Power and Ground Distribution: Service and Repair

Wiring And Plug Connectors, Repairing

CAUTION: Before beginning repairs on the electrical system:
- Obtain the anti-theft radio security code.
- Switch the ignition off.
- Disconnect the battery Ground (GND) strap.
- After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows according to Owner's Manual.


General Information

The Audi TT has a single wiring harness (for all connections) instead of separate wiring harnesses.

Always use repair set VAS 1978 when repairing the wiring harness or electrical connectors on the Audi TT







Wiring harness repair set VAS 1978
Detailed instructions for using VAS 1978 are given in the manual supplied
with the repair set.
The manual also gives examples showing how to repair open circuits in
wiring and malfunctioning plug connectors.

NOTE: Repairs must not be performed on shielded wiring associated with the ABS system.

0.35 Sq.mm Wiring, Repairing

NOTE:
- Repair set VAS 1978 includes repair wires of three different thicknesses (0.5 sq.mm, 1.5 sq.mm and 4.0 sq.mm cross sections), with corresponding crimp connectors.
- Use 0.5 sq.mm repair wire to repair 0.35 sq.mm wiring.
- Perform the repair as follows:







- Using the special pliers, strip off the insulation at the ends of the 0.35 sq.mm wiring so that the length of bare metal is twice as long as the joint required (approx. 12-14 mm).
- Fold back the bare metal to half this length.
- Using the special pliers, strip off the ends of the 0.5 sq.mm wire (approx. 6-7 mm).







- Using crimp connectors on the ends of the wires, crimp on both sides with crimping pliers.
- Do not crimp the insulation on the wires
- Make sure that the correct crimping slot is used (red color code for 0.5 sq.mm wires)







- After crimping the connector, seal it by shrinking with a hot air blower.
- Heat the crimp connector from the center outward until it is completely sealed and the adhesive comes out.
- Set the hot air blower to the correct temperature (refer to operating manual).
- When heating the connector, take care not to damage any other wiring, plastic parts or insulating material with the hot nozzle.
- If the wire was originally taped, wrap it again with yellow insulating tape. If necessary, secure the wiring with new cable ties.