Wiring Harnesses and Connectors
Wiring Harnesses and Connectors
=> [ Vehicle Electrical System, General Information ]
=> [ Wiring Harness and Connector Repairs, General Information ]
=> [ Airbag and Safety Belt Tensioner Wiring, Repairing ]
=> [ CAN-Bus Wiring, Repairing ]
=> [ Wire, 0.25 mm with Individual Crimp Connector, Repairing ]
=> [ Wire, 0.35 mm and Larger with Individual Crimp Connector, Repairing ]
=> [ Wire, 0.25 mm with Intermediate Wire Section, Repairing ]
=> [ Wire, 0.35 mm or Larger with Intermediate Wire Section, Repairing ]
Special tools, testers and auxiliary items required
• Wiring Harness Repair Kit (VAS 1978) with
• Upgrade kit (VAS 1978/50)
• or Wiring Harness Repair Set (VAS 1978A)
• The Upgrade Kit (VAS 1978/50) is required to bring the "old" Wiring Harness Repair Kit (VAS 1978) up to the new standard of the Wiring Harness Repair Set (VAS 1978A).
CAUTION!
• Wiring harness and socket repairs may only be carried out with the Wiring Harness Repair Kit (VAS 1978) or Wiring Harness Repair Set (VAS 1978A).
• Observe the country-specific requirements.
• Usage of the Wiring Harness Repair Kit (VAS 1978) or Wiring Harness Repair Set (VAS 1978A) is described extensively in the accompanying usage instructions.
• Repairs on open circuits and faulty connectors are also explained using examples.
Vehicle Electrical System, General Information
CAUTION!
Risk of injury.
• Pay attention to stickers designating high voltage components. Prior to performing repairs, residual voltage must first be discharged.
• 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.
CAUTION!
• Observe country-specific requirements.
• By disconnecting battery ground (GND) wire, safe work on vehicle electrical system is guaranteed. With the ignition switched off, disconnect battery ground cable.
• Before starting a repair, the cause of the damage must be eliminated first, i.e. sharp edges on chassis parts, faulty consumers, corrosion etc.
• If possible, do not loosen ground (GND) straps from body (danger of corrosion).
• Further information, e.g. installing and removing the individual components, is described in the appropriate repair manual.
Wiring Harness and Connector Repairs, General Information
• Observe general notes for repairs on the vehicle electrical system => [ Vehicle Electrical System, General Information ].
• Not all of the wire cross sections contained in the vehicle are in the Wiring Harness Repair Kit (VAS 1978) or Wiring Harness Repair Set (VAS 1978A). If the required wire cross-section is not present, the next greater cross-section must be used.
• For repairs on vehicle electrical system, soldering is not permitted.
• Do not repair crimp connectors. If necessary, lay a wire parallel to the faulty wire.
• After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.
• Shielded wires, such as RPM sensors and knock sensors, may not be repaired. If faulty, the entire harness must be replaced.
• Exclusive use is to be made of yellow wires for wiring harness repairs.
• Wiring harness repairs should not be made again in the wrapping on the vehicle-specific wiring harness.
• Mark repaired areas using yellow adhesive tape.
• Yellow wires and areas in the wiring harness wrapped with yellow adhesive tape mark a previously performed repair.
• Perform a function test after each repair. If necessary, check DTC memory, erase and/or bring systems into basic setting.
Airbag and Safety Belt Tensioner Wiring, Repairing
• Observe general notes for repairs on the vehicle electrical system => [ Vehicle Electrical System, General Information ].
• Observe the notes on wiring harness and connector repairs => [ Wiring Harness and Connector Repairs, General Information ] including identifying repair locations.
CAUTION!
Passenger protection malfunction due to faulty repairs to the airbag and belt tensioner wiring harness
• Repairs on the airbag and seat belt wiring must only be performed on the vehicle using the Wiring Harness Repair Kit (VAS 1978) or Repair Manual Wiring Set (VAS 1978A) and original replacement parts (connector housing, terminals, wires) in order to guarantee the repair quality required by Audi AG.
• Wires at individual airbag modules may not be repaired.
• If the wires or connectors on the airbag modules are damaged, the respective airbag module must be replaced for safety reasons.
• A maximum of two repairs may be performed when repairing wires of airbag- and seat belt tensioner system. Repairs increase the electrical resistance in the wire and may trigger malfunctions in the system On Board Diagnostic (OBD).
• Repairs in the area of the airbag or seat belt tensioner should be performed a maximum of 30 cm from the next terminal housing. Together with the identification using yellow adhesive tape, this procedure makes it possible to obtain a quick overview of previously performed repairs.
• Both wires to the airbag igniter have a twist with 20 ± 5 mm routing length. This routing length must be maintained when repairing the twisted wires.
• When repairing, both wires to the airbag igniters must be 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 must be greater than - B - = 100 mm without twisting of wires, e.g. in area of welded connectors - arrow -.
• 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 voided if airbag wiring harness repairs were not performed using original replacement parts and the Wiring Harness Repair Kit (VAS 1978) or Wiring Harness Repair Set (VAS 1978A).
CAN-Bus Wiring, Repairing
• Observe general notes for repairs on the vehicle electrical system => [ Vehicle Electrical System, General Information ].
• Observe the notes on wiring harness and connector repairs => [ Wiring Harness and Connector Repairs, General Information ] including identifying repair locations.
An unshielded two-strand wire - 1 and 2 - with a cross section of 0.35 mm2 or 0.5 mm2 can be used as CAN-Bus wiring.
• CAN bus wires have the following color coding:
• During repair work, both bus 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 must be greater than - B - = 50 mm without twisting of wires, e.g. in area of welded connectors - arrow -.
Wire, 0.25 mm with Individual Crimp Connector, Repairing
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.
• Free up wrapped wiring harnesses carefully.
- If necessary, removing the wiring harness wrapping using a knife.
- Cut out the damaged wire section using wire stripper (VAS 1978/3).
• If, by cutting out the damaged wire section, both ends of the vehicle-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 => [ Wire, 0.25 mm with Intermediate Wire Section, Repairing ].
- Adjust the sliding stop in the Wire Stripper (VAS 1978/3) 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.
- For the repair of a 0.25 mm 2 wire, use a small yellow crimp connector from the Wiring Harness Repair Set (VAS 1978A).
- To press the crimp connector, use the Crimping Pliers (Base Tool) (VAS 1978/1-2) with Exchangeable Head, 0.35-2.5mm² (VAS 1978/1-1).
- Slide the small yellow crimp connector onto both stripped, uninsulated wire ends on the vehicle-specific single wire and crimp them using crimp pliers.
• Do not crimp wire insulation.
After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.
- Put Shrink Tip For Hot Air Gun (VAS 1978/15) on to Hot Air Gun, 220 V/ 50 Hz (VAS 1978/14).
CAUTION!
Risk of damaging surrounding components.
• When heat-shrinking crimp connections, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the hot air gun.
• Always observe operating instructions of heat gun.
- Heat crimp connection using hot air gun 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.
• 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 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.
Wire, 0.35 mm and Larger with Individual Crimp Connector, Repairing
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.
• Free up wrapped wiring harnesses carefully.
- If necessary, removing the wiring harness wrapping using a knife.
- Cut out the damaged wire section using wire stripper (VAS 1978/3).
• If, by cutting out the damaged wire section, both ends of the vehicle-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 => [ Wire, 0.35 mm or Larger with Intermediate Wire Section, Repairing ].
- Adjust the sliding stop in the Wire Stripper (VAS 1978/3) 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 form the Wiring Harness Repair Set (VAS 1978A).
- Use the Crimping Pliers (Base Tool) (VAS 1978/1-2) to press the crimp connector.
The following exchangeable heads are available for the Crimping Pliers (Base Tool) (VAS 1978/1-2):
• Exchangeable Head, 0.35-2.5mm (VAS 1978/1-1)
• Exchangeable head, 4.0-6.0 mm² (VAS 1978/2 A)
- Slide crimp connection on to both stripped wire ends of vehicle-specific single wire and crimp them using crimp pliers.
• Do not crimp wire insulation.
After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.
- Put Shrink Tip For Hot Air Gun (VAS 1978/15) on to Hot Air Gun, 220 V/ 50 Hz (VAS 1978/14).
CAUTION!
Risk of damaging surrounding components.
• When heat-shrinking crimp connections, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the hot air gun.
• Always observe operating instructions of heat gun.
- Heat crimp connection using hot air gun 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.
• 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 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.
Wire, 0.25 mm with Intermediate Wire Section, Repairing
• Only 0.5 mm2 repair wires are available for repairing a 0.25 mm2 wire.
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.
• Free up wrapped wiring harnesses carefully.
- If necessary, removing the wiring harness wrapping using a knife.
- Route yellow repair wire next to damaged wiring harness and cut repair wire to the required length using wire stripper (VAS 1978/3).
- Cut damaged wire section from the vehicle-specific single wire.
- Adjust the sliding stop in the Wire Stripper (VAS 1978/3) 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 together 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.
- Adjust the sliding stop in the Wire Stripper (VAS 1978/3) pliers jaws to 6 to 7 mm for the wire to be stripped.
- Insert the yellow repair wire end from the front into the pliers jaws as far as the stop and squeeze the pliers together completely.
- Open pliers again and remove the stripped wire end.
- Repeat this procedure on the other repair wire end.
- For the repair of a 0.25 mm 2 wire, use a small yellow crimp connector from the Wiring Harness Repair Set (VAS 1978A).
- To press the crimp connector, use the Crimping Pliers (Base Tool) (VAS 1978/1-2) from the Wiring Harness Repair Set (VAS 1978A) with the Exchangeable Head, 0.35 mm-2.5 mm (VAS 1978/1-1).
- Slide the small yellow crimp connector onto the vehicle-specific single wire at one side and onto the repair wire at the other side.
- Crimp the crimp connection at both wire ends using crimp pliers.
- Repeat this procedure at the other repair wire end.
• Do not crimp wire insulation.
After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.
- Put Shrink Tip For Hot Air Gun (VAS 1978/15) on to Hot Air Gun, 220 V/ 50 Hz (VAS 1978/14).
CAUTION!
Risk of damaging surrounding components.
• When heat-shrinking crimp connections, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the hot air gun.
• Always observe operating instructions of heat gun.
- Heat crimp connection using hot air gun 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.
• 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 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.
Wire, 0.35 mm or Larger with Intermediate Wire Section, Repairing
• Only 0.5 mm2 repair wires are available for repairing a 0.35 mm2 wire.
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.
• Free up wrapped wiring harnesses carefully.
- If necessary, removing the wiring harness wrapping using a knife.
- Route yellow repair wire next to damaged wiring harness and cut repair wire to the required length using wire stripper (VAS 1978/3).
- Cut damaged wire section from the vehicle-specific single wire.
- Adjust the sliding stop in the Wire Stripper (VAS 1978/3) 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 together 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 form the Wiring Harness Repair Set (VAS 1978A).
- Use the Crimping Pliers (Base Tool) (VAS 1978/1-2) to press the crimp connector.
The following exchangeable heads are available for the Crimping Pliers (Base Tool) (VAS 1978/1-2):
• Exchangeable Head, 0.35-2.5mm (VAS 1978/1-1)
• Exchangeable head, 4.0-6.0 mm² (VAS 1978/2 A)
- Slide the crimp connector onto the vehicle-specific single wire at one side and onto repair wire at the other side.
- Crimp the crimp connection at both wire ends using crimp pliers.
- Repeat this procedure on the other wire ends.
• Do not crimp wire insulation.
After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.
- Put Shrink Tip For Hot Air Gun (VAS 1978/15) on to Hot Air Gun, 220 V/ 50 Hz (VAS 1978/14).
CAUTION!
Risk of damaging surrounding components.
• When heat-shrinking crimp connections, be careful not to damage any other wiring, plastic parts or insulating material with the hot nozzle of the hot air gun.
• Always observe operating instructions of heat gun.
- Heat crimp connection using hot air gun 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.
• 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 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.