VW Touran manuals

Volkswagen Touran Service Manual: 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-.
  Fiber-Optic Cable, Assembling
  Remove the locking pin -arrows-.
  Remove the tool set -arrow- and pull the locking pin back.
  Fiber-Optic Cable, Assembling
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.
  Fiber-Optic Cable, Assembling
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.
  Fiber-Optic Cable, Assembling
  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.
  Fiber-Optic Cable, Assembling
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.
  Fiber-Optic Cable, Assembling
  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.
  Fiber-Optic Cable, Assembling
Attaching Brass Pin Contact to Fiber-Optic Cable
  Fiber-Optic Cable, Assembling
  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.
  Fiber-Optic Cable, Assembling
  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-.
  Fiber-Optic Cable, Assembling
  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).
  Fiber-Optic Cable, Assembling
  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".
  Fiber-Optic Cable, Assembling
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.
  Fiber-Optic Cable, Assembling
  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.
  Fiber-Optic Cable, Assembling
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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