Wiring Harnesses and Connectors, Repairing

Wiring Harnesses and Connectors, Repairing

CAUTION!
Before beginning repairs on the electrical system:

• Obtain the anti-theft radio security code.

• Switch the ignition off.

• Disconnect the battery Ground (GND) strap.

• After reconnecting vehicle battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows according to Repair Information and/or Owner's Manual.

• Steps after reconnecting voltage supply => Battery.

=> [ Safety Precautions ]

=> [ General Information ]

=> [ 0.22 mm or 0.35 mm Wire Connection, Repairing ]

Safety Precautions

CAUTION!


• Before working on electrical system, disconnect battery ground (GND) strap.

• Before starting a repair, the cause of the damage must be eliminated first, i.e. sharp edges on body parts, faulty electrical components, corrosion etc.

• Further information, e.g. installing and removing the individual components is described in the appropriate Repair Information.

• Wiring harness repairs may only be carried out using yellow wires.

• Every yellow wire and every location on wiring harness wrapped in yellow insulating tape indicates a previous repair.

• Shielded wires such as e.g. RPM sensor and knock sensors may not be repaired.

CAUTION!
• Wires at individual airbag modules may not be repaired.

• If wires or connectors at airbag modules are damaged, the respective airbag module must be replaced for safety reasons.

• Repairs on airbag wiring set must be performed exclusively on vehicle-side using wiring harness repair kit (VAS1978) and original replacement parts (connector housing, terminals) in order to guarantee the repair quality required by Audi.

• Any warranty claims to Audi are void for repairs on airbag wiring set which were not performed using original replacement parts and wiring harness repair kit (VAS1978).

General Information

Special tools, testers and auxiliary items required

• wiring harness repair kit (VAS1978)

• Repairs to wiring harnesses and connectors must only be performed using the wiring harness repair kit (VAS1978).

Detailed instructions on how to use (VAS1978) are supplied with the repair kit.





The manual also explains how to repair open circuits and faulty connectors.

0.22 mm or 0.35 mm Wire Connection, Repairing

• Repair kit (VAS1978) includes repair wires of three different thickness (0.5 mm², 1.5 mm², 4.0 mm²) with the corresponding crimp connectors.

• Use 0.5 mm² repair wire to repair a 0.35 mm² wire.

• Perform repair as follows:

- Strip off wire ends of 0.22 mm² or 0.35 mm² -wire using (VAS1978/3) wire strip pliers (approx. 12 to 14 mm).





- Fold back half way the stripped wire ends.

- Using stripping pliers, strip off ends of 0.5 mm² wire (approx. 6 to 7 mm).

- Push crimp connectors over wire ends and crimp at both sides with (VAS1978/1) crimping pliers.





• Be sure to use the correct crimping insert (VAS1978/24) (red color code for 0.5 mm² wires).

• Do not crimp insulation at end of wire.

- After crimping, seal crimping connector using (VAS1978/14 ) hot air blower and (VAS1978/15) sealing device.





Heat crimp connector from center outward until it is completely sealed and adhesive emerges.

Adjust hot air blower to appropriate temperature according to instructions.

When heating connector, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle.

- If wire was originally wrapped, wrap it again using yellow insulating tape. If necessary, secure wiring using new cable ties.