Get Wires -> Wiring Harness and Connector Repairs Guide for Audi A1 SUV 2010-2017

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Electrical Equipment General Information - Edition 08.2019

2

Wiring Harness and Connector Re‐

pairs

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

page 98

⇒ “2.2 Wiring Harness Repair Set”, page 102

⇒ “2.3 Tool Descriptions”, page 104

⇒ “2.4 Wiring Harnesses, Repairing”, page 109

⇒ “2.5 Fiber-Optic Cables, Repairing”, page 136

⇒ “2.6 Antenna Wires, Repairing”, page 147

⇒ “2.7 Connector Housings and Connectors, Repairing”,

page 159

⇒ “2.8 Connector Housings, Releasing and Disassembling”, page

162

2.1

Vehicle Electrical System, General Re‐

pair Information

Caution

When disconnecting and connecting battery, the procedure

must be followed as described in the Repair Manual.

WARNING

Some tools are supplied with a tool safety clip, which is slid

over the tool points after using the tool, in order to protect other

workers from injuries and tool points from damage.

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.

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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

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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.

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♦ Observe the current notes in the corresponding repair manual

for all repairs.

♦ Observe country-specific regulations.

♦ Before working on the electrical system, the battery Ground

(GND) cable must be disconnected. By disconnecting the bat‐

tery GND cable (current disruption), the electrical system is

guaranteed to be safe to work on. Disconnecting the positive

battery cable is only required when removing the battery.

♦ Before starting a repair, the cause of the damage must be

eliminated first (for example sharp edges on chassis parts,

faulty electrical consumers, corrosion etc.).

♦ For the wiring harnesses if possible a high quality replacement

part is always delivered. This means that previously not re‐

quired connector housings may be present on the replace‐

ment part.

♦ Additionally bend back the non-necessary connector housing

when possible in a dry area of the vehicle and route them so

that no noises can result.

♦ Additionally to prevent capillary action seal the non-necessary

connector housing and single wires in wet areas of the vehicle

with water tight heat-shrinkable tube. The necessary compo‐

nents to seal the single wires can be found in the Parts

Catalog.

♦ Further information, for example, installing and removing the

individual components, can be found in the appropriate Repair

Manual.

♦ Soldering is not permissible for repairs to the vehicle electrical

system.

♦ Wiring harness and connector repairs on the vehicle electrical

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

system may only be performed using -VAS1978B- and previ‐

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

ous versions such as the -VAS631001- and the -VAS631003- .

Only use the yellow wire^ws^ithfr^ro^esm^pect^th^toe^thc^eo^corr^rre^ecs^tnp^eo^ssn^od^fiⁱⁿn^fog^rmw^ati^ioriⁿnⁱⁿg^thh^isa^dr^o‐^{cument. Copyright by AUDI AG.}

ness-repair kit.

♦ Wiring harness repairs may not be performed again in the

wrapping of the vehicle-specific wiring harness and are to be

marked with yellow adhesive tape. This indicated a previous

repair.

♦ Pinch and butt connectors must not be repaired. If necessary,

lay a wire parallel to the faulty wire. After crimping, crimp con‐

nections must be heat-shrunk using hot air gun to prevent

moisture penetration. Connectors with corresponding heat-

shrinkable tube must be protected moisture penetration.

♦ Always observe the supplementary notes for repairing wiring

harnesses on airbag- and seat belt tensioner systems, fiber

optic cables, CAN bus lines, FlexRay wires, and antenna

wires.

♦ A function test must be performed after every repair. If nec‐

essary, check Diagnostic Trouble Code (DTC) memory, erase

and/or bring systems into basic setting.

♦ If possible, do not loosen grounding straps from the body

(danger of corrosion).

♦ Not all wire cross-sections in the vehicle are contained in the

-VAS1978B- and its previous versions. If the required wire

cross-section is not present, the next greater cross-section

must be used.

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♦ Heat-resistant wires have been installed in the vehicle at var‐

ious locations, mainly in the engine compartment. Heat-resist‐

ant wires can be recognized by their somewhat duller and

softer insulation. Only heat-resistant wires may be used to re‐

pair these wires.

2.2

Wiring Harness Repair Set

⇒ “2.2.1 Wiring Harness Repair Set VAS1978 ”, page 102

⇒ “2.2.2 Upgrade Kit For VAS1978 VAS1978/50 ”, page 102

⇒ “2.2.3 Wiring Harness Repair Set VAS1978A ”, page 103

⇒ “2.2.4 Release Tool Set VAS1978/35 ”, page 103

⇒ “2.2.5 Wiring Harness Repair Set VAS631001 ”, page 103

⇒ “2.2.6 Wiring Harness Repair Set - Copper VAS631003 ”, page

104

2.2.1

Wiring Harness Repair Set - VAS1978-

The -VAS1978- makes optimal repair quality possible in the realm

of vehicle electronics. Using the tools, repairs affecting harness

connectors and for breaks in wiring can be performed. For this

purpose, complete repair wires with terminals already crimped on

are used and can be connected to vehicle-specific wiring harness

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

by the use of crimp connections. A pair of crimping pliers with

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

three different crimp slots and a hot air gun for shrinking the crimp

connec^wtiⁱo^thn^res^spp^ecr^to^tovi^thd^ee^cot^rr^ro^ecu^tnb^esle^s-^of^frⁱⁿe^foe^rme^al^tie^onctⁱⁿri^tc^hia^sl^doc^co^umn^enⁿe^t.c^Ct^oi^po^yrn^ig.^{ht by AUDI AG.}

Note

Additional information:

Refer to -VAS1978- Operating Instructions.

2.2.2

Upgrade Kit For VAS1978 -

VAS1978/50-

The -VAS1978/50- is required in order to bring the “old” -

VAS1978- up to the new standard of the -VAS1978A- . The

upgrade kit contains four assembly- and ten release tools as well

as new crimping pliers for crimp connections with Crimping Heads

2

²

for 0.35 - 2.5 mm -VAS1978/1-1- , 4.0 - 6.0 mm -VAS1978/2A-

and the -VAS1978/9-1- . Furthermore it contains new stickers, a

2

new set of user instructions, crimp connections for 0.35 mm -wire

cross sections and a roll of black felt adhesive tape.

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2.2.3

Wiring Harness Repair Set -

VAS1978A-

The new -VAS1978A- makes optimal repair quality possible in the

realm of vehicle electronics. Using the new pliers, repairs affect‐

ing harness connectors and for breaks in wiring can be per‐

formed. For this purpose, complete repair wires with terminals

already crimped on are used and can be connected to vehicle-

specific wiring harness by the use of the four different types of

crimp connections. A pair of new crimping pliers with crimping

heads and a hot air gun for shrinking the crimp connections pro‐

vide trouble-free electrical connection.

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.

Note

Additional information:

Refer to -VAS1978A- Operating Instructions.

2.2.4

Release Tool Set - VAS1978/35-

The -VAS1978/35- is used to release the various primary and

secondary locking mechanisms on VW-group vehicles. The set

consists of 26 different tools which can be used to professionally

release or assemble e.g. round connector systems, flat terminals

with one or two locks as well as single wire seals.

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.

2.2.5

Wiring Harness Repair Set -

VAS631001-

The -VAS631001- makes optimal repair quality possible in the

realm of vehicle electronics. Using this wiring harness repair set,

repairs affecting aluminum wires in the area of the harness con‐

nectors and for breaks in wiring can be performed. The copper

repair wires are also used and complete repair wires with already

crimped on/connected contacts. The connection with the vehicle-

specific wiring harness takes place with three different wire cross-

sections butt connectors.

The -VAS631001- for aluminum wires is comprised of the follow‐

ing components:

♦ Crimping tool without crimp insert and positioning aid -

VAS631001/1-

2

♦

Crimping insert and positioning aid 25 mm -aluminum wires -

VAS631001/2-

2

Crimping insert and positioning aid 4 mm -aluminum wires -

VAS631001/3-

2

Crimping insert and positioning aid 6 mm -aluminum wires -

VAS631001/4-

♦ Wire stripper for aluminum wires -VAS631001/5-

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Caution

For repairing the aluminum wires only use the corresponding

butt connectors with heat-shrinkable tube. Refer to the Parts

Catalog.

Note

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.

Additional information:

Refer to the -VAS631001- Owner's Manual.

2.2.6

Wiring Harness Repair Set - Copper -

VAS631003-

The -VAS631003- makes optimal repair quality possible in the

realm of vehicle electronics. With this wiring harness-repair kit

2

repairs can be performed on 10mm and 16mm wires in the area

of the connections and on open circuits. The repair wires are also

used an complete repair wires with already crimped on/connected

contacts. The connection with the vehicle-specific wiring harness

takes place with two different wire cross-sections butt connectors.

2

The -VAS631003- for 10mm and 16mm wires is comprised of

the following components.

♦ Case with Inlays - VAS631003/1-

♦ Hand Pliers - VAS631003/2-

♦ Insulation Removal Tool - VAS631003/3-

♦ Pair of Cable Cutters - VAS631003/4-

♦ Exchangeable head 10mm2 - VAS631003/5-

♦ Exchangeable head 16mm2 - VAS631003/6-

Note

Additional information:

Refer to the -VAS631003- Owner's Manual.

2.3

Tool Descriptions

⇒ “2.3.1 Crimping Pliers with Insert”, page 104

⇒ “2.3.2 Contact Release Tools”, page 105

⇒ “2.3.3 Single Wire Seal Assembly Tools”, page 106

⇒ “2.3.4 Wiring Harness Repair Set - Wire Strippers VAS1978/3

”, page 106

⇒ “2.3.2 Contact Release Tools”, page 105

⇒ “2.3.6 Crimping Pliers - .35-2.5mm VAS1978/1A ”, page 108

2.3.1

Crimping Pliers with Insert

Special tools and workshop equipment required

♦ Wiring Harness Repair Set - VAS1978B-

♦ Wiring Harness Repair Set - Crimping Head - 4-6mm -

VAS1978/2A-

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♦ Wiring Harness Repair - Crimping Head - .35-2.5mm -

VAS1978/1-1-

♦ Wiring Harness Repair - Crimping Plier - Base Tool -

VAS1978/1-2-

♦ Wiring Harness Repair - Interchangeable Head -

VAS1978/1-3-

The -VAS1978/1-2- with the -VAS1978/1-1- and the -

VAS1978/2A- are components of the -VAS1978B- . Additionally

there is also the -VAS1978/1-3- . These exchangeable heads with

the crimping pliers are inserted to crimp the crimp connector dur‐

ing a wiring harness repair.

Color of Crimp Con‐

nectors

Color of Crimping Slot Wire Cross-Section

Exchangeable Head

-VAS1978/1-3-

2

Transparent

None

0.13 mm /0.35 mm /0.5

2

mm

2

Transparent

Red

Blue

Yellow

Red

-VAS1978/1-1-

-VAS1978/2A-

0.35 mm through 0.5 mm

2

0.5 mm - 1.0 mm

2

Blue

Yellow

1.5 mm - 2.5 mm

2

Yellow

4.0 mm - 6.0 mm

Note

♦ Always be sure to use the correct crimping slot for the crimping

connection used.

♦ Do not crimp wire insulation.

2.3.2

Contact Release Tools

Various release tools are used to remove the different terminals

from connector housing without damage.

A selection of release tools are a component of the -VAS1978-

and the -VAS1978A- . The -VAS1978/35- contains the entire set

of release tools. Refer to

⇒ “2.2.4 Release Tool Set VAS1978/35 ”, page 103 .

WARNING

Some tools are supplied with a tool safety clip, which is slid

over the tool points after using the tool, in order to protect other

workers from injuries and tool points from damage.

Connector housings, unlocking and disassembling. Refer to

⇒ “2.8 Connector Housings, Releasing and Disassembling”, 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. Wiring Harness and Connector Repairs

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2.3.3

Single Wire Seal Assembly Tools

Assembly tools serve the purpose of allowing the single wire seals

to be slid without damage into the connector housing up to stop,

this achieves a complete seal between single wire and connector

housing.

Four assembly tools for single wire seals are components of the

-VAS1978B- and its previous versions.

Assembly of single wire seals. Refer to

⇒ “2.7.3 Single Wire Seals, Installing”, page 161 .

2.3.4

Wiring Harness Repair Set - Wire Strip‐

pers - VAS1978/3-

The -VAS1978/3- is used for professional stripping and cutting of

wires.

The -VAS1978/3- is a component of the -VAS1978B- and its pre‐

vious versions.

Wire stripper has an adjustable stop in its pliers-jaws which can

be set to the desired length of wire insulation to be removed.

Stripping

– Set the slideable stop in pliers-jaws to the desired length di‐

mension to be stripped.

– Insert wire end from front up to stop into jaws of pliers and

squeeze the pliers completely.

– Open pliers again and remove the stripped wire end.

– If necessary, cut wires using side-cutter function on the top of

the wire stripper.

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.

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2.3.5

Wiring Harness Repair Set - Hot Air

Blower - VAS1978/14A-

Caution

When heat-shrinking crimp connections, be careful not to dam‐

age any other wiring, plastic parts or insulating material with

the hot nozzle of the hot air gun.

Always observe operating instructions of heat gun.

The -VAS1978/14A- is used together with the -VAS1978/15A- to

heat-shrink the crimp connectors. After crimping, crimp connec‐

tions must be heat-shrunk using hot air gun to prevent moisture

penetration.

The -VAS1978/14A- is a component of the -VAS1978B- and its

previous versions.

– Insert the -VAS1978/15A- on the -VAS1978/14A- .

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

Caution

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

Risk of damaging surrounding components.

♦ When heat-shrinking crimp connections, be careful not to

damage any other wiring, plastic parts or insulating mate‐

rial with the hot nozzle of the hot air blower.

♦ Always observe operating instructions of heat gun.

– Heat crimp connection using the hot air blower lengthwise

from center outward until it is sealed completely and adhesive

comes out the ends.

•

This is how the completed repair location with individual crimp

connector should appear.

2. Wiring Harness and Connector Repairs

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2.3.6

Crimping Pliers - .35-2.5mm -

VAS1978/1A-

The - VAS1978/1A- or the -VAS1978/1-2- together with the -

VAS1978/1-1- , the -VAS1978/1-3- , or the -VAS1978/2A- are

used to press the crimp connector from the wiring harness-repair

kit.

Crimp connectors, press using the -VAS1978/1A- .

The following crimping heads are available for the -

VAS1978/1-2- :

♦ Wiring Harness Repair - Interchangeable Head -

VAS1978/1-3-

♦ Wiring Harness Repair - Crimping Head - .35-2.5mm -

VAS1978/1-1-

♦ Wiring Harness Repair Set - Crimping Head - 4-6mm -

VAS1978/2A-

♦ Wiring Harness Repair Set - Crimping Head - JPT -

VAS1978/9-1-

In conjunction with -VAS1978/9-1- , crimping pliers are used to

crimp terminals onto individual wires when repairing wiring cross-

2

sections up to 0.35 mm .

Changing the Crimping Head:

– Open crimp pliers completely.

– Disengage both locking pins -arrows- from crimp pliers basic

tool.

– Insert the required crimping head from above -arrow- in crimp

pliers basic tool.

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.

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– Lock the crimping head by pressing in the pins -arrows- into

crimp pliers basic tool.

2.4

Wiring Harnesses, Repairing

⇒ “2.4.1 Airbag and Belt Tensioner Wires, Repairing”,

page 109

⇒ “2.4.2 Repairing CAN Bus Wires”, page 111

⇒ “2.4.3 Repair Kit for FlexRay Wires with Coating”, page 112

⇒ “2.4.4 Repair Kit for FlexRay Wires without Coating”,

page 113

⇒ “2.4.5 0.22 mm 2 Wire, Repairing with Individual Crimp Con‐

nector”, page 114

⇒ “2.4.6 Repairing a Wire 0.35 mm 2 or Greater with Individual

Crimp Connector”, page 116

⇒ “2.4.7 Repairing a 0.22 mm 2 Wire with Intermediate Wire Sec‐

tion”, page 119

⇒ “2.4.8 Repair a wiring 0.35 mm 2 or greater with intermediate

wire section”, page 121

⇒ “2.4.9 10 mm2- or 16 mm2 Wires with Separate Butt Connec‐

tors, Repairing”, page 123

⇒ “2.4.10 2.,5 mm2, 4 mm2 or 6 mm2 Aluminum Wires with Sep‐

arate Butt Connectors, Repairing”, page 128

⇒ “2.4.11 0.13 mm2/0.35 mm2/0.5 mm2 Wire with Separate

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

Crimp Connector, Repairing”, page 132

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.

2.4.1

Airbag and Belt Tensioner Wires, Re‐

pairing

In addition to the general repairs on wiring harnesses, the follow‐

ing methods and instructions must be observed for repairs on

airbag- and seat belt tensioner wires:

WARNING

♦ The airbag and seat belt tensioner system can fail.

♦ Faulty repairs performed on airbag and seat belt tensioner

system can lead to malfunction in passenger protection.

♦ When performing repairs on airbag and seat belt tensioner

wiring harness, use only terminals, connectors and wires

designated for it. Refer to the Parts Catalog.

2. Wiring Harness and Connector Repairs

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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.

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Note

♦ Observe general notes for repairs on the vehicle electrical

system. Refer to

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

page 98 .

♦ Air bag wires and the safety belt tensioner wiring harness may

repaired only with the Wiring Harness Repair Set - VAS1978B-

and previous versions.

♦ A maximum of two repairs may be performed when repairing

wires of airbag- and seat belt tensioner system. Repairs in‐

crease the electrical resistance in the wire and may trigger

malfunctions in the system On Board Diagnostic (OBD).

♦ When repairing wiring harness of airbag- and seat belt ten‐

sioner system, the crimp connectors must always be heat-

shrunk to prevent corrosion.

♦ Do not wrap the repair point again into the vehicle-specific

wiring harness and mark the repair point quite visibly with yel‐

low insulating tape.

♦ Repairs in the area of the airbag or seat belt tensioner should

be performed a maximum of 30 cm (11.81 in.) from the next

connector housing. Together with the identification via yellow

insulating tape, this procedure makes it possible to obtain a

quick overview of previously performed repairs.

♦ Wires to the deploying units (airbags) have a wire-twisting with

a length of lay of 20 mm ± 5 (0.78 ± 0.196 in.) in series pro‐

duction. This length of lay is guaranteed via the norm part

numbers for wire pairs in series production and must be ob‐

served strictly for the repair lengths of twisted wires.

♦ During repair work, wires to deploying units (airbags) must

have the same length. When twisting together wires

-1 and 2-, length of lay of A = 20 mm ± 5 (0.78 ± 0.196 in.)

must be strictly observed.

♦ Wh_Pil_re_oted_co_tei_dn_bg_{y c}t_oh_pi_ys_ri,_ghn_t.o_Cos_pe_yic_ngti_fo_orn_pro_ivaf_teth_oe_{r co}w_mi_mre_er,_cif_ao_{l p}r_ue_rpx_osa_em_{s, i}p_nl_pe_a,_rti_on_{r in}a_wre_hoa_{le, is not}

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

of crimp connectors -arrow-, may be greater than B = 100 mm

(3.93^win^ith)^rw^espit^eh^co^{t to}u^tt^hetw^coi^rs^reti^cn^tng^esso^of^ftⁱⁿh^foe^rmw^atiⁱr^oeⁿsⁱⁿ.^{this document. Copyright by AUDI AG.}

♦ Repairs are to be documented in the Audi Service Plan under

“Space for workshop entries” with a short commentary of

scope of repairs, workshop stamp and signature.

♦ Any warranty claims to Audi AG are void for repairs on airbag

wiring set which were not performed using original replace‐

ment parts and Wiring Harness Repair Set - VAS1978B- .

2.4.2

Repairing CAN Bus Wires

Note

Observe general notes for repairs on the vehicle electrical sys‐

tem. Refer to

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

page 98 .

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♦ Unshielded, twisted two-wire lines -1 and 2- with a cross sec‐

2

tion of 0.35 mm or 0.5 mm can be used as CAN-Bus wiring.

♦ Repairs on CAN-Bus wires can be performed with repair wire

with matching cross section and also with twisted wires “green/

yellow” or “white/yellow” from the Parts Catalog.

♦ When repairing CAN bus wires, both wires must be same

length. When twisting together wires -1 and 2-, the lay length

of A = 20 mm (0.78 in.) must be observed.

♦ While doing this, no section of the wire, for example, in area

of crimp connectors -arrow-, may be greater than B = 50 mm

(1.96 in.) without twisting of the wires.

♦ Wrap repair points with yellow adhesive tape to mark a per‐

formed repair.

2.4.3

Repair Kit for FlexRay Wires with Coat‐

ing

Note

♦ Observe general notes for repairs on the vehicle electrical

system. Refer to

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

page 98 .

♦ The repair of FlexRay wires with coating can only take place

using FlexRay wires with coating from the Parts Catalog.

2

A two-layer wire -1 and 2- with a 0.35 mm profile is used as a

FlexRay wire.

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.

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♦ During repair work, both wires must have the same length.

♦ When twisting the wires -1 and 2- together, the -A- = 30 mm

(1.18) routing length must be maintained.

♦ While doing so, no section of wire may be greater than -B- =

50 mm (1.96 in.) without twisting the wires, for example in the

area of crimp connectors -arrow-.

♦ Maximum exposed wire length: -C- = 100 mm (3.93 in.).

♦ Protect the area being repairs from the environment. Use a

crimp connector with heat-shrinkable tube over the untwisted

location being repairs and waterproof insulation over the ex‐

posed wire.

♦ Mark the location of the repair with something suitable, for ex‐

ample, with yellow tape.

♦ Repairing both wires is identical to repair just one wire.

♦ Position both repaired location -arrows- -A- = 30 mm (1.18)

opposite each other.

♦ Crimp the cables with connectors.

1 - Repair location in the area without insulation

2 - Repair location with connectors

C - Maximum exposed length = 100 mm (3.93 in.)

2.4.4

Repair Kit for FlexRay Wires without

Coating

Note

♦ Observe general notes for repairs on the vehicle electrical

system. Refer to

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

page 98 .

♦ The repair of FlexRay wires without coating can only take

place using FlexRay wires without coating from the Parts Cat‐

alog.

Unshielded, twisted two-wire lines -1 and 2- with a cross section

2

of 0.35 mm can be used as FlexRay wires.

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

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♦ During repair work, both FlexRay wires must have the same

length.

♦ When twisting the wires -1 and 2- together, the -A- = 20 mm

routing length must be maintained.

♦ While doing so, no section of wire may be greater than -B- =

40 mm without twisting the wires, for example in the area of

crimp connectors -arrow-.

♦ Mark the location of the repair with something suitable, for ex‐

ample, with yellow tape.

♦ Repairing both FlexRay wires is identical to repairing just one

wire.

♦ Position both repaired locations -A- = 20 mm opposite each

other.

♦ Crimp the cables with connectors.

1 - Repair location in wiring harness

2 - Repair location with connectors

2.4.5

0.22 mm ²Wire, Repairing with Individ‐

ual Crimp Connector

Special tools and workshop equipment required

♦ Wiring Harness Repair Set - VAS1978B-

♦ Wiring Harness Repair Set - Wire Strippers - VAS1978/3-

♦ Wiring Harness Repair - Crimping Head - .35-2.5mm -

VAS1978/1-1-

♦ Wiring Harness Repair - Crimping Plier - Base Tool -

VAS1978/1-2-

♦ Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A-

♦ Wiring Harness Repair - Blower - Shrink Element -

VAS1978/15A-

Note

Observe general notes for repairs on the vehicle electrical sys‐

tem. Refer to

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

page 98 .

Procedure

– Free up the wire to be repaired approximately 20 cm (7.87 in)

on both sides of the repair point.

Caution

Risk of damaging the electrical wires.

♦ Expose wrapped wiring harnesses carefully.

– If necessary, removi_Pn_rog_tet_ch_tee_{d b}w_{y c}ir_oi_pn_yg_righh_t.a_Cr_on_pe_yins_gs_fow_{r p}r_ra_ivap_tep_oin_{r c}g_o._{mmercial 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.

114

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– Cut out the damaged section of wire using the -VAS1978/3- .

Note

If, by cutting out the damaged wire section, both ends of the ve‐

hicle-specific single wire are too short for a repair using a single

crimp connector, insert a repair wire section of matching length

with two crimp connections. Refer to

⇒ “2.4.7 Repairing a 0.22 mm 2 Wire with Intermediate Wire Sec‐

tion”, page 119 .

– Adjust the sliding stop in the -VAS1978/3- pliers jaws to 12 to

14 mm for the wire to be stripped.

– Insert wire end from front up to stop into jaws of pliers and

squeeze the pliers completely.

– Open pliers again and remove the stripped wire end.

– Twist bare strands one-half turn.

2

–

For the repair of a 0.22 mm wire, use a small transparent

crimp connector from the -VAS1978B- .

– To press the crimp connector, use the -VAS1978/1-2- with -

VAS1978/1-1- .

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.

– Slide the small transparent crimp connector onto both strip‐

ped, non-insulated wire ends on the vehicle-specific single

wire and crimp them using crimp pliers.

Note

Do not crimp wire insulation.

2. Wiring Harness and Connector Repairs

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After crimping, crimp connections must be heat-shrunk using hot

air gun to prevent moisture penetration.

– Insert the -VAS1978/15A- on the -VAS1978/14A- .

Caution

Risk of damaging surrounding components.

♦ When heat-shrinking crimp connections, be careful not to

damage any other wiring, plastic parts or insulating mate‐

rial with the hot nozzle of the hot air blower.

♦ Always observe operating instructions of heat gun.

– Heat crimp connection using the hot air blower lengthwise

from center outward until it is sealed completely and adhesive

comes out the ends.

•

This is how the completed repair location with individual crimp

connector should appear.

Note

♦ Make sure that crimp connections do not lie directly next to

each other when several wires need to be repaired. Arrange

the crimp connectors at a slight offset so that the circ_Pu_rm_otef_ce_ter_d‐_{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

ence of the wiring harness does not become too large.

♦ If the repair point was previous taped, this point must be^wta^ithp^ree^sd^{pect to the correctness of information in this document. Copyright by AUDI AG.}

again with yellow insulating tape after repairs.

♦ Secure the repaired wiring harness if necessary with a cable

tie to prevent flapping noises while driving.

2.4.6

Repairing a Wire 0.35 mm ²or Greater

with Individual Crimp Connector

Special tools and workshop equipment required

♦ Wiring Harness Repair Set - VAS1978B-

♦ Wiring Harness Repair - Crimping Head - .35-2.5mm -

VAS1978/1-1-

♦ Wiring Harness Repair - Crimping Plier - Base Tool -

VAS1978/1-2-

♦ Wiring Harness Repair - Crimping Head - .35-2.5mm -

VAS1978/1-1-

♦ Wiring Harness Repair Set - Crimping Head - 4-6mm -

VAS1978/2A-

♦ Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A-

♦ Wiring Harness Repair - Blower - Shrink Element -

VAS1978/15A-

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Note

Observe general notes for repairs on the vehicle electrical sys‐

tem. Refer to

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

page 98 .

Procedure

– Free up the wire to be repaired approximately 20 cm on both

sides of the repair point.

Caution

Risk of damaging the electrical wires.

♦ Expose wrapped wiring harnesses carefully.

– If necessary, removing the wiring harness wrapping.

– Cut out the damaged section of wire using the -VAS1978/3- .

Note

If, by cutting out the damaged wire section, both ends of the ve‐

hicle-specific single wire are too short for a repair using a single

crimp connector, insert a repair wire section of matching length

with two crimp connections. Refer to

⇒ “2.4.8 Repair a wiring 0.35 mm 2 or greater with intermediate

wire section”, page 121 .

– Adjust the sliding stop in the -VAS1978/3- pliers jaws to 6 to 7

mm for the wire to be stripped.

– Insert wire end from front up to stop into jaws of pliers and

squeeze the pliers completely.

– Open pliers again and remove the stripped wire end.

– For the repair, use a suitable crimp connector from the -

VAS1978B- .

Note

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

♦ Always be sure to use the corresponding crimp connector and

the correct crimping slot for the crimping c^woⁱn^thn^ree^sc^pet^cio^{t t}n^{o t}u^hes^ce^od^rre.^cR^tnee^s‐^{s of information in this document. Copyright by AUDI AG.}

fer to ⇒ “2.3.1 Crimping Pliers with Insert”, page 104 .

♦ Do not crimp wire insulation.

2. Wiring Harness and Connector Repairs

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– Use the -VAS1978/1-2- to press the crimp connector.

The following exchangeable heads are available for the -

VAS1978/1-2- :

♦ -VAS1978/1-1-

♦ -VAS1978/2A-

– Slide crimp connection onto both stripped wire ends of vehicle-

specific single wire and crimp them using crimp pliers.

Note

Do not crimp wire insulation.

After crimping, crimp connections must be heat-shrunk using hot

air gun to prevent moisture penetration.

– Insert the -VAS1978/15A- on the -VAS1978/14A- .

Caution

Risk of damaging surrounding components.

♦ When heat-shrinking crimp connections, be careful not to

damage any other wiring, plastic parts or insulating mate‐

rial with the hot nozzle of the hot air blower.

♦ Always observe operating instructions of heat gun.

– Heat crimp connection using the hot air blower lengthwise

from center outward until it is sealed completely and adhesive

comes out the ends.

•

This is how the completed repair location with individual crimp

connector should appear.

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.

118

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Note

♦ Make sure that crimp connections do not lie directly next to

each other when several wires need to be repaired. Arrange

the crimp connectors at a slight offset so that the circumfer‐

ence of the wiring harness does not become too large.

♦ If the repair point was previous taped, this point must be taped

again with yellow insulating tape after repairs.

♦ Secure the repaired wiring harness if necessary with a cable

tie to prevent flapping noises while driving.

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

2.4.7

Repairing a 0.22 mm ²Wire with Inter‐

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

mediate Wire Section

Note

♦ Observe general notes for repairs on the vehicle electrical

system. Refer to

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

page 98 .

2

♦

For repairing a 0.22 a repair wire can be used as the inter‐

2

mediate wire with a cross section of 0.35-mm or 0.5-mm .

Procedure

– Free up the wire to be repaired at two places approximately

20 cm on both sides of the repair point.

Caution

Risk of damaging the electrical wires.

♦ Expose wrapped wiring harnesses carefully.

– If necessary, removing the wiring harness wrapping.

– Route the yellow repair wire next to the damaged wiring har‐

ness and cut the repair wire to the required length using the -

VAS1978/3- .

– Cut damaged wire section from the vehicle-specific single

wire.

2. Wiring Harness and Connector Repairs

119

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– Adjust the sliding stop in the -VAS1978/3- pliers jaws to 12 to

14 mm for the wire to be stripped.

– Insert the vehicle-specific single wire end from the front into

the pliers jaws as far as the stop and squeeze the pliers to‐

gether completely.

– Open pliers again and remove the stripped wire end.

– Twist bare strands one-half turn.

– Repeat the procedure on the other end of the vehicle-specific

individual wire.

– Ad^Pju^ros^tet^ctt^eh^de^bys^cl^oi^pd^yi^rn^igg^ht.s^Ct^oo^pp^yini^gn^fot^rh^pe^riva-^tV^eA^orS^co1^m9^m7^er8^ci/^a3^{l p}-^up^rpl^oie^ser^ss^{, in}ja^pw^arts^orto^{in w}6^hoto^le,7^{is not}

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

mm for the wire to be stripped.

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

– Insert the yellow repair wire end from the front into the pliers

jaws as far as the stop and squeeze the pliers together com‐

pletely.

– Open pliers again and remove the stripped wire end.

– Repeat this procedure on the other repair wire end.

2

–

For the repair of a 0.22 mm wire, use a small transparent

crimp connector from the -VAS1978B- .

– Use die -VAS1978/1-2- with -VAS1978/1-1- from the -

VAS1978B- to crimp the wire.

– Push the small transparent crimp connector on the side of the

stripped, non-insulated wire ends of vehicle-specific single

wire on the other side of the repair wire stripped wire ends.

– Crimp the crimp connection at both wire ends using crimp pli‐

ers.

– Repeat this procedure at the other repair wire end.

Note

Do not crimp wire insulation.

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After crimping, crimp connections must be heat-shrunk using hot

air gun to prevent moisture penetration.

– Insert the -VAS1978/15A- on the -VAS1978/14A- .

Caution

Risk of damaging surrounding components.

♦ When heat-shrinking crimp connections, be careful not to

damage any other wiring, plastic parts or insulating mate‐

rial with the hot nozzle of the hot air blower.

♦ Always observe operating instructions of heat gun.

– Heat crimp connection using the hot air blower lengthwise

from center outward until it is sealed completely and adhesive

comes out the ends.

•

This is how the completed repair location with the inserted wire

and two crimp connectors should look.

Note

♦ Make sure that crimp connections do not lie directly next to

each other when several wires need to be repaired. Arrange

the crimp connectors at a slight offset so that the circumfer‐

ence of the wiring harness does not become too large.

♦ If the repair point was previous taped, this point must be taped

again with yellow insulating tape after repairs.

♦ Secure the repaired wiring harness if necessary with a cable

tie to prevent flapping noises while driving.

2.4.8

Repair a wiring 0.35 mm ²or greater with

intermediate wire section

Note

♦ Observe general notes for repairs on the vehicle electrical

system. Refer to

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

page 98 .

♦ For the repair use repair wires with a cross section of 0.35

2

mm through 6.0-mm .

Procedure

– Free up the wire to be repaired at two places approximately

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

20 cm on both sides of the repair point.

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

2. Wiring Harness and Connector Repairs

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Caution

Risk of damaging the electrical wires.

♦ Expose wrapped wiring harnesses carefully.

– If necessary, removing the wiring harness wrapping.

– Route the yellow repair wire next to the damaged wiring har‐

ness and cut the repair wire to the required length using the -

VAS1978/3- .

– Cut damaged wire section from the vehicle-specific single

wire.

– Adjust the sliding stop in the -VAS1978/3- pliers jaws to 6 to 7

mm for the wire to be stripped.

– Insert the vehicle-specific single wire end from the front into

the pliers jaws as far as the stop and squeeze the pliers to‐

gether completely.

– Open pliers again and remove the stripped wire end.

– Repeat the procedure on the other end of the vehicle-specific

individual wire.

– For the repair, use two suitable crimp connectors_Pf_rr_oo_tem_ctedth_be_{y c}-_{opyright. Copying for private or commercial purposes, in part or in whole, is not}

VAS1978B- .

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.

Note

♦ Always be sure to use the corresponding crimp connector and

the correct crimping slot for the crimping connection used. Re‐

fer to ⇒ “2.3.1 Crimping Pliers with Insert”, page 104 .

♦ Do not crimp wire insulation.

– Use the -VAS1978/1-2- to press the crimp connector.

The following exchangeable heads are available for the -

VAS1978/1-2- :

♦ Wiring Harness Repair - Crimping Head - .35-2.5mm -

VAS1978/1-1-

♦ Wiring Harness Repair Set - Crimping Head - 4-6mm -

VAS1978/2A-

– Slide the crimp connector onto the vehicle-specific single wire

at one side and onto repair wire at the other side.

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– Crimp the crimp connection at both wire ends using crimp pli‐

ers.

– Repeat this procedure on the other wire ends.

Note

Do not crimp wire insulation.

After crimping, crimp connections must be heat-shrunk using hot

air gun to prevent moisture penetration.

– Insert the -VAS1978/15A- on the -VAS1978/14A- .

Caution

Risk of damaging surrounding components.

♦ When heat-shrinking crimp connections, be careful not to

damage any other wiring, plastic parts or insulating mate‐

rial with the hot nozzle of the hot air blower.

♦ Always observe operating instructions of heat gun.

– Heat crimp connection using the hot air blower lengthwise

from center outward until it is sealed completely and adhesive

comes out the ends.

•

This is how the completed repair location with the inserted wire

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

and two crimp connectors should look.

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.

Note

♦ Make sure that crimp connections do not lie directly next to

each other when several wires need to be repaired. Arrange

the crimp connectors at a slight offset so that the circumfer‐

ence of the wiring harness does not become too large.

♦ If the repair point was previous taped, this point must be taped

again with yellow insulating tape after repairs.

♦ Secure the repaired wiring harness if necessary with a cable

tie to prevent flapping noises while driving.

2.4.9

10 mm²- or 16 mm²Wires with Separate

Butt Connectors, Repairing

Special tools and workshop equipment required

♦ Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A-

from the Wiring Harness Repair Set - VAS1978B-

2. Wiring Harness and Connector Repairs

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♦ Wiring Harness Repair - Blower - Shrink Element -

VAS1978/15A- from the Wiring Harness Repair Set -

VAS1978B-

♦ Wiring Harness Repair Set VAS631 003 - VAS631003-

Note

♦ Observe general notes for repairs on the vehicle electrical

system. Refer to

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

page 98 .

2

♦

For the repair there are repair wires with a 10mm or 16mm

cross section.

♦ There are also separate repair wires with a crimped on/con‐

nected contact available for the repair.

Procedure

– For the wire cross-section install the suitable crimp insert and

crimp stamp as follows on the crimping pliers:

– Open the crimping pliers from the -VAS631003- .

– Remove the locking pin -1- all the way in the direction of

-arrow A-.

– Open the adapter -2- in the direction of -arrow B-.

– Push in the crimp stamp -1- until it clicks into place in the mount

-2- on the adapter in direction of -arrow A-.

– Push in the crimp insert -3- until it engages audibly in the

mount -4- of the crimping pliers -arrow B-.

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.

124

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– Close the adapter -1- in the direction of -arrow A-.

– Push the locking pin -2- in the direction of -arrow- all the way.

– Free up the wire to be repaired approximately 20 cm on both

sides of the repair point.

Caution

Risk of damaging the electrical wires.

♦ Expose wrapped wiring harnesses carefully.

– If necessary, removing the wiring harness wrapping.

– Cut the damaged section of the wire with wire cutters from the

-VAS631003- .

Note

♦ When both ends of the vehicle-specific single wire are too

short after cutting out the damaged wire section for a repair

with a separate butt connector, insert a corresponding long

piece of yellow repair wire with two butt connectors.

♦ When repairing the single wire with crimped on/connected

contact place the yellow repair wire near the damaged vehicle-

specific single wire and cut to the required length.

– Adjust the sliding stop in the wire stripper pliers jaws from the

-VAS631003- to the length for the wire to be stripped.

2

♦

10 mm wires: 14 mm

2

16 mm wires: 16.5 mm

– Insert wire end from front up to stop into jaws of pliers and

squeeze the pliers completely.

– Open pliers again and remove the stripped wire end.

•

The insolation must be cut cleanly and remove from the wires.

No insolation can remain on bare wires.

The single wires must not be damaged.

– For the repair remove the corresponding butt connection and

a heat-shrinkable tube from the -VAS631003- .

– Push the heat-shrinkable tube on one of the wires.

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

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– Position the butt connection -1- with the first crimping position

centered on the crimp insert -2-.

•

The dimension -a- must be the same on both sides

– Turn the quick feed lever -3- counter-clockwise -arrow- until

the butt connection -1- is secured.

– Insert the wire -2- with the bare wire end all the way in the butt

connection -1- -arrow-.

•

All single wires must be pushed into the butt connection.

– Completely close and open the crimping pliers several times,

until the crimp insert goes downward by itself in its original

position.

Note

The wire insulation must not be crimped at the same time.

– Repeat the wire crimping on the other side as described.

– Remove the securing pin in the direction of -arrow A- until it

stops.

– Open the adapter in the direction of -arrow B-.

– Remove the crimped butt connectors.

Correct crimping results

2

A - 10 mm , Star crimp

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

2

B - 16 m_pm_erm,_ittB_ed-C_unr_lei_sm_sp_{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.

126

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After crimping the heat-shrinkable tube must positioned over the

butt connection and heat-shrunk with a hot air gun, to prevent

moisture from entering.

– Insert the -VAS1978/15A- on the -VAS1978/14A- .

Caution

Risk of damaging surrounding components.

♦ When heat-shrinking the heat-shrinkable tube, be careful

not to damage any other wiring, plastic parts or insulating

material with the hot nozzle of the hot air blower.

♦ Always observe operating instructions of heat gun.

– Position the heat-shrinkable tube -1- by feeling the contours

centered over the butt connection -2-.

•

The dimension -a- must be approximately the same on both

sides

– Heat the heat-shrinkable tube using the hot air blower length‐

wise from center outward until it is sealed completely and

adhesive comes out the ends.

•

The completed repair location -3- must look like so.

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

^wiN^tho^ret^se^{pect to the correctness of information in this document. Copyright by AUDI AG.}

♦ Make sure that the butt connections do not lie directly next to

each other when several wires need to be repaired. Arrange

the butt connection at a slight offset so that the circumference

of the wiring harness does not become too large.

♦ If the repair point was previous taped, this point must be taped

again with yellow insulating tape after repairs.

♦ Secure the repaired wiring harness if necessary with a cable

tie to prevent flapping noises while driving.

2. Wiring Harness and Connector Repairs

127

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Early Release

– Push the lever -1- downward in direction of -arrow A-.

– Turn the quick feel lever -2- clockwise in direction of

-arrow B- until the crimp insert is in its original position.

If releasing by hand is not possible then:

– Push the lever -1- downward in direction of -arrow A-.

– Place the socket from the -VAS631 003- on the bolt -3- on the

rear side.

– Turn the socket counter-clockwise in direction of -arrow C-

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

until the crimp insert is in its original position,

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 use the butt connectors after they are early released.

2.4.10

2.,5 mm², 4 mm²or 6 mm²Aluminum

Wires with Separate Butt Connectors,

Repairing

Special tools and workshop equipment required

♦ Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A-

from the Wiring Harness Repair Set - VAS1978B-

♦ Wiring Harness Repair - Blower - Shrink Element -

VAS1978/15A- from the Wiring Harness Repair Set -

VAS1978B-

♦ Wiring Harness Repair Set - VAS631001-

Note

♦ Observe general notes for repairs on the vehicle electrical

system. Refer to

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

page 98 .

2

♦

For the repair there are copper repair wires with a 2.5mm or

2

4 mm or 6 mm cross section.

♦ There are also separate copper repair wires with a crimped on

contacts available for the repair.

Procedure

– Install the corresponding crimp insert, crimp stamp and con‐

tact positioner for the wire cross-section with the contact cross

bar as follows on the crimping tool.

– Open the crimping tool from the -VAS631001- .

– Remove the locking pin -1- all the way in the direction of

-arrow A-.

– Open the mount -2- in the direction of -arrow B-.

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– Insert the crimp insert -1- in the crimping tool so that the crimp

insert -1- is flush with the front of the clamps.

– Tighten the crimp insert with the pins -2- in direction of

-arrow A- and the knurled screw hand tight.

– Insert the crimp stamp -3- that fits the crimp insert in the mount.

– Secure the crimp stamp with the pin -4- in direction of

-arrow B- and the knurled screw hand-tight.

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.

– Close the adapter -1- in the direction of -arrow A-.

– Push the locking pin -2- in the direction of -arrow- all the way.

– Insert the contact cross bar -1- in the contact positioner -2-.

– Position the contact positioner with the contact cross bar on

the crimping tool -5- at the same time push the holes in the

contact positioner -2- over the knurled screw -4-.

– Install the knurled bolt -3- and tighten hand-tight.

– Free up the wire to be repaired approximately 20 cm on both

sides of the repair point.

Caution

Risk of damaging the electrical wires.

♦ Expose wrapped wiring harnesses carefully.

– If necessary, removing the wiring harness wrapping.

2. Wiring Harness and Connector Repairs

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– Cut the damaged section of the wire with wire stripper from the

-VAS631001- .

Note

When both ends of the vehicle-specific single wire are too short

after cutting out the damaged wire section for a repair with a sep‐

arate butt connector, insert a corresponding long piece of yellow

copper repair wire with two butt connectors.

– Insert the wire end from the front all the way in to the wire

cross-section corresponding mount in the jaws of the pliers.

– Push the pliers completely together.

– Open pliers again and remove the stripped wire end.

•

The insolation must be cut cleanly and remove from the wires.

No insolation can remain on bare wires.

The single wires must not be damaged.

– For the repair remove the corresponding butt connection with

a heat-shrinkable tube from the -VAS631001- .

– Push the heat-shrinkable tube on one of the wires.

– Place the butt connection -1- in the contact positioner -2-.

•

The butt connection -1- must be flush with the contact posi‐

tioner -2- -arrow A-.

– Push the contact cross bar -3- all the way in the direction of

the -arrow B- and secure it with the butt clamp -1-.

•

The tab -4- on the butt connection -1- must engage in the

groove -5- on the contact cross bar -3-.

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.

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– Insert the wire -2- with the bare wire end all the way in the butt

connection -1- -arrow-.

•

All single wires must be pushed into the butt connection.

The insolation end can at a maximum be flush with the front

edge of the insolation crimps.

– Close the crimping tool completely until it reopens by itself.

– Push the contact cross bar -2- all the way in the direction of

-arrow-.

– Remove the butt connection -1- from the contact positioner

-3-.

– Turn the crimping tool for the second crimping.

– Repeat the wire crimping on the other side as described.

– Remove the securing pin -1- in the direction of -arrow A- until

it stops.

– Open the mount -2- in the direction of -arrow B-.

– Remove the crimped butt connectors.

Correct crimping results

•

The wire ends must project 0.1 mm to 1.0 mm on the front edge

of the wire crimps, dimension -a-

•

The insolation end must not be crimped in the wire crimps.

The insolation end can at a maximum be flush with the front

edge of the insolation crimps -arrows-.

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

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After crimping the heat-shrinkable tube must positioned over the

butt connection and heat-shrunk with a hot air gun, to prevent

moisture from entering.

– Insert the -VAS1978/15A- on the -VAS1978/14A- .

Caution

Risk of damaging surrounding components.

♦ When heat-shrinking the heat-shrinkable tube, be careful

^Pron^teo^ctet^dto^byd^coa^pm^yriga^hg^t.e^Coa^pynⁱⁿy^go^fot^rh^pre^ivr^atw^{e o}ir^ri^cn^omg^m, ^ep^rl^ca^ias^{l p}t^uic^rpop^sa^esr^,tⁱs^{n p}o^ar^rti^on^rsⁱⁿu^wl^ha^ot^lein^{, i}g^{s 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.

material with the hot nozzle of the hot air blower.

♦ Always observe operating instructions of heat gun.

– Position the heat-shrinkable tube -1- centered over the butt

connection -2-.

•

The dimension -a- must be approximately the same on both

sides

– Heat the heat-shrinkable tube using the hot air blower length‐

wise from center outward until it is sealed completely and

adhesive comes out the ends.

•

The completed repair location -3- must look like so.

Note

♦ Make sure that the butt connections do not lie directly next to

each other when several wires need to be repaired. Arrange

the butt connection at a slight offset so that the circumference

of the wiring harness does not become too large.

♦ If the repair point was previous taped, this point must be taped

again with yellow insulating tape after repairs.

♦ Secure the repaired wiring harness if necessary with a cable

tie to prevent flapping noises while driving.

2.4.11

0.13 mm²/0.35 mm²/0.5 mm²Wire with

Separate Crimp Connector, Repairing

Special tools and workshop equipment required

♦ Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A-

from the Wiring Harness Repair Set - VAS1978B-

♦ Wiring Harness Repair - Crimping Plier - Base Tool -

VAS1978/1-2- from Wiring Harness Repair Set - VAS1978B-

♦ Wiring Harness Repair - Interchangeable Head -

VAS1978/1-3-

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Note

♦ Observe general notes for repairs on the vehicle electrical

system. Refer to

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

page 98 .

2

♦

For the repair there are repair wires with a 0.35 mm and

2

0.5 mm cross section.

Procedure

– Install the - VAS1978/1-3- -1- as follows on the -

VAS1978/1-2- :

– Open the -VAS1978/1-2- .

– Remove the locking pin -2- all the way in the direction of the

-arrow A-.

– Insert the -VAS1978/1-3- -1- in the direction of the -arrow B-

centered in the -VAS1978/1-2- .

– Push back in the locking pin -2- all the way.

– Free up the wire to be repaired approximately 20 cm on both

sides of the repair point.

Caution

Risk of damaging the wires.

♦ Expose wrapped wiring harnesses carefully

– If necessary remove the wiring harness wrapping.

– Cut out the damaged wire section using a cutting wire.

Note

♦ When both ends of the vehicle-specific single wire are too

short after cutting out the damaged wire section for a repair

with a separate crimp connector, insert a corresponding long

piece of yellow repair wire with two crimp connectors.

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

♦ When repairing the single wire with crimped on/connected

con^wta^ithc^rt^ep^spl^ea^cc^{t t}e^{o t}t^hh^ee^coy^rre^ecl^tlⁿo^ew^ssr^oe^{f i}p^nfa^ori^mr^aw^tioiⁿreⁱⁿn^the^isa^dor^ct^uh^me^end^t.a^Cm^opa^yrg^ighe^td^byv^Ae^Uh^Di^Ic^Al^Ge^.-

specific single wire and cut to the required length.

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– Insert the wire end -2- all the way -arrow- in the cross section

fitting mount on the -VAS1978/1-3- -1-.

– Completely push together the crimping pliers and hold them

together.

– Remove the wire end -2- from the -VAS1978/1-3- -1- to strip.

– Open the crimping pliers again.

•

The insulation must be cut cleanly and removed from the

wires.

•

No insulation can remain on bare wires.

The single wires must not be damaged.

– Use the small transparent crimp connector from the -

VAS1978B- .

2

–

For 0.31 mm wires additionally push a heat-shrinkable tube

on the wires. Refer to the Parts Catalog.

– Push the crimp connector -2- all the way in the direction of the

-arrow A- in the clamp opening on the -VAS1978/1-3- .

– Push the striped wire -1- in the direction of the -arrow B- in the

crimp connector -2-.

•

All single wires must be pushed in the crimp connector -2-

Do not crimp wire insulation -arrow C-.

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

– Push the crimping pliers completely together and then open.

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

– Remove the wire with the crimp connector.

– Repeat the wire crimping with the crimp connector on the other

side as described.

– Remove the locking pin -1- all the way in the direction of the

-arrow A-.

– Pivot the upper section on the -VAS1978/1-3- -2- in the direc‐

tion of the -arrow B-.

– Remove the crimped crimp connector.

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Correct Crimping Results

– After crimping, crimp connections must be heat-shrunk using

hot air gun to prevent moisture penetration.

2

•

On 0.31 mm wires and additional heat-shrinkable tube must

be heat-shrunk to ensure a complete seal.

– Insert the -VAS1978/15A- on the -VAS1978/14A- .

Caution

Risk of damaging the wires.

♦ When heat-shrinking the heat-shrinkable tube, be careful

not to damage any other wiring, plastic parts or insulating

material with the hot nozzle of the hot air blower.

♦ Always observe operating instructions of heat gun.

2

–

•

For 0.13 mm wires position the heat-shrinkable tube -1- by

feeling the contours centered over the crimp connector -2-.

The dimension -a- must be approximately the same on both

sides.

– Heat the heat-shrinkable tube/crimp connector using the hot

air blower lengthwise from center outward until it is sealed

completely and adhesive comes out the ends.

•

The completed repair location -3- must look like so.

Note

♦ Make sure that crimp connections do not lie directly next to

each other when several wires need to be repaired. Arrange

the crimp connectors at a slight offset so that the circumfer‐

ence of the wiring harness does not become too large.

♦ If the repair point was previous taped, this point must be taped

again with yellow insulating tape after repairs.

♦ Secure the repaired wiring harness if necessary with a cable

tie to prevent flapping noises while driving.

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

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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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– 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- .

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-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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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-.

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– 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 .

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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

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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.

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– 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

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– 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 .

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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

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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.

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2.6

Antenna Wires, Repairing

⇒ “2.6.1 Aerial Cable Repair Set VAS6720”, page 147

⇒ “2.6.2 Replacing a Complete Antenna Wire”, page 157

2.6.1

Aerial Cable Repair Set VAS6720

Checking the antenna wire. Refer to ⇒ page 147

Replacing the tool head. Refer to ⇒ page 147

Cutting the antenna wire. Refer to ⇒ page 148

Removing the insulation from the shield. Refer to ⇒ page 148

Removing the outer jacket of insulation: ⇒ page 151

Removing the inner insulation. Refer to ⇒ page 152

Crimping the inner conductor. Refer to ⇒ page 153

Crimping the outer conductor. Refer to ⇒ page 155

Special tools and workshop equipment required

♦ Aerial Cable Repair Set - VAS6720-

The -VAS6720- makes it possible to perform a quality repair on

antenna wires RG 174 (blue) and RTK 031 (black). The set con‐

tains the insulation removal tools and the crimping tools for both

antenna wires. Moreover, all the individual parts needed are in

the kit. Only the zero-coded coupler (green) is needed. All other

connection wires for the different Infotainment systems can be

found in the Parts Catalog in table 035-XX. These adapter an‐

tenna wires must always be ordered separately depending on the

vehicle type. All part numbers needed for reordering can be found

in this table. The each compartment in the kit has a part number.

The re^Pp^ra^oti^er^ctk^edit^bi^ys^cob^pa^yrs^ige^htd^{. C}o^opn^yint^gh^fe^orW^privi^ar^ti^en^og^{r c}H^oma^mrn^ere^cias^ls^puR^rpe^osp^esa^,iⁱr^{n p}S^ae^rtt^{or in whole, is not}

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

VAS1978B.

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

Note

Additional information: -VAS6720- Operating Instructions.

Checking the Antenna Wire

Before starting the repair, determine which antenna wire using

the gauge.

♦ -1- System RG 174 = blue

♦ -2- System RTK 031 = gray

The positioners on the heads of the tools are color coded on both

systems.

Replacing Tool Head

– Select the appropriate tool head based on the antenna wire

test. Refer to ⇒ page 147 .

– Open the handle on the pliers all the way.

2. Wiring Harness and Connector Repairs

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– Release and remove both locking pins in direction of

-arrows- from the handle.

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

– Attach the necessary tool head^wt^ito^{h r}t^eh^spe^ech^{t t}a^on^thd^el^ce^orrf^er^co^tnm^essth^ofe^inft^oo^rmp^atiⁱn^{on in this document. Copyright by AUDI AG.}

direction of -arrow-.

– Insert the pins in direction of -arrows- into the handle in order

to lock the tool head into place.

Cutting Antenna Wire

– Slide the antenna wire -2- into the cutting device -1-.

– Close the tool then open it again.

– Pull the antenna wire out of the cutting device.

Removing Insulation From The Shield

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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.

– Push the locking pin -1- all the way into the rotating cutting

piece.

– Push the antenna wire -2- all the way into the rotating cutting

piece. The locking pin -3- can not be seen completely.

2. Wiring Harness and Connector Repairs

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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.

– Push the blade holder -1- against the axle of the rotating cut‐

ting segment until it locks into place. The gap -2- under the

blade holder is completely closed.

– Hold the antenna wire so that it cannot turn.

– Turn the rotating cutting segment -3- 2 times in direction of

-arrow- until it starts to turn easily.

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– Pull the release pin -1-. The blade holder unlocks and sepa‐

rates from the antenna wire.

– Push the locking pin -2- all the way into the rotating cutting

piece. The antenna wire is pushed out of the rotating cutting

segment.

– Remove insulation from the antenna wire.

– Remove any insulation remaining on the rotating cutting seg‐

ment.

Removing Outer Jacket of Insulation

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

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– Slide the antenna wire -2- in the mount -3- into the tool head

until it stops -1-.

– Close the tool then open it again.

– Remove the antenna wire -4-.

Removing Inner Insulation

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.

152

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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.

– Push the antenna wire -2- in the mount -1- all the way into the

tool head.

– Close the tool then open it again.

– Remove the antenna wire -3-.

Crimping Inner Conductor

2. Wiring Harness and Connector Repairs

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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.

– Select the appropriate tool head based on the antenna wire

test. Refer to ⇒ page 147 or ⇒ page 147 .

– Unfold the positioner -2-.

– Open the positioning plate -3-. The positioning plate swivels

upward.

– Push the inner contact -1- all the way into the positioner and

loosen the positioning plate. The inner contact is attached.

– Fold the positioner back in. The inner contact -4- is positioned

inside the tool head.

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– Slide the antenna wire -1- into the inner contact -2- in the tool

head. Hold the positioner tight while doing this.

– Lock the tool until it opens by itself.

– Open the positioning plate -3- and pull out the antenna wire.

Crimping Outer Conductor

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

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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.

– Slide the sleeve -2- and outer contact -1- over the inner con‐

ductor. The knurled contact piece must be pushed under the

shield -3-, but over the aluminum foil.

– Slide the outer contact -4- all the way on. Make the bushing/

pin fit correctly when doing this.

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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.

– Push the sleeve -3- up to the outer contact.

– Open the tool and fold out the positioner -1-.

– Position the outer contact -2- in the tool head on the contact

edge -4-.

– Close the tool then open it again.

– Pull out the antenna wire.

2.6.2

Replacing a Complete Antenna Wire

Special tools and workshop equipment required

2. Wiring Harness and Connector Repairs

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♦ -1- Adapter wire, for connection to radio; length: approximately

30 cm

♦ -2- Connecting wire, available in various lengths

♦ -3- Adapter wire, for connection to antenna; length: approxi‐

mately 30 cm

A repair procedure has been developed for replacing antenna

wires. Instead of a complete antenna wire, connecting wires of

different lengths and various adapter leads are now available as

replacement parts.

Replacement parts. Refer to Parts Catalog; Special Catalog

“Electrical Connection Elements”; Accessories; Subgroup 35

chart 035-20.

Note

♦ Do not repair antenna wires. Replace them using connector

and adapter wires available as original replacement parts.

♦ These origina^Pl^p^rr^e^oe^r^t^m^ep^c^it^tl^t^e^ea^d^dc^b^ue^yⁿm^l^c^e^o^s^pe^s^y^an^ri^u^gt^t^h^hp^t^o^.^ra^C^is^or^e^pt^ds^y^bⁱⁿ^ya^g^Ar^foe^U^r^D^ps^I^riu^A^va^Git^t^.^ea^A^ob^U^rl^D^ce^o^I^m^Afo^G^mr^e^d^r^oa^c^e^ial^sl^lⁿ^pa^o^un^t^rp^gt^o^ue^s^a^en^r^s^an^,ⁿⁱ^taⁿ^ee^pa^o^r^r^t^a^o^c^r^cⁱⁿ^ep^w^t^h^a^onl^y^e,^liⁱ^a^s^bⁿ^il^o^ity^t

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

wires and wire cross sections that need to be replaced.

♦ The wires are now to be used for all Audi models for all the

antenna wire cross sections fitted.

♦ All adapter leads and connecting wires are suitable for various

transmission and reception signals.

♦ The repair concept can also be used as a testing or retrofitting

solution.

Procedure

Example: antenna wire from the radio to the antenna is faulty.

– Separate the connectors of the faulty antenna wiring from their

components.

– Determine the path of the faulty antenna wire in the vehicle

and measure the total length of antenna wire to be replaced.

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•

The entire length of the antenna wire consists of the length of

the required adapter leads -1 and 3- as well as the connecting

wire -2-.

– Subtract 60 cm from the total length of antenna wire meas‐

ured, to receive the length of connecting wire required.

– Obtain the correct length of the required adapter wires and

connecting wires as an original replacement part. Refer to the

Parts Catalog.

– Cut the connectors off of the faulty antenna wiring.

•

Leave the rest of the defective antenna wire in the vehicle.

– Connect the adapter wires to the devices in the vehicle.

– Provide harness connectors with piece of foam hose to avoid

rattle.

– Route and secure the connecting wire parallel to the old an‐

tenna wire.

Note

Antenna wires must not be kinked or excessively bent! The bend‐

ing radius must not be less than 50 mm.

– Connect the connecting wire with the adapter leads.

– To prevent rattling noise, provide antenna connectors with a

suitable section of foam sheathing.

– Perform a function test.

2.7

Connector Housings and Connectors,

Repairing

⇒ “2.7.1 Connector Housings and Connectors, Repair Informa‐

tion”, page 159

⇒ “2.7.2 Contacts in Connector Housing, Repairing”, page 160

⇒ “2.7.3 Single Wire Seals, Installing”, page 161

⇒ “2.7.4 Connector Housing with Insulation Displacement Con‐

nections, Repairing”, page 162

2.7.1

Connector Housings and Connectors,

Repair Information

Note

♦ Observe general notes for repairs on the vehicle electrical

system. Refer to

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

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.

page 98 .

♦ Allocation of crimp contacts with correct fit to connector hous‐

ing is performed according to the part number stamped in on

the connector housing. Refer to the Parts Catalog; Special

Catalog “Electrical Connecting Components”; Electrical

Equipment; subgroup 71 chart 970-00.

♦ Damaged connector housings must always be replaced.

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2.7.2

Contacts in Connector Housing, Repair‐

ing

Procedure

– First, open or release if necessary the secondary lock of the

connector housing. Refer to

⇒ “2.8 Connector Housings, Releasing and Disassembling”,

page 162 .

– Release contact (primary lock) using the appropriate release

tool. Refer to

⇒ “2.8 Connector Housings, Releasing and Disassembling”,

page 162 .

– Pull the contact back out of the connector housing -arrow- at

the single wire (with the single wire seal if necessary).

– Cut off the old contact (with the single wire seal) from the ve‐

hicle-specific wiring harness.

– Take the yellow repair wire with the correct contact out of the

-VAS1978B- .

– Free up the wire to be repaired approximately 20 cm on both

sides of the repair point.

Caution

Risk of damaging the electrical wires.

♦ Expose wrapped wiring harnesses carefully.

– If necessary, removing the wiring harness wrapping.

– Slide the new repair wire contact into the corresponding con‐

nector housing compartment until it engages.

– If necessary, install the single wire seal on the repair wire. Re‐

fer to ⇒ “2.7.3 Single Wire Seals, Installing”, page 161 .

– Shorten the repair wire and the vehicle-specific wiring harness

single wire as needed using the -VAS1978/3- .

– Remove the insulation from the ends of the repair wire and

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

_perv_me_itth_edic_ul_ne_le-_ss_sp_aue_thc_oi_rf_ii_sc_eds_bi_yn_Ag_Ule_DIw_AGir_.e_AUa_Dn_Id_AGc_dr_oim_esp_not_th_gue_are_ann_ted_es_orw_acit_ch_eptth_ane_{y l}c_iar_bi_im_lityp‐

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

ing wires and a crimp connector. Refer to

⇒ “2.4.5 0.22 mm 2 Wire, Repairing with Individual Crimp Con‐

nector”, page 114 or

⇒ “2.4.6 Repairing a Wire 0.35 mm 2 or Greater with Individual

Crimp Connector”, page 116 .

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2.7.3

Single Wire Seals, Installing

Procedure

Note

♦ Single wire seals prevent the penetration of water and dirt into

the connector housing. They are installed, for example, in the

engine compartment and must be reinstalled after a repair.

♦ Single wire seal is crimped on at the factory together with con‐

tact on the wire, this is not the case for repair wires. The single

wire seal must be slid onto the wire before crimping the repair

wire.

♦ Single wire seals must always fit with the repair wire cross-

section. Outer circumference of single wire seal is aligned

according to chamber ^Pc^ri^or^tc^ecu^tem^{d b}fe^{y c}r^oe^pn^yrc^ige^ht.o^Cf^opth^yine^gc^foo^{r p}n^rin^vae^tec^oto^{r c}r^omh^mo^eu^rcs^ia‐^{l 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.

ing. Perform assembly using only the assembly tool with cor‐

rect fit.

– Put single wire seal -A- onto free end of repair wire.

•

When doing this, the single wire seal small diameter must point

toward the connector housing.

– Slide the single wire seal -A- onto the repair wire up to the

connector housing and then into the housing as far as the stop

using the appropriate assembly tool -B-.

– Shorten the repair wire and the vehicle-specific wiring harness

single wire as needed using the -VAS1978/3- .

– Crimp the stripped ends of repair wire and single wire of ve‐

hicle-specific wiring harness using crimping pliers and a crimp‐

ing pliers. Refer to

⇒ “2.4.5 0.22 mm 2 Wire, Repairing with Individual Crimp Con‐

nector”, page 114 or

⇒ “2.4.6 Repairing a Wire 0.35 mm 2 or Greater with Individual

Crimp Connector”, page 116 .

2. Wiring Harness and Connector Repairs

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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

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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.

⇒ “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

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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.

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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.

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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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Electrical Equipment General Information - Edition 08.2019

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.

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