Wiring Harness: Service and Repair

General

In the Audi A4 there are no longer any partial cable harnesses in the interior of the vehicle, only one complete wiring harness.

Wiring harness and connector repairs in the Audi A4 may only be carried out using the VAS1978 wiring harness repair kit.







VAS1978 wiring harness repair kit

The VAS1978 is described in detail in the kits operating instructions.

Repairing breaks in the wiring harness and faulty harness connectors, for example, is also described.


NOTE: Effective immediately, harness connectors for the ABS system may also be repaired.


0.35 square mm connector, repairing


NOTE:
- There are three different repair connector thicknesses (0.5 square mm, 1.5 square mm, 4.0 square mm) with corresponding crimp connectors in the VAS1978 wiring harness repair kit.
- Use 0.5 square mm repair wire to repair a 0.35 square mm connector.
- The repair procedure is as follows:







- Strip end of 0.35 square mm wire connector to twice its length (approx. 12-14 mm) using wire stripper.
- Fold back half the length of bare metal part.
- Strip end of 0.5 square mm wire (approx. 6-7 mm) using wire stripper.







- Push crimp connector over wire ends and crimp on both sides using stop pliers.

The insulation on the connector ends may not be crimped.

- Make sure that the correct red crimping slot for 0.5 square mm is used.







- After crimping, crimp connector must be shrunk using hot air blower.

The crimp connector must be heated from the center towards both ends until it is completely sealed and the adhesive oozes out.

The hot-air blower must be set to the appropriate temperature in accordance with its operating instructions.

While shrinking, make sure that no other connectors, plastic parts or insulating material is damaged by the hot air jet.
- If repair connector was previously taped, this area must be taped again with yellow insulation tape. If necessary, secure wiring with new tie wraps.