Disconnecting from Wiring Harness Connector

Removing Unplug connector for fiber optic cable from appropriate control unit. Release the locking m ...

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