Fiber-Optic Cable, Assembling

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.

Special Tools And Workshop Equipment Required

Fiber-Optic Conductor Repair Set VAS 6223A
Hose Cutting Pliers VAS 6228
Vehicle Diagnostic Tester

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 VAS 6223/1.

-- Remove the locating pin in the direction of the -arrow-.

Fig 1: Identifying Locking Pins

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-- Position the tool head in the direction of the -arrow-.

Fig 2: Identifying Tool Set

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-- Push the locking pin back.

Fiber optic cable, cutting to length

-- Open the Fiber-Optic Repair Set - Pliers and lay the fiber-optic cable -1- in direction of the -arrow- in the mount.

Fig 3: Identifying Method To Cut Fiber Optic Cable To Length

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-- Establish length of fiber optic cable required.

-- Close the Fiber-Optic Repair Set - Pliers VAS 6223/1 to cut the fiber-optic cable to length.

Stripping

-- Open the Fiber-Optic Repair Set - Pliers VAS 6223/1.

Fig 4: Identifying Open Position For VAS 6223/1

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-- Position the wire stripper lever in the lower position in direction of the -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 VAS 6223/1 until it stops and keep closed.

Fig 5: Identifying Closed Position For VAS 6223/1

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-- Turn the wire stripper lever in the direction of the -arrow-.

-- Remove the fiber-optic cable.

Precision cutting (production of optical end face)

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

Fig 6: Identifying Position Of Fiber-Optic Cable In Cutting Position

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Insulation must make contact with cutting point stop.

-- Close the Fiber-Optic Repair Set - Pliers VAS 6223/1 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.

Fig 7: Identifying Visual Inspection Of Cut Wire

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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.

-- Position the tool head in the direction of the -arrow-.

Fig 8: Identifying Change Of Tool Head

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-- Slide the safeguard on the Fiber-Optic Repair Set - Pliers VAS 6223/1 in direction of the -arrow- so that the word "Stift" (pin) is legible.

Fig 9: Identifying Movement Of Fuse On VAS 6223/1 To Show "Stift"

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

Fig 10: Identifying Inserted Brass Pin And Securing Lever

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-- Close the securing lever on the Fiber-Optic Repair Set - Pliers VAS 6223/1 in the direction of the -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 VAS 6223/1.

Fig 11: Identifying Inserted Fiber Optic Cable

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-- 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-.

Fig 12: Checking Proper Attachment Of Brass Pin Contact To Fiber Optic Cable

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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 .

To install the new fiber optic cable in wiring harness connector, refer to FIBER-OPTIC CABLE, DISCONNECTING FROM WIRING HARNESS CONNECTOR .

Corrugated tube, install on fiber optic cable.

-- Cut the corrugated tube to the fitting length using Hose Cutting Pliers VAS 6228.

Fig 13: Cutting Corrugated Tube To Appropriate Length Using Air Hose Pliers VAS 6228 Or A Sharp Knife

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The corrugated tube must be cut on the wave peak -arrow-, not in the wave trough.
Use the Hose Cutting Pliers VAS 6228 or a sharp knife for cutting.
The corrugated tube must not be cut using a side cutter under any circumstances.
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 VAS 6223/10.

Fig 14: Guiding Fiber-Optic Cable Into Corrugated Tube With VAS 6223/10

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-- 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.