Adapter Wire Sets, Gear Recognition Sensor 2 and Gear Recognition Sensor, Installing
Adapter Wire Sets, Gear Recognition Sensor 2 and Gear Recognition Sensor, Installing
Special tools, testers and auxiliary items required
• Wiring Harness Repair Set (VAS 1978 B)
• Adapter Wire Set (420 971 164)
Technical background
Starting in March 2008 and VIN "WAUZZZ42_8N005581" only gear recognition sensors - 21 and 26 - ((G604), (G616)) with gold contacts are being installed. Up until now the gear recognition sensors ((G604), (G616)) had tin-plated contacts.
In the future, replacement sensors will have gold contacts only.
• When installing new gear recognition sensors or if a transmission is replaced on a vehicle built prior to VIN "WAUZZZ42_8N005581", the connector must be adapted to the sensor due to the possibility of contact corrosion.
• Always use connectors pins) made of the same material (gold-plated - gold-plated or tin-plated - tin-plated).
• Gold contacts reduce resistance and are less sensitive to corrosion as long as the connector and pin are gold-plated.
Conditions for using the adapter wire sets:
• Replacing a transmission with tin-plated contacts on the gear recognition sensors (vehicles before VIN "WAUZZZ42_8N005581") with a transmission with gold-plated contacts on the gear recognition sensors.
• Replacing Gear Recognition Sensor 2 (G616) and Gear Recognition Sensor (G604) on a transmission with tin-coated contacts on the sensors and wiring harness (vehicles before VIN "WAUZZZ42_8N005581").
• Wiring harness or connector to one of the gear recognition sensors is damaged.
• If one of the gear recognition sensors, on a vehicle built prior to VIN "WAUZZZ42_8N005581" is damaged, then both gear recognition sensors must be replace (no interchanging). Both adapter wire harnesses must be installed. The Adapter Wire Set (420 971 164) generally has gold-plated contacts on the connector - A -.
• Only gear recognition sensors with gold-plated contacts can be ordered.
• If a wiring harness or a connector for the gear recognition sensor on a vehicle built before VIN "WAUZZZ42_8N005581" is damaged, then a different wiring harness, the Gear Recognition Sensor 2 (G616) and the Gear Recognition Sensor (G604) must be replaced.
Replace the adapter wiring sets:
- Remove the rear bumper cover.
CAUTION!
There is a risk of injury. The pressure in the R tronic hydraulic system may be up to 50 bar.
• Always reduce system pressure first before working on the R tronic hydraulic system. Refer to => [ Hydraulic System, R Tronic, Building System Pressure ] Procedures.
- Body Protectors, Installing. Refer to => [ Body Protectors, Installing ] Body Protectors, Installing.
- Remove the left - 1 - and right - 3 - engine compartment trim.
- Remove the engine cover - 2 -.
- Remove the air filter housing.
- Remove the air guide hoses - 1 - and - 6 - from the air filter housing.
- Disconnect the electrical connectors:
3 on the Mass Air Flow (MAF) Sensor 2 (G246)
5 on the Mass Air Flow (MAF) Sensor (G70)
- Loosen hose clamps - 2 - and - 4 - and remove the air filter housing.
- Remove the bolts - 1 - and the heat shield - arrow -.
- Disconnect the electrical connectors - 1 - on the Gear Recognition Sensor 2 (G616).
• Ignore item - 2 - and - 3 -.
- Disconnect the electrical connectors - 1 - on the Gear Recognition Sensor (G604).
• Ignore item - 2 - and - 3 -.
- Remove the cable tie and move the protective hose - 1 - to the right.
• Specified separating location - arrow -, so that the repair locations are under the R tronic shift actuator heat shield.
CAUTION!
Impairment to the vehicle functions.
• The wiring harness- 3 - for Gear Recognition Sensor 2 (G616) may not be interchanged with the wiring harness - 2 - for Gear Recognition Sensor (G604).
- First join both twisted signal wires - 1 - and - 2 - from the Adapter Wire Set (420 971 164) with the twisted signal wires on the vehicle wire set.
• The signal wires are already twisted on the current vehicle wire set as well as on the Adapter Wire Set (420 971 164).
• Pay close attention to the wire pin assignment on the old connector and wire connections.
CAUTION!
Impairment to the vehicle functions.
• Follow the description for repairing the wiring harness exactly.
• Pay attention to any country specific requirements.
When repairing, both signal wires leading to the gear recognition sensors must have the same length. When twisting the wires - 1 and 2 -, length - A - = 15 ± 10 mm.
The wire may not be longer than - B - = 80 mm without twisting the wire, for example, near the pinch connector - arrow -.
- Connect the adapter wire set, water-proof, to the vehicle wiring harness; follow the procedure exactly.
• Be careful not to place the pinch connector directly next to the wires being repaired. Arrange the pinch connectors slightly offset so that the number of wiring harnesses does not get too large.
- After connecting and twisting the signal wires, shorten and connect the third wire - 3 -.
• If the repair location was unwrapped before, then this location must be wrapped with yellow adhesive tape after the repair.
• Attach the repair wiring harness with a cable tie. This will prevent rattling noises while driving.
- Pull the Adapter Wire Set (420 971 164) - 2 and 3 - protective cover over the repair locations.
- Connect the connector - 1 - on the Gear Recognition Sensor 2 (G616).
• Ignore item - 2 - and - 3 -.
- Connect the connector - 1 - on the Gear Recognition Sensor (G604).
• Ignore item - 2 - and - 3 -.
- Route the wires - 2 and 3 - and secure with cable ties.
- Align the wiring harness so that the repair locations are at the correct position - arrow - and secure with a cable tie.
Further installation is in reverse order, paying attention to the following:
- Install heat shield.
- Install the air filter housing.
- Install the engine compartment trim.
- Install the rear bumper cover.
- Perform gear selector basic setting. Refer to => [ Gear Selector Basic Setting ] Testing and Inspection.
Document the repair in the Audi Maintenance booklet under " dealership entries" with a short comment of what was repaired and when, the dealership and stamp and signature.