Audi Workshop Service and Repair Manuals

Repairing an 0.25 mm2 wire by connecting in an additional wire   Note For repairing an 0.25 mm2 wire only 0.5 mm2 repair wires are available. Procedure –  Release a length of approx. 20 cm of the defective wire at two points on both sides of the repair joint.   Caution Risk of damage to electrical wiring. Take care when releasing wiring from wrapped wiring harnesses. –  If necessary, use a knife to remove wrapping of wiring harness.

–  Lay yellow repair wire next to damaged wiring harness and use wire stripper -VAS 1978/3- to cut repair wire to required length. –  Cut damaged section out of original vehicle wire.

–  Set adjustable stop in jaws of wire stripper -VAS 1978/3- to 12 ... 14 mm (length to be stripped). –  Working from the front, insert end of original vehicle wire into jaws of wire stripper as far as it will go and press wire stripper together completely. –  Open wire stripper again and take out stripped end of wire. –  Fold back half of the stripped wire ends. –  Repeat procedure at other end of original vehicle wire.

–  Set adjustable stop in jaws of wire stripper -VAS 1978/3- to 6 ... 7 mm (length to be stripped). –  Working from the front, insert end of the yellow repair wire into jaws of wire stripper as far as it will go and press wire stripper together completely. –  Open wire stripper again and take out stripped end of wire. –  Repeat procedure at other end of repair wire. –  To repair an 0.25 mm2 wire, take a small yellow crimp connector out of the wiring harness repair set -VAS 1978 B-.

–  To fit crimp connectors from wiring harness repair set -VAS 1978 B-, use crimping pliers (base tool) -VAS 1978/1-2- with head adapter 0.35 mm² - 2.5 mm² -VAS 1978/1-1-. –  Slide small yellow crimp connector over original vehicle wire on one side and over repair wire on the other.

–  Use crimping pliers to fasten crimp connector to both wire ends. –  Repeat procedure at other end of repair wire.   Note Take care not to crimp insulation of wire.

After crimping, hot air blower must be used to shrink-fit crimp connector to prevent moisture from ingressing. –  Attach shrink element for hot air blower -VAS 1978/15A- to hot air blower, 220 V/ 50 Hz -VAS 1978/14A-.   Caution Risk of damage to surrounding components. t  When shrinking crimp connectors, take care not to damage any other pipes/wires, plastic parts or insulating material with hot nozzle of the hot air blower. t  Always observe operating instructions for hot air blower.

–  Working from centre outwards, use hot air blower to heat crimp connector in longitudinal direction until it is completely sealed and adhesive emerges at ends. l  A wire repaired using inserted repair wire and two crimp connectors must look as shown in illustration.   Note

t  If several wires have to be repaired, make sure crimp connectors are not directly adjacent to one another. Offset the crimp connectors slightly to restrict the size of the wiring harness. t  If the repair location was previously wrapped, yellow adhesive tape must be wrapped around this location again on completion of repair. t  If necessary, secure the repaired wiring harness with a cable tie to prevent rattling noises when the vehicle is driven.