Get Wires -> Fiber-Optic Cables, Repairing 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

Early Release

– Push the operating lever -1- upward in the direction of the

-arrow A-.

– At the same time push the crimping pliers together and then

open.

Caution

♦ Do not use the crimp connector after it is early released.

2.5

Fiber-Optic Cables, Repairing

⇒ “2.5.1 Determine Position of the Error”, page 136

⇒ “2.5.2 Fiber-Optic Cable, Preparing with the Fiber-Optic Con‐

ductor Repair Set VAS6223A ”, page 137

⇒ “2.5.3 Fiber-Optic Cable, Preparing with the Fiber-Optic Con‐

ductor Repair Set VAS6223A ”, page 141

⇒ “2.5.4 Fiber-Optic Cable, Disconnecting from Wiring Harness

Connector”, page 145

2.5.1

Determine Position of the Error

Special tools and workshop equipment required

♦ Vehi_Pc_rl_oe_tecD_tei_da_bg_yn_coo_ps_yrt_ii_gc_ht.T_Ce_ops_yt_ie_ngr_{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.

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.

Procedure

It is very difficult to find the exact location of the problem. Replace

the damaged fiber-optic cable and lay a new wire parallel to the

defective fiber-optic cable.

Note

♦ Via the “Guided Fault Finding” it can be determines which

component of the fiber-optic cable is damaged.

♦ A fiber-optic cable that needs repair is represented by a “yel‐

low” color.

– Perform in the “Off-board Diagnostic Information System Serv‐

ice” the “Ring break diagnosis” function in the Vehicle Diag‐

nostic Tester .

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Electrical Equipment General Information - Edition 08.2019

– Remove the affected components.

– Disconnect the connector from the components.

– Assemble the fiber-optic cable:

♦ Refer to

⇒ “2.5.2 Fiber-Optic Cable, Preparing with the Fiber-Optic

Conductor Repair Set VAS6223A ”, page 137

♦ Refer to

⇒ “2.5.3 Fiber-Optic Cable, Preparing with the Fiber-Optic

Conductor Repair Set VAS6223A ”, page 141

2.5.2

Fiber-Optic Cable, Preparing with the Fi‐

ber-Optic Conductor Repair Set -

VAS6223A-

Special tools and workshop equipment required

♦ Fiber Optic Repair Set - VAS6223B-

♦ Hose Cutting Pliers - VAS6228-

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.

Checking Remaining Cut Indicator

– Start by checking remaining cut indicator:

♦ The -VAS6223/1- cutting device can perform approximately

1260 cuts. The blade is rotated for each further cut.

♦ The remaining cut indicator -arrow - displays the last 150 cuts

available.

♦ Once no further cuts are available, the blade is blocked. It must

be replaced. Refer to the Operatin^Pg^roI^ten^cs^tet^dru^byc^ct^oio^pyn^ris^ght^t.h^Ca^ot^pycⁱⁿo^gm^foe^{r p}w^rivi^at^th^{e 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.

-VAS6223/1- .

2. Wiring Harness and Connector Repairs

137

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Electrical Equipment General Information - Edition 08.2019

-VAS6223/1- Preparing

– Release the transport safety device on the cutter by loosening

the bolt -arrow-.

Fiber Optic Cable, Cutting to Length

– Establish length of fiber optic cable required.

– Open -VAS6223/1- and insert fiber-optic cable -1- into trim‐

ming station.

– Close cutting tool to cut fiber optic cable to length.

Stripping

– Open the -VAS6223/1- .

•

Stripping lever must be in lower position -arrow-.

– Place the fiber optic cable -1- in the stripping point.

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

•

The end of the fiber-optic cable must be flush with the rear side

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

of the cutting pliers.

– Close -VAS6223/1- until stop and keep closed.

– Lift the stripping lever -arrow- upward.

– Open the cutting tool and take out the fiber-optic cable -1-.

– Detach the separated section of the insulation from the fiber-

optic cable.

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Electrical Equipment General Information - Edition 08.2019

Precision Cutting (production of optical end face)

– Slide the fiber-optic cable -1- into the cutting station.

•

The insulation must make contact with the cutting point stop

-arrow-.

– Close the -VAS6223/1- .

– Press the cutting unit down -arrow-.

– Open -VAS6223/1- and remove fiber-optic cable -1-.

Note

The fiber-optic cable should only be placed on a completely clean

surface.

Transport Protection, Activating

– Close the -VAS6223/1- .

– Tighten the hex socket bolt -arrow- for the transport safety de‐

vice on the cutter.

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.

Attaching Brass Pin Contact to Fiber-Optic Cable

– Open securing lever on -VAS6223/2- in direction of

-arrows 1 and 2-.

2. Wiring Harness and Connector Repairs

139

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Electrical Equipment General Information - Edition 08.2019

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

– Close the safety lever on the -VAS6223/2- -arrow-.

– Slide the fiber optic cable -2- into the brass pin contact -1- as

far as spring-loaded stop.

– Slide fiber-optic cable further in up to fixed stop and close -

VAS6223/2- .

– Open the crimping pliers for fiber-optic cable and remove the

fiber-optic cable with the brass pin contact.

Caution

Do not bend the fiber-optic cable too much. The bending radius

must be no less than 25 mm.

– Make sure the brass pin contact -2- is secured correctly on the

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

fiber-optic cable -1-.

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.

•

Four crimp points must be visible at the brass connection pin.

The brass pin contact must not be able to be removed by hand

from the 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-op‐

tic cables. Refer to Parts Catalog.

♦ For installing the new fiber optic cable in the wiring harness

connector. Refer to

⇒ “2.5.4 Fiber-Optic Cable, Disconnecting from Wiring Har‐

ness Connector”, page 145 .

140

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Corrugated Tube, Install on Fiber Optic Cable.

– Cut the corrugated tube to the appropriate length.

•

Use the -VAS6228- or a sharp knife for cutting.

The corrugated tube must not be cut through using a side cut‐

ter under any circumstances

•

The corrugated tube must be cut on the wave peak -arrow-,

not in the wave trough.

– Guide fiber-optic cable into -VAS6223/10- as shown in illus‐

tration.

– Position the crimping pliers for fiber-optic cable at the slot on

the corrugated tube.

– Slide the crimping pliers for fiber-optic cable along the slot on

the circumference of the corrugated tube. The fiber optic cable

is then routed in the corrugated tube.

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.

2.5.3

Fiber-Optic Cable, Preparing with the Fi‐

ber-Optic Conductor Repair Set -

VAS6223A-

Special tools and workshop equipment required

♦ Fiber-Optic Conductor Repair Set - VAS6223A-

♦ Hose Cutting Pliers - VAS6228-

♦ 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.

2. Wiring Harness and Connector Repairs

141

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Electrical Equipment General Information - Edition 08.2019

Mount Tool Head for the -VAS6223/1- .

– Remove the locking pin -arrows-.

– Remove the tool set -arrow- and pull the locking pin back.

Fiber Optic Cable, Cutting to Length

– Establish length of fiber optic cable required.

– Open the -VAS6223/1- and lay the fiber-optic cable -1- in the

mount.

– Close the -VAS6223/1- to cut the fiber-optic cable lengths.

Stripping

– Open the -VAS6223/1- .

– Position the wire stripper in the lower position -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.

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.

142

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Electrical Equipment General Information - Edition 08.2019

– Close the -VAS6223/1- until the stop and keep closed.

– Bend the wire stripper upward -arrow- and remove the fiber-

optic cable.

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.

Precision Cutting (production of optical end face).

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

•

Insulation must make contact with cutting point stop.

– Close the -VAS6223/1- and remove the wire.

– Visually inspect the wire -1- to make sure that it was cut cor‐

rectly and that there are no burrs on the front surface.

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.

2. Wiring Harness and Connector Repairs

143

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Electrical Equipment General Information - Edition 08.2019

– Change tool head -arrow-.

– Slide the safeguard on the -VAS6223/1- -arrow- so that the

word “Stift” (pin) is legible.

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

– Close the securing lever on the -VAS6223/1- -arrow-.

– Insert the fiber-optic cable into the brass pin contact -arrow-

all the way up to the threaded stop and then close the -

VAS6223/1- .

– Open the fiber-optic cable pliers and remove the fiber-optic

cable along with the brass contact pin.

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.

Caution

Do not excessively bend or kink the fiber-optic cables (mini‐

mum bending radius 25 mm).

– Make sure the brass pin contact -2- is secured properly on the

fiber-optic cable -1-.

•

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-op‐

tic cables. Refer to Parts Catalog.

♦ To install the new fiber optic cable in wiring harness connector.

Refer to

⇒ “2.5.4 Fiber-Optic Cable, Disconnecting from Wiring Har‐

ness Connector”, page 145 .

144

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Electrical Equipment General Information - Edition 08.2019

Corrugated Tube, Install On Fiber Optic Cable

– Cut corrugated tube to appropriate length.

•

Use the -VAS6228- or a sharp knife for cutting.

The corrugated tube must not be cut through using a side cut‐

ter under any circumstances

•

The corrugated tube must be cut on the wave peak -arrow-,

not in the wave trough.

The corrugated tube must audibly engage in the fiber-optic

cable housing when installing.

– Guide the fiber-optic cable into the -VAS6223/10- as shown.

– Position corrugated tube assembly pliers on slot on the tube.

– Position crimping pliers for fiber-optic cable at slot of corruga‐

ted tube. The fiber optic cable is then routed in the corrugated

tube.

2.5.4

Fiber-Optic Cable, Disconnecting from

Wiring Harness Connector

Caution

Do not bend the fiber-optic cable too much. The be^Pn^rd^oti^en^ctg^edr^ba^yd^ci^ou^pys^{right. 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.

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.

2. Wiring Harness and Connector Repairs

145

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Electrical Equipment General Information - Edition 08.2019

Removing

– Unplug connector for fiber optic cable from appropriate control

unit.

– Release the catch in the fiber optic cable connector in direction

of -arrow-.

– Pull the fiber optic cable basic module -2- out of connector

housing -1-.

Caution

♦ Make colored dots to mark assignment of the fiber optic

cable -5- to the corresponding sockets in the base module

-1-.

♦ Note the arrows -3- for allocation on the base module “IN”

and “OUT”.

– Release the secondary catch -6- (blue pin) using a small

screwdriver in direction of -arrow-.

– Release the catch -2- and remove the fiber-optic cable -5- with

brass connector pin -4- from the base module -1-.

Installing

Install in reverse order of removal. Note the following:

Note

♦ Cover the open connector -2- for the fiber-optic cable using

the -VAS6223/9- -1-.

♦ The protective cap prevents contaminatio^Pn^roo^tef^cto^edr^bm^{y c}e^oc^pyh^ria^ghn^t.i^Cc^oa^pl^{ying 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

damage to end face of fiber optic cable which would impair

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

signal transmission.

– Install fiber optic cable in line with markings.

146

Rep. Gr.97 - Wires

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