Vehicle Electrical System, General Repair Information

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

When disconnecting and connecting the Battery -A-, the procedure must be followed as described in the repair information, refer to BATTERY, DISCONNECTING AND CONNECTING .

WARNING:

Some tools are supplied with a tool safety clip, which is slid over the tool points after using the tool, in order to protect other workers from injuries and tool points from damage.

When performing repairs, always heed any notes, cautions and warnings found in the applicable repair manual.
Observe the country-specific requirements.
Disconnect the Battery -A- before working on the electrical system, refer to BATTERY, DISCONNECTING AND CONNECTING . By disconnecting the Battery -a- (current disruption), the electrical system is guaranteed to be safe to work on. Disconnecting the positive battery cable is only required when removing the Battery -A-.
Before beginning repair work, always eliminate any cause of damage (sharp body edges, faulty electrical components, corrosion).
Further information, for example, installing and removing the individual components, can be found in the appropriate repair manual.
Soldering is not permissible for repairs to the vehicle electrical system.
Wiring harness and connector repairs to vehicle electrical system may only be performed using the Wiring Harness Repair Set VAS 1978/Wiring Harness Repair Set VAS 1978A/Wiring Harness Repair Set VAS 1978B.
Wiring harness repairs are only to be done using yellow wires.
Wiring harness repairs may not be performed again in the wrapping of the vehicle-specific wiring harness and are to be marked with yellow adhesive tape.
These yellow wires and every location on wiring harness wrapped in yellow insulating tape indicates a previous repair.
Crimp connections must never be repaired. Route a wire parallel to the faulty wire.
After crimping, the crimp connectors must be heat-shrunk using the Wiring Harness Repair Set - Hot Air Blower VAS 1978/14A to prevent moisture penetration.
Always observe the supplementary notes also for repairing wiring harnesses on airbag-system and belt tensioners, fiber optic cables, CAN-Bus wires, antenna wires and wires with cross-sections up to 0.35 mm ² , refer to WIRES WITH CROSS SECTION UP TO 0.35 MM .
A function test must be performed after every repair. If necessary, check DTC memory, erase and/or bring systems into basic setting.
If possible, do not loosen ground (GND) straps from body (danger of corrosion).
Not all wire cross-sections in the vehicle are contained in the Wiring Harness Repair Set VAS 1978B and its previous versions. If the required wire cross-section is not present, the next greater cross-section must be used.
Shielded harnesses may not be repaired. If faulty, the entire harness must be replaced.
Heat-resistant wires have been installed in the vehicle at various locations, mainly in the engine compartment. Heat-resistant wires can be recognized by their somewhat duller and softer insulation. Only heat-resistant wires may be used to repair these wires.