Audi A4: Connector Housings and Connectors, Repairing
Connector Housings and Connectors, Repair Information
Note
- Observe general notes for repairs on the vehicle electrical
system. Refer to
→ Chapter "Vehicle Electrical System, General Repair
Information".
- Allocation of crimp contacts with correct fit to connector
housing is performed according to the part number stamped in on
the connector housing. Refer to the Parts Catalog; Special
Catalog "Electrical Connecting Components"; Electrical
Equipment; subgroup 71 chart 970-00.
- Damaged connector housings must always be replaced.
Contacts in Connector Housing, Repairing
Procedure
- First, open or release if necessary the secondary lock of
the connector housing. Refer to
→ Chapter "Connector Housings, Releasing and Disassembling".
- Release contact (primary lock) using the appropriate release
tool. Refer to
→ Chapter "Connector Housings, Releasing and Disassembling".
- Pull the contact back out of the connector housing
-arrow- at the single wire (with
the single wire seal if necessary).
- Cut off the old contact (with the single wire seal) from the
vehicle-specific wiring harness.
- Take the yellow repair wire with the correct contact out of
the Wiring Harness Repair Set -VAS1978B-.
- Free up the wire to be repaired approximately 20 cm on both
sides of the repair point.
Caution
Risk of damaging the electrical wires.
Expose wrapped wiring harnesses carefully.
- If necessary, removing the wiring harness wrapping using a
knife.
- Slide the new repair wire contact into the corresponding
connector housing compartment until it engages.
- If necessary, install the single wire seal on the repair
wire. Refer to
→ Chapter "Single Wire Seals, Installing".
- Shorten the repair wire and the vehicle-specific wiring
harness single wire as needed using the Wiring Harness Repair
Set - Wire Strippers -VAS1978/3-.
- Remove the insulation from the ends of the repair wire and
vehicle-specific single wire and crimp the ends with the
crimping wires and a crimp connector. Refer to
→ Chapter "0.22 mm 2 Wire, Repairing
with Individual Crimp Connector" or
→ Chapter "Repairing a Wire 0.35 mm 2
or Greater with Individual Crimp Connector".
Single Wire Seals, Installing
Procedure
Note
- Single wire seals prevent the penetration of water and dirt
into the connector housing. They are installed, for example, in
the engine compartment and must be reinstalled after a repair.
- Single wire seal is crimped on at the factory together with
contact on the wire, this is not the case for repair wires. The
single wire seal must be slid onto the wire before crimping the
repair wire.
- Single wire seals must always fit with the repair wire
cross-section. Outer circumference of single wire seal is
aligned according to chamber circumference of the connector
housing. Perform assembly using only the assembly tool with
correct fit.
- Put single wire seal -A- onto
free end of repair wire.
- When doing this, the single wire seal small diameter must
point toward the connector housing.
- Slide the single wire seal -A-
onto the repair wire up to the connector housing and then into
the housing as far as the stop using the appropriate assembly
tool -B-.
- Shorten the repair wire and the vehicle-specific wiring
harness single wire as needed using the Wiring Harness Repair
Set - Wire Strippers -VAS1978/3-.
- Crimp the stripped ends of repair wire and single wire of
vehicle-specific wiring harness using crimping pliers and a
crimping pliers. Refer to
→ Chapter "0.22 mm 2 Wire, Repairing
with Individual Crimp Connector" or
→ Chapter "Repairing a Wire 0.35 mm 2
or Greater with Individual Crimp Connector".
Connector Housing with Insulation Displacement Connections, Repairing
Note
- For technical reasons, the connector housing for the wire
terminals can be supplied only with the contacts pushed in.
- These contacts can be removed at every other connector
housing in the event they are not required.
- Repair wires which have already been equipped with
corresponding contacts crimped on are available. Refer to the
Parts Catalog.
READ NEXT:
Information on Releasing and Disassembling Connector Housings
Note
Observe general notes for repairs on the vehicle electrical
system. Refer to
→ Chapter "Vehicle Electrical System,
Contact Surface Cleaning Set -VAS6410-, Using
The Contact Surface Cleaning Set -VAS6410- makes optimal
repair quality possible in the realm of vehicle electronics.
Using the tools, service work can
The electro-static discharge ESD Work Surface -VAS6613-
protect electronic components from getting damaged by an
electro-static charge.
This makes is possible to perform repairs on sensitive
ele
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