Repairs of the electrical installation in Škoda vehicles
Contents
1. 34 GB 4 2 2 Examples of service practice a When installing the non original GPS the GPS cable set was fitted to the original electric installation of the vehicle to the cable set of the QC steering column electronics J527 and instrument panel This prevented the original bundle from moving freely jamming and colliding with the steering column The malfunction of the insulation package the body end of the conductor and the breakage of the fuse SC39 have been the cause of the engine shutting off while driving and it was not possible to restart the engine Correct procedure Guide and fasten the cable set of the non original accessories in sucha way that a malfunction of the original electrical installation does not occur whereby the point of view of Skoda in regards to additional installations of electrical equipment applies GB 35 b When fitting the drawgear in a non branded service station a supply conductor of the drawgear was connected to the supply conductor of the QC steering column electronics The conductor coupling was carried out improperly with a quick release coupling see figure that has caused the interruption of the feed for the QC column electronics J527 The vehicle has stopped while driving and the engine could not be restarted Correct procedure Carry out the installation of the approved type of drawgear for the vehicle in a standard way according to the installation instruction which was appro2. ssssssssssssssssnensnsnnnsnnnnnnnnunnnunnnsnnnnnnnnnnnnnne 29 5 Repairs of the plug connectors and terminal Strips ccssccsscsssscsscsssscsscesseceesecsesessecsesessesasseceesaseecessesassecsesassesesasaseas 37 GB 3 GB 1 Skoda service documentation Correct method of carrying out repairs of the electrical installation Source Skoda workshop manual electrical systems general information 97 cable selected chapters relating to the repairs of the electrical installation 1 1 Compliance with the repair procedures according to the valid service documentation General repair instructions for the electrical system of the vehicle WARNING gt On modules affixed with stickers that warn of high voltage in the system of the vehicle the residual voltage must be eliminated before the repair e g switch on the consumer after disconnecting the battery and subsequently switch it off again gt Some tools have a protective cap which has to be refitted on the tip of the tool after using it because of the possible injury and damage to the tip Note gt Comply with country specific regulations gt When disconnecting and connecting the battery follow the prescribed procedure Electrical systems repair group 27 gt Before beginning the repair the cause of damage must first be resolved such as sharp edges of the body parts defective power consumers corrosion etc Note gt If possible do not loosen the earth
3. Preserve the threaded connections with the appropriate preservative page 29 Comply with the procedure for battery connection Electrical systems repair group 27 12 GB 1 3 3 Cleaning the battery terminals and poles WARNING Risk of accident Pay attention to the warning notes and safety instructions when working with batteries gt Page 2 Note gt To avoid breaking the threaded connection such as when exceeding the tightening torque due to the lack of static friction in the thread no rust remover contact spray or grease must be used for battery terminals Disconnect the battery Electrical systems repair group 27 Check the battery terminals for corrosion or contamination The battery terminals are cleaned by circular movements of the wire brush for battery poles and terminals Mor 1 0792 i The battery poles are cleaned by circular movements of the cleaner for battery terminals and poles which is placed with the underside on the battery pole After cleaning comply with the procedure for battery connection gt Electrical systems repair group 27 Sel wy h kJ ite me GB 1 3 4 Treatment with preservatives Note gt The lack of preservatives can cause damage and failure of the on board power supply gt Risk of corrosion Note gt All threaded connections must be tightened to the specified tightening torque gt Use a container with an attached ho
4. Repairs of the electrical installation in Skoda vehicles Self study programme SKODA Service Introduction This publication was created with the aim of supporting the service network of Skoda in the proper execution of repairs of the electrical installation for vehicles and summarises all the important principles and recommenda tions regarding the prescribed operation use of recommended tools and equipment according to the valid service documentation including the notes for the corresponding passages in the current literature At the same time the examples referring to incorrect repair procedures which are listed most often and occur most frequently as well as their negative effects and recommendations on how the repair should be performed in the correct way are listed here The corresponding module of the service training is an addition to this Self Study Programme No 92 Contents MUCO ronan pac teawecstae A EE E A 2 CODCOD E E E A E E EE AE AE A E E E A 3 1 Skoda service documentation Correct method of carrying out repairs of the electrical installation sssr 5 2 Use OF recommended tools and devices sisiscsisacisensciacsansecivsi sen ninsiascavesslusbsssntsncialssuasishes od aiiadsiaseennarnaviscaeniabiiiediadasieeredesans 15 3 List of valid TPI referring to the repairs of the electrical installation in Skoda vehicles sssseseseeeeen 28 4 Common errors when carrying out repairs of the electrical installation
5. The operating instruction for the hot air fan must be strictly observed After pressing in the swaged socket fitting must be shrunk with a hot air fan Warm up the swaged socket fitting in the longitudinal direction from the inside out until the connection seals perfectly and the adhesive flows out When pressing make sure that the other conductors plastic parts or upholstery do not get damaged with the hot nozzle If the repaired conductors were previously bundled they must be insulated again with a yellow insulating tape If necessary you must reattach the conductor with a cable clamp HL 1910 E PPc 18 Hot air gas fan with special nozzle completion shrinking and connection seal NOTE The operating instruction for the hot air gas fan must be strictly observed The hot air gas fan is delivered as part of the equip ment upon request The butane gas igniter gas is used so that gas bottles for refilling can be bought commercially The advantage is that it does not have to be fed in GB Folding knife with a blade g Mechanism for quick and easy replacement of the blades 6 Pad under the thumb for maximum pressure E Fixture of the blade with locking device O Release lever for quickly snap shutting the blade 20 GB In addition to the service case a set of release tools cutter is required for repairing the electrical installation for releasing the plug connectors from the terminal
6. MPI 1AV Four cylinder diesel engine Power assisted steering SKODA OCTAVIA 1 9 Itr TDI diesel engine SKODA OCTAVIA Convenience electronics system KODA OCTAVIA Mechanical gearbox 02K 02 1 6 Itr and 1 8 Itr petrol engines Automatic gearbox fundamentals Automatic gearbox 01M 1 9 Itr 50 kW SDI 1 9 Itr 81 kW TDI diesel engines 1 8 Itr 110 kW and 1 8 Itr 92 kW petrol engines OCTAVIA CAN BUS databus OCTAVIA CLIMATRONIC OCTAVIA Vehicle safety OCTAVIA 1 4 Itr 44 kW engine and gearbox 002 OCTAVIA ESP fundamentals design function OCTAVIA 4 x 4 all wheel drive 2 0 Itr 85 kW and 88 kW petrol engines Radio navigation system design and function SKODA FABIA technical information SKODA FABIA electrical systems SKODA FABIA electro hydraulic power assisted steering 1 4 Itr 16 V 55 74 kW petrol engines KODA FABIA 1 9 Itr TDI Unit injection Mechanical gearbox 02T and 002 SkodaOctavia model 2001 Euro On Board Diagnosis Automatic gearbox 001 Six speed gearbox 02M kodaFabia ESP Exhaust emissions Extended service intervals Three cylinder petrol engines 1 2 Itr SkodaSuperb Vehicle presentation part SkodaSuperb Vehicle presentation part II kodaSuperb 2 8 Itr 142 kW V6 petrol engine kodaSuperb 2 5 Itr 114 kW TDI V6 diesel engine kodaSuperb automatic gearbox 01V SKODA Service No zl 52 53 54 55 56 5 58 59 60 61 62 63 64 65 66 6 7 68
7. 0 Itr 1 6 Itr 1 2 Itr diesel engines with Common Rail injection system Bluetooth in Skoda vehicles Vehicle sensor drive mechanism 1 4 Itr 132 kW TSI petrol engine with dual charging compressor turbocharger kodaFabia II RS Vehicle presentation KESSY system in Skoda vehicles START STOP system in Skoda vehicles Immobilisers in Skoda vehicles Brake and stabilisation systems Sensors in Skoda vehicles Safety and Convenience Improve customer satisfaction with the help of the CSS study we The paper was made out of chlorine free bleached cellulose S00 2002 91 20 CGB Technical status 06 2010 All rights and technical modifications reserved KODA AUTO a s https portal Skoda auto com
8. 69 70 7 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 Designation 2 0 Itr 85 kW petrol engine with balancing shafts and 2 Stage suction line kodaFabia 1 4 Itr TDI engine with the unit injection system SkodaOctavia Vehicle presentation SkodaOctavia Electrical components FSI petrol engines 2 0 Itr 110 kW and 1 6 Itr 85 kW Automatic gearbox DSG 02E Diesel engine 2 0 Itr 103 kW TDI with pump nozzle units 2 0 Itr 100 kW TDI with pump nozzle units SkodaOctavia Chassis and electromechanical power assisted steering kodaOctavia RS 2 0 Itr 147 kW FSI turbo engine 2 0 Itr 103 kW 2V TDI diesel engine particle filter with additive Radio navigation systems in Skoda vehicles SkodaRoomster Vehicle presentation part SkodaRoomster Vehicle presentation part Il kodaFabia Il Vehicle presentation kodaSuperb Il Vehicle presentation part kodaSuperb Il Vehicle presentation part II 2 0 Itr 125 kW TDI diesel engine with Common Rail injection system 1 4 Itr 92 kW TSI petrol engine with turbocharger 3 6 Itr 191 kW FSI petrol engine All wheel drive with Haldex coupling of the IV generation SkodaYeti Vehicle presentation part SkodaYeti Vehicle presentation part II LPG system in Skoda vehicles 1 2 Itr 77 kW TSI petrol engine with turbocharger supercharging 7 speed dual clutch automatic gearbox OAM Green line vehicles Geometry Passive safety Auxiliary heating 2
9. all the points at the cable set that are marked with the yellow insulating tape identify the previous repair A function test must be carried out after each repair If necessary you must read off the data in the fault memory and restore the original state of the system GB 21 Assignment of individual conductors conductor seals swaged socket fittings press gutters Conductor and conductor seal The service set VAS 1978B does not include all the cable cross sections used in the vehicle If the cable cross section is not available you must use the next higher cross section Bags which include the service conductors are colour marked The conductor seals are in compartments that also differ in colour According to the colour marking you can select the corresponding press coupling conductor seal and gutter for the crimping tool Example If you want to use a conductor of 0 5 mm with the red identification from the bag you must use the colour identification for the following red press coupling The red press coupling must further be pressed into the gutter of the crimping tool marked in red The corresponding conductor seal also lies in the compartment with the red identification Separate conductor Cable cross section Colour Press coupling Press gutter in mm identification of the crimping tool compartments for the conductor seal Swaged socket fittings press gutters for crimping tool The service set VAS 1978B include
10. is covered by the company Skoda Auto 5 5 2 Selected cases of incorrect repair procedures for plug connectors and terminal strips a When repairing the electrical installation of the QC gearbox the incorrect release tool was used and for this reason there has been damage to the terminal strip socket and the corresponding pin it was the CAN high conductor between the terminal strip T25 and the QC gearbox The vehicle stopped while driving and the ESP warning light came on The cause was the lack of contact on the deformed pin in the terminal strip see figure below a em ing oo z Gero Es att all uae 5 ail a p gt dmm _ b mE LE _ n pi i e a pe a ai i Correct procedure When repairing plug connectors and terminal strips always use the recommended tools devices and components and proceed according to the manufacturer s recommendations Je GB Notes Notes Notes Overview of the previously edited self study programmes No Oto CG Shor bi AWN mS BR KR KR KR KR KR KR KR KR WWW WWW W WWW NNNNNNNNNN amp 2 2 2 a Z OWONDURWNHOWODANDURKRWNHOWOOANDUKRWNHDOVON DAUM ABRWN gt Designation Mono Motronic Central locking Vehicle alarm Working with wiring plans SKODA FELICIA Safety of the SKODA vehicles Principles of ABS not published ABS FELICIA Immobilizer with transponder Air conditioning in the vehicle Air conditioning FELICIA 1 6 engine
11. trips and for their reinstallation in particular universal device for releasing secondary fuses at terminal strips unlocking devices for flat and circular connectors assembly devices for fitting the seals in the terminal strips The use of this set and the correct procedure for unlocking and releasing the plug connectors including their reinstallation are described and illustrated in detail in chapter 5 of this SSP and in the relevant operating instructions which are enclosed with each set of release tools Use of service case for the repairs of the electrical installation The following points are emphasised and extracted from the detailed description of individual operations see instruction VAS 1978B technical information enclosed with each case Safety instructions For all repairs please keep the current information enclosed in the relevant technical manuals and in the manual Service Technics Important Before working on the electrical system the flat band of the battery must be disconnected Before carrying out the repair procedure you must first of all eliminate the cause of the fault e g sharp edges of the body part defective consumer corrosion etc For more information such as the instructions for the installation and removal of individual assembly parts can be found in the corresponding service manual Only yellow conductors must be used for the repair of cable sets These yellow conductors and
12. Additional information and use of the set Operating instruction for the service case gt The assignment of the correct release tools can be found in the table see Operating instruction for the set release tools 1 2 1 Repair of the cables for pyrotechnic components Note gt Comply with the general repair instructions for the electrical system of the vehicle gt Comply with the general repair instructions for the conductor bundles and plug connectors WARNING Inadequate repairs of the cables for pyrotechnic components e g airbag belt tensioner may result in insufficient protection of the passengers gt To ensure a quality repair the repairs of the cables for pyrotechnic components must be carried out exclusively with the service case for the repairs of electrical bundles using original spare parts connector sockets contacts conductors see Catalogue of original parts Vv The cables on individual airbag units must not be repaired Vv The corresponding airbag modules must be replaced for safety reasons in case of damage to the cables or the plug connectors on the airbag modules Note gt Repairs on the cables for pyrotechnic components can only be carried out on two repair points of the cables The repair points increase the electrical line resistance and thus induce faults in its own diagnostic system gt The cable with the repair point must not be put back into the original bundle in t
13. Page 2 Note gt To avoid breaking the threaded connection such as when exceeding the tightening torque due to the lack of static friction in the thread no rust remover contact spray or grease must be used for battery terminals gt The grey abrasive discs are only suitable for minor contaminations and soft surfaces gt The red abrasive discs are only suitable for minor contaminations and hard surfaces Disconnect the earth cable of the battery Electrical systems repair group 27 Unscrew the capnut and remove the cable lug from the threaded connection Check the threaded connection in regards to corrosion contamination and damage Select arespective adapter and an appropriate polishing pad 7 a DN hy Note Vv Clean the threaded connection carefully so that the zinc coating is not removed gt In regards to the different thicknesses of the zinc coating it is necessary to perform the visual inspection on the cleaned surface in the course of the cleaning procedure Vv If the underlying layer of copper is exposed when removing the zinc coating a galvanic cell can occur causing intense corrosion Fit an appropriate adapter onto the threaded connection and remove rust and dirt by rotational movements Check the cleaned area continuously After cleaning screw together the connections to the specified tightening torque if necessary with the protection against rotation fan
14. ach other GB 31 d The wrong choice of the connection for conductors e g repair of the broken interrupted conductor bundle for the side or rear door at the point where the bundle bends when opening and closing the door even after the repair has been performed correctly breaking of the repaired conductor will reoccur in close proximity to the press coupling after a short period of time Correct procedure Carry out the repair connecting a new conductor with the recommended press coupling including seal at the point where breaking of the bundle cannot occur when the door is opened or closed 32 GB e Failure to comply with correct values and incorrect attachment of the fuses when exchanging them in the E box and the consequential problems and faults during vehicle operation Incorrect attachment of the fuses in the E box The fuse SB12 5 A is missing in the position F12 incorrectly fitted in the position F11 the fuse SB19 30 A is missing in the position F19 incorrectly fitted in the position F18 The vehicle cannot be started if the fuses are not fitted correctly Incorrect value of the fuse Instead of the fuse SB13 with the correct value 30A the fuse with the value 5A was fitted during the repair While driving the indicator light for lubrication lights up and the display Switch off engine Pojstka SB13 i comes on ve The engine has stalled and could no longer be Started Correct pr
15. ently this case is no longer available and it has been fully replaced with the VW service case VAS 1978B from which it originated The tools devices components and repair procedure are identical for both cases for details see the relevant instructions enclosed with the sets The Skoda service case does not include a set of release tools Cutter to release the contacts of the terminal Strips For the repairs of the terminal strips with plug connectors this service case is supplemented either A with the set of release tools S 506815V and S 506825V Or B with the set of release tools VAS 1978 35 supplemented with the set S 506840V The use of all the sets is explained in the relevant operating instructions enclosed with the sets GB eT 3 List of valid TPI referring to the repairs of the electrical installation in Skoda vehicles 2014734 faults in the Parking Assist System Octavia II 2018564 fill in the designation 2026007 faults in the engine electronics caused by the collision of the electric motor bundle Fabia 1l 2027432 rain penetrating the terminal strips for fog lights daily lighting horn and into the terminal strip which feeds the independent heating Superb II The details regarding this technical product information as well as the other newly issued TPI can be found in ELSAPro or in the portal B2B 28 GB 4 Common errors when carrying out repairs to the electrical installation 4 1 If the c
16. he vehicle and must be visibly marked with the yellow insulating tape Mor 1 0 499 Note gt The repairs in the area of the pyrotechnic components should be carried out at a distance of at least 30 cm to the next connector socket This together with the marking of the repair point with the yellow adhesive tape enables a quick overview of previous repairs tax 30 crm Vv Both cables for the airbag igniters are twisted with a twist length of 20 5 mm This twist length must be kept for the repair of the twisted cable Note gt After the repair both cables for the girbag igniters must have the same length Upon rotation of the conductors 1 and 2 the length A 20 mm must be observed gt Thus the conductive part without rotated conductors arrow in the repair point must not be longer than B 100 mm 1 2 2 Repair of the cables for the CAN databus Note gt Comply with the general repair instruc tions for the electrical system of the vehicle gt Comply with the general repair instruc tions for the conductor bundles and plug connectors The unshielded twisted pair cable 1l and 2 witha diametre of 0 35 mm or 0 5 mm The cables for the CAN databus are provided with the following colour coding CAN High line drive orange black CAN High line Convenience CAN High line infotainment orange purple CAN Low Tine al After the repair the two bus lines must have
17. iate assembly devices GB 23 Description of repair Make sure that the swaged socket fittings are shifted below one another when repairing certain conductors within a bundle so that they do not lie side by side When interrupting the electrical line the following steps must be carried out in the following order Cover both parts of the interrupted conductor and loosen from the bundle Strip both parts of the broken line Connect the line with a press coupling Seal the connection resistance to moisture penetration Repair of the uninterrupted conductor at a repair point with an interruption Cover the conductor to be repaired on each side over a length of approx 20 cm starting from the point of interruption and release If necessary remove the bandage Insulate the ends of both conductor parts over a length of approximately 6 7mm using an insulated plier Fit the insulated conductor ends into the press coupling of the appropriate size colour on both sides and press the coupling together with the corresponding press jaw See colour identification on both ends using the pliers Thereby the insula tion of the conductor ends must not grip into the conductive coupling part and must not be pressed To the contrary the insulated conductor ends must not protrude from the coupling Subsequently the swaged socket fitting must be heated along the centre of the coupling towards the outside with a h
18. mination damage etc Select arespective adapter and an appropriate polishing pad Note gt Alternatively a grinding slip can be used 10 gt To avoid breaking the threaded connection such as when exceeding the tightening torque due to GB Note Vv Clean the cable lug carefully so that the zinc coating is not removed gt In regards to the different thicknesses of the zinc coating it is necessary to perform a visual inspection on the cleaned surface in the course of the cleaning process gt Before beginning the repair the cause of damage must first be resolved such as sharp edges of the body parts defective power consumers corrosion etc Fit an appropriate adapter onto the cable lug and remove rust and dirt by rotational movements Check the cleaned area continuously Mor 1o0789 Check the cable lug for burrs if necessary remove them with a burr removal tool Reset the cable lug and tighten to the specified tightening torque Note The required tightening torque must be kept for an optimum contact of the cleaned components After tightening preserve the connection with a suitable preservative i Nar 1orgo Comply with the procedure for battery connection gt Electrical systems repair group 27 GB 1 1 3 2 Repair of the threaded connections WARNING Risk of accident Pay attention to the warning notes and safety instructions when working with batteries gt
19. nding plug connector is secured with a secondary lock if yes first of all lock in the recommended way 2 Select a correct and undamaged tool which is intended for releasing and removing the plug connector in the corresponding terminal strip 3 Handle carefully use minimum force when unlocking the locking tang do not damage the terminal strip while doing so 4 Release the plug connector with back pressure never by pulling it 5 Carefully press on the release and recommended tool up to the chamber end of the terminal strips possibly up to the fixed stop hold it in this position while removing the plug connector without force GB 37 5 2 Using the set for unlocking and removing the plug connectors with conductors from the terminal strips 5 2 1 Secondary unlocking Prior to unlocking and removing the plug connectors from the terminal strips the so called secondary fuse must be unlocked While doing so only the prescribed unlocking devices must be used See instructions for use of individual sets of release tools Examples for unlocking a Take out the safety comb NOTE In some cases the secondary unlocking is carried out by shifting the safety comb a few mm pull it out a little straigth ahead and thus the safety comb must not be fully removed from the terminal strip 38 GB Volkswagen Technical Site http vwts ru http volkswagen msk ru_http vwts info OFPOMHbIN apxnB pokymeHTa nn no aBTOMOOMNAM Volks
20. ocedure Checking the fuse assembly in the E box replacing the poorly equipped fuses When replacing the fuses observe their correct value and proper attachment in the E box GB 33 4 2 Problems that may arise when installing non original equipment and accessories in Skoda vehicles 4 2 1 Additional installation of electrical equipment Point of view of the company Skoda Auto Skoda Auto recommends that only electrical equipment is installed in Skoda vehicles that was approved by the Skoda departments The additional installations of non approved equipment and modifications of the electrical equipment of the vehicle are not supported by Skoda Auto see TI 07 001 on portal B2B When installing approved equipment proceed exactly according to the specific installation instruction If the installation procedure is not observed or when additionally installing non approved equipment not all of the electrical functions of the vehicle will operate correctly There may even be damage to the control units of the vehicle In case of a complaint about a vehicle which was retrofitted with non approved electrical equipment this equipment must be switched off before repairing or transmitting a technical repair request the vehicle must be restored back to its original condition If this is not done and it is determined that the fault was caused by an unauthorised additional installation the service is redebited by the warranty department
21. orrect repair procedure is not observed the following can occur a Faulty insulation of the cable connection near the lambda probe possibility of moisture penetrating the terminal strips of the lambda probe The repair was not properly carried out TPI 2018564 Correct procedure Use a service case to insulate the conductor ends so that the conductor insulation is ensured and moisture penetration is avoided when using the corresponding press coupling and the following connector seal GB 29 b The connection of interrupted conductors near the lambda probe is carried out by soldering breakage of the soldered connection during operation inadequate moisture protection Correct procedure Do not solder when repairing the electrical system of Skoda vehicles see the general repair instructions for cable sets and plug connectors in the workshop manual Use a service case in order to connect the corresponding conductors with the relevant press coupling and seal with the hot air fan 30 GB c When repairing the conductor bundle re establish the connection of several interrupted conductors at the same position in the bundle problems that arise from the increased diametre of the bundle at the repair point Incorrect Correct Correct procedure Observe the operating instruction enclosed in the service case See chapter 2 of this SSP description of repair and the connection points of individual conductors shifting against e
22. ot air fan until it fully seals and the sealant flows out The heating temperature is set according to the requirements of the manufacturer usually 350 degrees Celsius Warning When fitting the seal make sure that the hot end of the fan does not damage another cable or the plastic parts 24 GB Repair of the interrupted conductor with two repair points two interruptions Cover and release the interrupted conductor for repair in the vicinity of both interrupted points see the repair of the interrupted conductor at a repair point For the repair between the points of interruption use the yellow repair conductor from the case or from the supply of spare parts with the same initially higher if possible cross section as for the repaired cable The repair procedure selection and use of press couplings their pressing on and sealing is consistent with the repair procedure for the interrupted conductor at a repair point Installation of swaged socket fittings for repairs of certain conductors within a bundle GB Make sure that the swaged socket fittings are shifted below one another when repairing certain conductors within a bundle so that they do not lie Side by side Safety instructions When repairing the conductors in the area of the airbag and the seat belt tensioners as well as in damp places certain rules must be observed It is possible to repair a maximum of 2 points on each adapter The repair point
23. s Installing the conductor with seal in the terminal strip is described on page 22 of this brochure Assembly devices for conductors with seal set of release tools VAS 1978 35 46 GB Examples for installing the conductors with seal in the terminal strips a Conductor with plug connector and seal ready for installation Inserting the conductor with seal in the assembly device GB 47 48 Inserting the plug connector with seal into the terminal strip Pressing the seal into the terminal strip up to the stop GB GB b Conductor with plug connector and seal ready for installation Inserting the plug connector with seal into the terminal strip with the use of the assembly device Pressing the seal into the terminal strip Up to the stop 49 50 c Conductor with plug connector and seal ready for installation Inserting the conductor with seal in the assembly device GB GB Inserting the plug connector with seal into the terminal strip Pressing the seal into the terminal strip Up to the stop Important note The prerequisite for a successful fault elimination which has been repeated several times in full scope is also valid for the repairs of plug connectors and terminal strips Use only recommended tools and procedures If a fault occurs by ignoring the rules and recommendations of the manufacturer neither the appropriate complaints are acknowledged nor the cost of the repair
24. s four different sizes of swaged socket fittings for 0 35 mm for 0 5 1 0 mm for 1 5 2 5 mm for 4 0 6 0 mm Contacts gold contacts The conductor contacts are available in the standard or gold plated version When carrying out the repair the contact to be used must always be the same version as the series contact The gold contacts are used for example on lambda probes or on knock sensors 22 GB Heat resistant cables At various points in the vehicle especially in the engine compartment heat resistant cables are used The heat resistant cables can be recognised on the duller and softer insulation To carry out repairs on these conductors only the heat resistant cables must be used Conductor seal The conductor seal protects against dust and ingress of water into the contacts of the fuse body They are used for example in the engine compartment and are always installed after the repair The conductor seal is crimped together with the con tact at the conductor in series This is different when carrying out repairs Before pressing in the service conductor you must first fit a seal onto the conductor While doing so the stop sleeve at the crimping point must face away from the fuse body see drawing The conductor seal must always correspond to the cross section of the relevant service conductor The outer diametre refers to the diametre of the fuse body chamber with contacts For the assembly only use the appropr
25. s increase the electrical resistance of the conductor and can cause faults in its own diagnostic system Roll up the original cable set including the repair points Mark the repair point with a yellow insulating tape When repairing the airbag conductors and the seat belt tensioners as well as in damp places you must always crimp the swaged socket fittings This will prevent corrosion Repair points in the area of the airbag or the seat belt tensioner Points in the area of the airbag or the seat belt tensioners that are being repaired must be located a maximum of 30 cm from the next fuse body with contacts terminal strips This together with the identification using a yellow insulating tape allows a quick overview of the previously performed repairs Repairs of the terminal strips plastic fuse body with contacts For technical reasons the fuse body with contacts for the cutting and clamping procedure must only be delivered with cutting and clamping plug contacts If you do not need these contacts you can dispose of them in the same manner as any other fuse body with contacts Service conductors are already available with appropriate crimp contacts See order information and catalogue of spare parts EP 198 Electrical connecting elements 26 max 30 cm Cutting and clamping elements GB Unlocking and removing the terminal strips fuse bodies with contacts The shapes of fuse bodies with contac
26. se for applying the preservative gt Conservation wax is used for cool areas gt Conservation wax for cavities is used for warm areas gt The preservative automatically penetrates at the appropriate points through the capillary action Keep the hose under the conductor shoe and spray around the pin and cable lug Mor 1 07 o4 Keep the hose above the conductor shoe and spray around the pin and cable lug Mor 10795 14 GB 2 Use of recommended tools and devices 2 1 1 Service case VW VAS 1978B The repairs of individual components of the electrical installation conductors plug connectors terminal strips etc of the Skoda vehicles as of model year 1996 must only be carried out using the recommended set of tools and components that are part of the service case Currently it is recommended to use the VW service case VAS 1978B that is also used by other corporate brands for this purpose Legend GB Note Unlocking devices Unlocking of secondary fuses Unlocking of circular rack systems Stripper Crimping tool with adapter Electrical hot air fan Hot air gas fan Folding knife with a blade Plug connector for adapter worldwide O D lt N D Nn Other pictograms For more information see Technical information Warning Cutting off gt Bir Warming up C Donon CI gt These symbols with explanations are given in the operating instruc
27. se tool cutter for plug connectors S506815V gt Set with release tool cutter for plug connectors S5O6825V or gt Service case for repair of electrical bundles VAS 1978B gt Set of release tools cutter for plug connectors VAS 1978 35 supplemented by the set of release tools cutter S506840V The service case contains the necessary tool except the set of release tools and the material Quality repairs of the electrical networks can be carried out with the service case The repairs of the plug connectors and interrupted lines can be carried out with the tools The complete repair instructions are used for the repair of crimped plug connectors and press couplings that are connected to the conductor bundles in the vehicle Repair instructions from the Electronic catalogue of original parts ETKA The crimping tool provided with three different pressing profiles and the hot air gun serve to shrink the press couplings in order to properly connect the cables For any subsequent order simply name the order number for the spare part which you can find in the converter table enclosed with the operating instruction The set of release tools cutter is used to release various primary and secondary plug connectors in the terminal trips The systems with circular plug connectors and the flat contacts with one or two detents can be properly released or installed as well as the simple cables can be sealed using the cutters Note gt
28. straps at the body risk of corrosion gt Comply with the current instructions in the relevant workshop manual when carrying out repairs General repair instructions for conductor bundles and plug connectors Note Vv Comply with the general repair instructions for the electrical system of the vehicle Vv Do not solder when repairing the electrical system of the vehicle Vv After pressing the press coupling must shrink when using a hot air gun in order to prevent moisture from penetrating Vv The shielded cables such as for example the cables for the speed and knock sensors must not be repaired If damaged they must be completely replaced Vv If the required cross section of the conductor bundle does not exist in the repair set the next larger cross section must be used Vv Mark the repair points with a yellow adhesive tape Vv The points of the cable set which are marked with the yellow adhesive tape identify the previous repair Vv Carry out a function test after each repair If possible display the faults stored in the memory erase the faults and if necessary carry out the basic setting of the repaired system using the VAS diagnostics measuring and information system GB 5 1 2 Repair of the conductor bundles and plug connectors Required special tools test and measuring devices and auxiliary means gt Service case for the repair of the electrical bundles S5O4500V gt Set with relea
29. the same length Upon rotation of the conductors 1 and 2 the twist length A 20 mm must be observed Vv gt Thus the conductive part without rotated conduc tors arrow in the repair point must not be longer than B 50 mm 1 3 Using the set for cleaning the contact areas VAS 6410 The repairs in the area of the contact transfers for threaded connections of cable sets in the high power circuit and battery connection must be carried out with a set for cleaning the contact areas VAS 6410 releasing and charging current grounding conductors battery terminals and poles Note gt The repairs shown in the illustrations serve only as an example of how to use the set gt Set for cleaning the contact areas VAS 6410 A ee 2 er p T GB 9 1 3 1 Repair of the cable lugs Note the lack of static friction in the thread no rust remover contact spray or grease must be used on cable lugs gt The grey abrasive discs are only suitable for minor contaminations and soft surfaces gt The red abrasive discs are only suitable for minor contaminations and hard surfaces WARNING Risk of accident Pay attention to the warning notes and safety instructions when working with batteries Disconnect the earth cable of the battery Electrical systems repair group 27 Unscrew the capnut and remove the cable lug from the threaded connection Check the cable lug in regards to corrosion conta
30. tion of the service case and describe the various operations for the repair of the electrical installation of the vehicle Unlocking of flat rack systems Assembly devices se of devices Insulation with insulated pliers Cutting with insulated pliers Swaged socket fittings with crimping tool Shrinking with electrical hot air fan Shrinking with hot air gas fan Cable shortening with folding knife with a blade Repair of individual conductors Please observe the following instructions Directional arrow Additional information 15 The service case VAS 1978B contains the following tools Stripper with conductor cutter stripping and cutting off the conductor aS E Sre S Stripper with conductor cutter for stripping and cutting off the conductors a A stripper of 6 7 mm is used for stipping the conductor ends The description and the symbols are taken from the operating instruction enclosed in the service case 16 Crimping tool with adapter crimping head for various sizes of swaged socket fittings The service set VAS 1978B includes 4 different sizes of swaged socket fittings yellow A 1 for 0 35 mm for 0 5 1 0 mm 1 1 for 1 5 2 5 mm for 4 0 6 0 mm E Crimping tool with crimping head for JPT contact Crimping head for 0 35 2 5 mm E Crimping head for 4 0 6 0 mm GB 17 Electrical hot air fan with special nozzle completion shrinking and connection seal NOTE
31. ts in the operating instruction are only informative and clearly describe the work with the secondary fuse General notes To unlock always use specific unlocking devices Contacts must never be released from the fuse body by force Details can be found in chapter 5 The damaged fuse bodies with contacts must always be replaced A new fuse body with contacts can be ordered via the OTC division Kassel The attachments of the chambers and pins can be found partly at the secondary fuse or on the rear of the fuse body with contacts The secondary fuse differs from the rest of the fuse body with contacts in its colour Thus the identification of the secondary fuse and the work procedure is made easier The installation points for the plug connections can be found in the chapters Circuit diagrams Fault Finding Electrical or Installation points The detailed description for unlocking the fuse body with contacts can be found in the description of the set for unlocking devices VAS 1978 35 To meet the standard of Skoda another set of tools must be purchased in addition to the set of release tools cutter 95506840V For unlocking individual contact systems comply with the operating instructions in the manual 2 1 2 Skoda service case For repairs of electrical installations in Skoda vehicles as of model year 1996 a set of tools must be used which is also included in the service case of Skoda the order no was S 504500V curr
32. ved by the vehicle manufacturer see the point of view of Skoda Important note At the end of this chapter it must be emphasised once more that when relating to the complaint settlement in regards to the failure of the electrical installation in Skoda vehicles as a cause of the use of incorrect tools and equipment non compliance with prescribed repair procedures where appropriate the installation of non approved equipment and accessories in the vehicle is proven the appropriate complaint to the responsible departments of Skoda is recognised in any case or covered the cost of repair and the correction of the consequences of the failure are covered by the responsable who caused the error by ignoring the rules and recommendations no matter whether it is to the service organisation or the owner of the vehicle or not 36 GB 5 Repairs of the plug connectors and terminal strips 5 1 Recommended set of release tools In order to meet the standards of Skoda the set of release tools recommended by the manufacturer for the repair of plug connectors and terminal strips must be used cutter e g VAS 1978 35 supplemented by the set S 50684 0V or the set of release tools S 506815V and S 506 825V which have been recommended for the repairs of the plug connectors and terminal strips using the service case of Skoda S 504500V Basic rules for removing the plug connectors with the release and recommended tools 1 Determine whether the correspo
33. wagen Skoda Seat Audi Safety comb another example for unlocking GB 39 bD Open the flap see arrow 40 GB c Lock the stop GB After locking the stop pull out the terminal strip with the plug connectors 41 5 2 2 Primary unlocking of the plug connectors in the terminal strip Only use the prescribed unlocking devices according to the operating instructions referring to the individual sets of release tools for the primary unlocking and removal of the plug connectors from the body of the terminal strips as well as for their reinstallation and sealing Examples for unlocking a Releasing the secondary fuse Releasing the plug connector with the prescribed tool Removing the plug connector with conductor 42 GB GB c Releasing the secondary fuse Releasing the plug connector with the prescribed tool Removing the plug connector with conductor 43 44 d Releasing the secondary fuse Releasing the plug connector with the prescribed tool Removing the plug connector with conductor GB GB e Removing the terminal strip with plug connectors after releasing the secondary fuse stop Releasing the plug connector with the prescribed tool Removing the plug connector with conductor 45 5 2 3 Installing the conductor with seal in the terminal strip The procedure is described in the operating instruction for the service case and even for the set of release tool
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