Get Wires -> Connector Housings, Releasing and Disassembling Guide for Audi A1 SUV 2010-2017

Audi A1 2011 ➤ , Audi A1 Sportback 2018 ➤ , Audi A2 2001 ➤ , Audi A3 20 ...

Electrical Equipment General Information - Edition 08.2019

2.7.4

Connector Housing with Insulation Dis‐

placement Connections, Repairing

Note

♦ For technical reasons, the connector housing for the wire ter‐

minals can be supplied only with the contacts pushed in.

♦ These contacts can be removed at every other connector

housing in the event they are not required.

♦ Repair wires which have already been equipped with corre‐

sponding contacts crimped on are available. Refer to the Parts

Catalog.

2.8

Connector Housings, Releasing and

Disassembling

⇒ “2.8.1 Information on Releasing and Disassembling Connector

Housings”, page 162

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

⇒ “2.8.2 Secondary Lock”, page 163

⇒ “2.8.3 Primary Lock”, page 163

⇒ “2.8.4 Round Connector Systems”, page 164

⇒ “2.8.5 Flat Connector Systems”, page 165

⇒ “2.8.6 Special Connector Systems”, page 166

2.8.1

Information on Releasing and Disas‐

sembling Connector Housings

Note

♦ Observe general notes for repairs on the vehicle electrical

system. Refer to

⇒ “2.1 Vehicle Electrical System, General Repair Information”,

page 98 .

♦ Always use the release tools intended for the releasing proc‐

ess. Under no circumstances may terminals be pulled force‐

fully out of connector housings.

♦ Damaged connector housings must always be replaced. New

connector housings may be ordered via OTC Kassel.

♦ Small screwdrivers may be used as an aid to release the sec‐

ondary locks.

♦ The chamber/connector assignment is partially stamped on

the secondary lock or the rear side of the connector housing.

♦ Detailed information on component locations of harness con‐

nectors. Refer to ⇒ Wiring diagrams, Troubleshooting & Com‐

ponent locations.

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The allocation of the correct release tools to the respective locking

mechanisms can be found in the table in the -VAS1978/35- Op‐

erating Instructions.

2.8.2

Secondary Lock

The secondary lock is a housing securing mechanism (second

locking mechanism) that secures all wires in one connector hous‐

ing. If a secondary lock is installed at a connector housing, it must

always be opened or removed using specified tool before releas‐

ing and pulling out individual crimp contacts.

Secondary lock is distinguished by a different color from the rest

of the connector housing. It simplifies recognizing the secondary

lock and clarifies its function.

The shapes of the connector housings depicted here are only a

selection which, as an example, should make clear the various

functions of the secondary lock.

Example 1

Housing securing mechanism is released by removing a “comb”

-arrow-.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

Example 2

Housing securing mechanism is released by opening a “flap”

-arrow-.

Example 3

Housing securing mechanism can be released by disengaging a

“slider” -arrow-.

2.8.3

Primary Lock

The primary lock is the locking mechanism of an individual crimp

contact in the connector housing.

2. Wiring Harness and Connector Repairs

163

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If necessary, housing securing mechanisms (secondary locks)

must be released or removed using specified tool before releasing

the contacts. Refer to ⇒ “2.8.2 Secondary Lock”, page 163 .

The shapes of the primary locks depicted in the following are only

a selection which, as an example, should make clear the various

functions of the primary lock.

♦ Round connector systems. Refer to

⇒ “2.8.4 Round Connector Systems”, page 164 .

♦ Flat connector systems. Refer to

⇒ “2.8.5 Flat Connector Systems”, page 165 .

♦ Special connector systems. Refer to

⇒ “2.8.6 Special Connector Systems”, page 166 .

The allocation of the correct release tool for the respective locks

can be found in the table in the -VAS1978/35- Operating Instruc‐

tions.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

2.8.4

Round Connector Systems

Note

If necessary, housing securing mechanisms (secondary locks)

must be released or removed using specified tool before releasing

the contacts. Refer to ⇒ “2.8.2 Secondary Lock”, page 163 .

– Guide the release tool which fits the connector housing into

release channel on connector housing.

– Grasp contact at wire and push it gently into connector housing

in direction of -arrow-.

Note

By pushing the contact in the direction of the connector housing,

contact retaining tabs are lifted off the housing shoulder and re‐

leased using the release tool.

– At the same time, push the release tool in the direction of the

connector housing -arrow- and pull the released contact out of

the connector housing.

– After removing the contact, release tool can be pulled out of

the connector housing again.

164

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2.8.5

Flat Connector Systems

Note

If necessary, housing securing mechanisms (secondary locks)

must be released or removed using specified tool before releasing

the contacts. Refer to ⇒ “2.8.2 Secondary Lock”, page 163 .

Flat Connector System with One Retaining Tab

– Guide the release tool which fits the connector housing into

release channel on connector housing.

– Grasp contact at wire and push it gently into connector housing

in direction of -arrow-.

Note

By pushing the contact in the direction of the connector housing,

the contact retaining tab is lifted off the housing shoulder and can

be released using the release tool.

– At the same time, push the release tool in the direction of the

connector housing and pull the released contact out of the

connector housing in direction of -arrow-.

– After removing the contact, release tool can be pulled out of

the connector housing again.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

Flat Connector System with Two Retaining Tabs

– Guide the release tool which fits the connector housing into

release channel on connector housing.

– Grasp contact at wire and push it gently into connector housing

until it stops -arrow-.

Note

By pushing the contact in the direction of the connector housing,

contact retaining tabs are lifted off the housing shoulder and re‐

leased using the release tool.

2. Wiring Harness and Connector Repairs

165

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Electrical Equipment General Information - Edition 08.2019

– At the same time, push the release tool in the direction of the

connector housing and pull the released contact out of the

connector housing -arrow-.

– After removing the contact, release tool can be pulled out of

the connector housing again.

Asymmetrical

– Guide the release tool which fits the connector housing into

release channel on connector housing.

– Grasp contact at wire and push it gently into connector housing

-arrow-.

Note

By pushing the contact in the direction of the connector housing,

contact retaining tabs are lifted off the housing shoulder and re‐

leased using the release tool.

– At the same time, push the release tool in the direction of the

connector housing and pull the released contact out of the

connector housing -arrow-.

– After removing the contact, release tool can be pulled out of

the connector housing again.

2.8.6

Special Connector Systems

Note

If necessary, housing securing mechanisms (secondary locks)

must be released or removed using specified tool before releasing

the contacts. Refer to ⇒ “2.8.2 Secondary Lock”, page 163 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

166

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Fasten Contacts

– Guide the release tool which fits the connector housing into

release channel on connector housing.

– Grasp contact at wire and push it gently into connector hous‐

ing.

Note

By pushing the contact in the direction of the connector housing,

contact retaining tabs are lifted off the housing shoulder and re‐

leased using the release tool.

– At the same time, push the release tool in the direction of the

connector housing and pull the released contact out of the

connector housing -arrow-.

– After removing the contact, release tool can be pulled out of

the connector housing again.

GT 150/280 Contacts

– Guide the release tool which fits the connector housing under

retaining tab into connector housing.

– Push tool into connector housing until it stops -arrow-.

Contact is ejected from the connector housing.

– After ejecting the contact, release tool can be pulled out of the

connector housing again.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

2. Wiring Harness and Connector Repairs

167

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Contacts without Retaining Tabs

– Insert release tool under retaining tab of connector housing.

– Push release tool through until it stops by gently lifting

-arrow-.

Contact is ejected from the connector housing.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

168

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Wires -> Connector Housings, Releasing and Disassembling for Your Audi A1 SUV 2010-2017

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