Electrical Equipment General Information
Wiring Harnesses and Connectors, Repairing
=> [ General Notes on Repairs on Vehicle Electrical System ]
=> [ General Notes for Repairing Wiring Harnesses and Connectors ]
=> [ Electrostatic Discharge Work Surface VAS 6613 ]
=> [ Pyrotechnic Component Wire, Repairing ]
=> [ CAN Bus Wire, Repairing ]
=> [ FlexRay Wire, Repairing ]
=> [ 0.25 mm Wire with Individual Crimp Connector, Repairing ]
=> [ 0.35 mm Wire or Greater with Individual Crimp Connector, Repairing ]
=> [ 0.25 mm Wire with Intermediate Wire Section, Repairing ]
=> [ 0.35 mm Wire or Greater with Intermediate Wire Section, Repairing ]
Special tools, testers and auxiliary items required
• Wiring Harness Repair Set (VAS 1978 B)
• Repairs to the wiring harnesses and connectors must only be performed using the wiring harness repair set (VAS 1978 B).
• Observe the country specific requirements.
• Use of the (VAS 1978 B) is described in detail in the attached operating instructions.
• Repairs on open circuits and faulty connectors are also explained using examples.
General Notes on Repairs on Vehicle Electrical System
Risk of injury.
• Pay attention to decals designating high voltage components. When performing repairs, residual voltage must 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.
• Observe the country specific requirements.
• By disconnecting the battery ground (GND) cable, safe work on the vehicle electrical system is guaranteed. With the ignition turned off, disconnect the ground cable from the battery.
• Before starting a repair, the cause of the damage must be eliminated first, for example, sharp edges on chassis parts, faulty electrical consumers, corrosion, etc.
• If possible, do not loosen the ground (GND) straps from body (danger of corrosion).
• Further information relating, for example to the removal and installation of individual components can be found in the appropriate repair information.
General Notes for Repairing Wiring Harnesses and Connectors
• Observe general notes for repairs on the vehicle electrical system. Refer to => [ General Notes on Repairs on Vehicle Electrical System ].
• The wiring harness repair set (VAS 1978 B) does not contain all the wire cross sections in the vehicle. If the required wire cross section is not present, the next greater cross section must be used.
• For repairs on the 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 the hot air gun to prevent moisture penetration.
• Shielded wires such as for speed 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 the Diagnostic Trouble Code (DTC) memory, erase and/or bring systems into basic setting.
Electrostatic Discharge Work Surface VAS 6613
• The electrostatic discharge work surface (VAS 6613) protect electronic components from getting damaged by an electrostatic charge.
• This makes is possible to perform repairs on sensitive electronic components on an open mat.
- Place the electrostatic discharge mat - 3 - on a clean, dry table.
- Connect the ground - 2 - to one of the buttons on the mat.
- Connect the ground connector adapter - 1 - to the adapter connector on a outlet with contact protection or connect the alligator clip to a ground in the building or a water pipe.
- Connect the wrist strap - 4 - to one of the buttons on the mat.
- Attach the wrist strap directly to your wrist - never to your shirt sleeve or jacket sleeve.
If working on especially sensitive electronic component and with the pad exposed, use only nonmagnetic tools, for example, a socket wrench (T10072)
Pyrotechnic Component Wire, Repairing
• Observe general notes for repairs on the vehicle electrical system.
• Observe the notes on wiring harness and connector repairs. Refer to => [ General Notes for Repairing Wiring Harnesses and Connectors ] including identifying repair locations.
Passenger protection malfunction due to faulty repairs to the wires for pyrotechnic components, for example, airbag, belt tensioner.
• Repairs to wires for pyrotechnic components may only be performed on the vehicle side using the wiring harness repair set (VAS 1978 B) and original replacement parts (connector housing, contacts, wires) in order to guarantee the repair quality required by Audi AG.
• Wires at individual airbag units may not be repaired.
• If the wires or connectors on the airbag units are damaged, the respective airbag unit must be replaced for safety reasons.
• A maximum of two repairs may be performed when repairing wires for pyrotechnic components. 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 pyrotechnic components should be performed a maximum of 30 cm from the next connector 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 may be greater than - B - = 100 mm without twisting the wires, e.g. in the area of crimp 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 void for repairs on airbag wiring harness which were not performed using original replacement parts and (VAS 1978 B).
CAN Bus Wire, Repairing
• Observe general notes for repairs on the vehicle electrical system.
• Observe the notes on wiring harness and connector repairs.
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:
• When repairing CAN bus wires, both wires must be 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 - = 50 mm without twisting the wires, for example, in the area of crimp connectors - arrow -.
FlexRay Wire, Repairing
• Observe general notes for repairs on the vehicle electrical system.
• Observe the notes on wiring harness and connector repairs.
A two layer wire - 1 and 2 - with a 0.35 mm 2 profile is used as a FlexRay wire.
• During repair work, both wires must have the same length.
• When twisting the wires - 1 and 2 - together, the - A - = 30 mm routing length must be maintained.
• While doing so, no section of wire may be greater than - B - = 30 mm without twisting the wires, for example, in the area of crimp connectors - arrow -.
• Maximum exposed wire length: 100 mm.
• 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 exposed wire.
0.25 mm 2 Wire with Individual Crimp Connector, Repairing
Procedure
- Free up the wire to be repaired approximately 20 cm on both sides of the repair point.
Risk of damaging the electrical wires.
• Expose 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. Refer to => [ 0.25 mm Wire with Intermediate Wire Section, Repairing ].
- Adjust the sliding stop in the (VAS 1978/3) jaws to 12 to 14 mm for the wire to be stripped.
- Insert wire end from front up to stop into jaws of the pliers and squeeze the pliers completely.
- Open the pliers again and remove the stripped wire end.
- Twist the bare strands one half turn.
- For the repair of a 0.25 mm 2 wire, use a small yellow crimp connector from the (VAS 1978 B).
- To press the crimp connector, use the (VAS 1978/1-2) with (VAS 1978/1-1).
- Slide the small yellow crimp connector onto both stripped, non-insulated wire ends on the vehicle specific single wire and crimp them using crimp pliers.
• Do not crimp the wire insulation.
After crimping, crimp connections must be heat shrunk using hot air gun to prevent moisture penetration.
- Place the (VAS 1978/15A) on the (VAS 1978/14A).
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 blower.
• Always observe operating instructions of heat gun.
- Heat the 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.
• 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.
0.35 mm 2 Wire or Greater with Individual Crimp Connector, Repairing
Procedure
- Free up the wire to be repaired approximately 20 cm on both sides of the repair point.
Risk of damaging the electrical wires.
• Expose 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. Refer to => [ 0.35 mm Wire or Greater with Intermediate Wire Section, Repairing ].
- Adjust the sliding stop in the (VAS 1978/3) jaws to 6 to 7 mm for the wire to be stripped.
- Insert wire end from front up to stop into jaws of the pliers and squeeze the pliers completely.
- Open the pliers again and remove the stripped wire end.
- For the repair, use a suitable crimp connector form the (VAS 1978 B).
- Use the (VAS 1978/1-2) to press the crimp connector.
The following exchangeable heads are available for the (VAS 1978/1-2):
• Exchange head, 0.35 mm2 - 2.5 mm2 (VAS 1978/1-1)
• Exchangeable head, 4.0-6.0 mm2 (VAS 1978/2 A)
- Slide crimp connection onto 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.
- Place the (VAS 1978/15A) on the (VAS 1978/14A).
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 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.
• 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.
0.25 mm 2 Wire 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.
Risk of damaging the electrical wires.
• Expose 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 (VAS 1978/3) 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 the 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 (VAS 1978/3) 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 (VAS 1978 B).
- To press the crimp connector, use the (VAS 1978/1-2) with (VAS 1978/1-1) from the (VAS 1978 B).
- 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.
- Place the (VAS 1978/15A) on the (VAS 1978/14A).
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 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.
• 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.
0.35 mm 2 Wire or Greater 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.
Risk of damaging the electrical wires.
• Expose 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 (VAS 1978/3) 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 the 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 (VAS 1978 B).
- Use the (VAS 1978/1-2) to press the crimp connector.
The following exchangeable heads are available for the (VAS 1978/1-2):
• Exchange head, 0.35 mm2 - 2.5 mm2 (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.
- Place the (VAS 1978/15A) on the (VAS 1978/14A).
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 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.
• 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.