Volkswagen Tiguan Service and Repair Manual: Contact Housings, Releasing and Disassembling

Releasing and Disassembly Contact Housings, General Information

Note

• Observe general notes for repairs on the vehicle electrical system.
• Always use the release tools intended for the releasing process. Under no circumstances may terminals be pulled forcefully out of terminal housings.
• Damaged contact housings must always be replaced. New contact housings may be ordered via OTC Kassel.
• Small screwdrivers may be used as an aid to release the secondary locks.
• Chamber/pin assignment is located partially stamped in on secondary lock or rear side of terminal housing.
• Detailed information on component locations of harness connectors.

The allocation of the correct release tools to the respective locking mechanisms can be found in the table in the Release Tool Set -VAS1978/35- Operating Instructions.

Secondary Lock

The secondary lock is a housing securing mechanism (second locking mechanism) that secures all wires in one contact housing. If a secondary lock is installed at a contact housing, it must always be opened or removed using specified tool before releasing and pulling out individual crimp contacts.

Secondary lock is distinguished by a different color from the rest of the contact housing. It simplifies recognizing the secondary lock and clarifies its function.

The shapes of the terminal housings depicted here are only a selection which, as an example, should make clear the various functions of the secondary lock.

Example 1

Housing securing mechanism is released by removing a "comb"-arrow-.

Example 2

Housing securing mechanism is released by opening a "flap"-arrow-.

Example 3

Housing securing mechanism can be released by disengaging a "slider"-arrow-.

Primary Lock

The primary lock is the locking mechanism of an individual crimp contact in the contact housing.

If necessary, housing securing mechanisms (secondary locks) must be released or removed using specified tool before releasing the contacts.

The shapes of the primary locks depicted in the following are only a selection which, as an example, should make clear the various functions of the primary lock.

• Round connector systems.
• Flat connector systems.
• Special connector systems.

The allocation of the correct release tool for the respective locks can be found in the table in the Release Tool Set -VAS1978/35- Operating Instructions.

Round Connector Systems

Note

If necessary, housing securing mechanisms (secondary locks) must be released or removed using specified tool before releasing the contacts.

• Guide the release tool which fits the contact housing into release channel on contact housing.
• Grasp contact at wire and push it gently into contact housing -arrow-.

Note

By pushing the contact in the direction of the contact housing, the contact retaining tabs are lifted off the housing shoulder and can be released using the release tool.

• At the same time, push release tool in direction of contact housing -arrow- and pull the released contact out of contact housing.
• After removing the contact, release tool can be pulled out of the contact housing again.

Flat Connector Systems

Note

If necessary, housing securing mechanisms (secondary locks) must be released or removed using specified tool before releasing the contacts.

Flat Connector System with One Retaining Tab

• Guide the release tool which fits the contact housing into release channel on contact housing.
• Grasp contact at wire and push it gently into contact housing -arrow-.

Note

By pushing the contact in the direction of the contact housing, the contact retaining tab is lifted off the housing shoulder and can be released using the release tool.

• At the same time, push release tool in direction of contact housing and pull the released contact out of contact housing -arrow-.
• After removing the contact, release tool can be pulled out of the contact housing again.

Flat Connector System with Two Retaining Tabs

• Guide the release tool which fits the contact housing into release channel on contact housing.
• Grasp contact at wire and push it gently into contact housing until it stops in direction of -arrow-.

Note

By pushing the contact in the direction of the contact housing, the contact retaining tabs are lifted off the housing shoulder and can be released using the release tool.

• At the same time, push release tool in direction of contact housing and pull the released contact out of contact housing in direction of -arrow-.
• After removing the contact, release tool can be pulled out of the contact housing again.

Asymmetrical

• Guide the release tool which fits the contact housing into release channel on contact housing.
• Grasp contact at wire and push it gently into contact housing -arrow-.

Note

By pushing the contact in the direction of the contact housing, the contact retaining tabs are lifted off the housing shoulder and can be released using the release tool.

• At the same time, push release tool in direction of contact housing and pull the released contact out of contact housing -arrow-.
• After removing the contact, release tool can be pulled out of the contact housing again.

Special Connector Systems

Note

If necessary, housing securing mechanisms (secondary locks) must be released or removed using specified tool before releasing the contacts.

Faston Contacts

• Guide the release tool which fits the contact housing into release channel on contact housing.
• Grasp contact at wire and push it gently into contact housing.

Note

By pushing the contact in the direction of the contact housing, the contact retaining tabs are lifted off the housing shoulder and can be released using the release tool.

• At the same time, push release tool in direction of contact housing and pull the released contact out of contact housing -arrow-.
• After removing the contact, release tool can be pulled out of the contact housing again.

GT 150/280 Contacts

• Guide the release tool which fits the contact housing under retaining tab into contact housing.
• Push tool into contact housing until it stops -arrow-.

Contact is ejected from the contact housing.

• After ejecting the contact, release tool can be pulled out of contact housing again.

Contacts without Retaining Tabs

• Insert release tool under retaining tab of terminal housing.
• Push release tool through until it stops by gently lifting -arrow-.

Contact is ejected from the contact housing