Audi A4 Owners & Service Manuals

Audi A4: Repairing a Wire 0.35 mm 2 or Greater with Individual Crimp Connector

Audi A4 (B9) 2016-2024 Service Manual / Electrical System / Electrical Equipment General Information / Wiring / Repairing a Wire 0.35 mm 2 or Greater with Individual Crimp Connector

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.

Expose wrapped wiring harnesses carefully.

- If necessary, removing the wiring harness wrapping using a knife.

- Cut out the damaged section of wire using the Wiring Harness Repair Set - Wire Strippers -VAS1978/3-.

  Note

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 → Chapter "Repair a wiring 0.35 mm 2 or greater with intermediate wire section".

N97-0017

- Adjust the sliding stop in the Wiring Harness Repair Set - Wire Strippers -VAS1978/3- 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 from the Wiring Harness Repair Set -VAS1978B-.

  Note

  • Always be sure to use the corresponding crimp connector and the correct crimping slot for the crimping connection used. Refer to → Chapter "Crimping Pliers with Insert".
  • Do not crimp wire insulation.

N97-0016

- Use the Wiring Harness Repair - Crimping Plier - Base Tool -VAS1978/1-2- to press the crimp connector.

The following exchangeable heads are available for the Wiring Harness Repair - Crimping Plier - Base Tool -VAS1978/1-2-:

  • Wiring Harness Repair - Crimping Head - .35-2.5mm -VAS1978/1-1-
  • Wiring Harness Repair Set - Crimping Head - 4-6mm -VAS1978/2 A-

N97-10491

- Slide crimp connection onto both stripped wire ends of vehicle-specific single wire and crimp them using crimp pliers.

  Note

Do not crimp wire insulation.

N97-10490

After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.

- Insert the Wiring Harness Repair - Blower - Shrink Element -VAS1978/15A- on the Wiring Harness Repair Set - Hot Air Blower -VAS1978/14A-.

  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 blower.
  • Always observe operating instructions of heat gun.

N97-0013

- 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.

N97-0010

  Note

  • 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.

N97-0011

Repairing a 0.22 mm 2 Wire with Intermediate Wire Section

  Note

For repairing a 0.222 a repair wire can be used as the intermediate wire with a cross section of 0.35-mm2 or 0.5-mm2.

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.

Expose wrapped wiring harnesses carefully.

- If necessary, removing the wiring harness wrapping using a knife.

- Route the yellow repair wire next to the damaged wiring harness and cut the repair wire to the required length using the Wiring Harness Repair Set - Wire Strippers -VAS1978/3-.

- Cut damaged wire section from the vehicle-specific single wire.

N97-0017

- Adjust the sliding stop in the Wiring Harness Repair Set - Wire Strippers -VAS1978/3- 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.

N97-0016

- Adjust the sliding stop in the Wiring Harness Repair Set - Wire Strippers -VAS1978/3- 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 0.22 mm 2 wire, use a small transparent crimp connector from the Wiring Harness Repair Set -VAS1978B-.

N97-0016

- Use die Wiring Harness Repair - Crimping Plier - Base Tool -VAS1978/1-2- with Wiring Harness Repair - Crimping Head - .35-2.5mm -VAS1978/1-1- from the Wiring Harness Repair Set -VAS1978B- to crimp the wire.

- Push the small transparent crimp connector on the side of the stripped, non-insulated wire ends of vehicle-specific single wire on the other side of the repair wire stripped wire ends.

N97-10491

- Crimp the crimp connection at both wire ends using crimp pliers.

- Repeat this procedure at the other repair wire end.

  Note

Do not crimp wire insulation.

N97-10490

After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.

- Insert the Wiring Harness Repair - Blower - Shrink Element -VAS1978/15A- on the Wiring Harness Repair Set - Hot Air Blower -VAS1978/14A-.

  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 blower.
  • Always observe operating instructions of heat gun.

N97-0013

- 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.

N97-0012

  Note

  • 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.

N97-0011

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