Get Wires ->Tool Descriptions Guide for Audi A1 SUV 2010-2017

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Electrical Equipment General Information - Edition 08.2019

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-

104

Rep. Gr.97 - Wires

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

Electrical Equipment General Information - Edition 08.2019

♦ 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

105

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Electrical Equipment General Information - Edition 08.2019

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.

106

Rep. Gr.97 - Wires

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Electrical Equipment General Information - Edition 08.2019

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

107

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Electrical Equipment General Information - Edition 08.2019

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.

108

Rep. Gr.97 - Wires

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Wires ->Tool Descriptions for Your Audi A1 SUV 2010-2017

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