Wire Cross-Section 0.22 mm or 0.35 mm, Repairing

Wire Cross-Section 0.22 mm or 0.35 mm, Repairing

Procedure

• Wiring harness repair set (VAS 1978) contains repair wires of three different cross-sections (0.5 mm2, 1.5 mm2, 4.0 mm2) and the corresponding crimp connectors.

• 0.5 mm2 repair wire must be used for repairing 0.35 mm 2 wire.

Perform the repair as follows:

- Strip the ends of the 0.22 mm2 and 0.35 mm2 wires to a length of 12... 14 mm using the stripping pliers (VAS 1978/3).





- Fold back half of the stripped wire ends.

- Strip the ends of the 0.5 mm2 repair wire to a length of 6 to 7 mm using the stripping pliers (VAS 1978/3 ).

- Slip crimp connector over ends of wires and crimp on both sides using crimping tool (VAS 1978/1).





• Be sure to select the correct red crimp insert ( VAS 1978/24) for 0.5 mm2 wires.

• Do NOT crimp the insulation on the wires.

- After crimping, you must shrink-fit the crimp connector using the hot-air blower, 220 V/ 50 Hz (VAS 1978/14) and hot-air blower shrink fitting (VAS 1978/15 ).





• Crimp connector must be heated working outwards from center until it is completely sealed and adhesive emerges.

• Set the hot air blower to the correct temperature; refer to => operating manual for (VAS 1978).

- When shrink-fitting, ensure no other wires, plastic components or insulating materials are damaged by the hot nozzle.

- If repair wire was previously wrapped, yellow insulating tape must again be wound around this point; reattach wire with a cable tie if necessary.

- Reconnect battery. Required steps Audi A4 & S4 => Battery, Engine Compartment, Disconnecting and Connecting. Required steps Audi RS4 => Battery, Luggage Compartment, Disconnecting and Connecting.