Get Wires -> Wiring Harnesses, Repairing Guide for Audi A1 SUV 2010-2017

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

Electrical Equipment General Information - Edition 08.2019

– 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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Electrical Equipment General Information - Edition 08.2019

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.

110

Rep. Gr.97 - Wires

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Electrical Equipment General Information - Edition 08.2019

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 .

2. Wiring Harness and Connector Repairs

111

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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.

112

Rep. Gr.97 - Wires

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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

113

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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

Rep. Gr.97 - Wires

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Electrical Equipment General Information - Edition 08.2019

– 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

115

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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-

116

Rep. Gr.97 - Wires

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Electrical Equipment General Information - Edition 08.2019

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

117

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Electrical Equipment General Information - Edition 08.2019

– 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

Rep. Gr.97 - Wires

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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.

120

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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

121

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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.

122

Rep. Gr.97 - Wires

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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-

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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

125

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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

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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.

130

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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

131

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Electrical Equipment General Information - Edition 08.2019

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-

132

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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.

2. Wiring Harness and Connector Repairs

133

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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

135

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