Modular wiring routing with corrugated tubing on front seat

WARNING: This page does not describe the selected car, but rather 15 other vehicles, including the 2008 Audi S4, 2008 Audi RS 4, 2008 Audi A4, 2007 Audi S4, and 2007 Audi RS 4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Identifying Trim Removal Wedge 3409

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Trim removal wedge 3409

General information

With the introduction of modular wiring routing, the complete sheathing of the entire wiring harness with a fabric strap between the seat tray and the connectors to the connector station has been eliminated. A two-shell corrugated tubing in which the wires are routed separately has been implemented.

Opening corrugated tubing and removing individual wire

CAUTION: Observe safety precautions for work on airbags → Airbag safety precautions .

Move front seat as far back and up as possible.

Fig 2: Uncliping Connector Station Cover Under Front Seat

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unclip connector station cover - 1 - under front seat.
Use Trim Removal wedge 3409 to do this.
Disengage cover - 1 - on corrugated tubing side.

Fig 3: Releasing Cable Bracket On Connector Station By Pressing Retaining Tabs On Both Sides

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Release cable bracket - 2 - on connector station by pressing retaining tabs on both sides - arrows -.

1 - Wiring harness

3 - Corrugated tubing, two-shelled

CAUTION: Before handling airbag units (e.g. disconnecting electrical connector), the person handling it must "electrostatically discharge". This can be done by touching door striker, for example.

Remove front seat → Front seats (standard seat), removing and installing
Attach seat to Fixture For Seat Repair VAS 6136.

Fig 4: Using Trim Removal Wedge 3409 To Open Cable Bracket

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using Trim Removal Wedge 3409, open cable bracket - 1 -.
Remove cable bracket - 1 - from corrugated tubing - 2 -.

Fig 5: Removing Bolt & Cable Clip From Corrugated Tubing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolt - 1 -.
Remove cable clip - 2 - from corrugated tubing - 3 -.

Fig 6: Opening Fabric Band & Corrugated Tubing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Open fabric band - 2 - in area of - arrow -.
Open corrugated tubing - 1 -.

Install individual wires and close corrugated tubing

Installation is reverse of removal. Observe the following when doing so:

CAUTION:

Observe safety precautions for work on airbags → Airbag safety precautions .
Before handling airbag units (e.g. disconnecting electrical connector), the person handling it must "electrostatically discharge". This can be done by touching door striker, for example.

When bundling and placing individual wires in corrugated tubing, ensure wires are not twisted.

NOTE:

Note installation position of two-part corrugated tubing to wiring harness and position of cable bracket to corrugated tubing.

Fig 7: Ensuring Side Of Cable Bracket Connects To Last Rib On Corrugated Tubing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

The beginning of the corrugated tubing - 4 - should be placed immediately after the clip - 2 - or cable tie.

3 - Wiring harness to connector station

Ensure two-part corrugated tubing - 4 - locks cleanly over entire length.
Ensure side - arrow A - of cable bracket - 1 - connects to the last rib - arrow B - on the corrugated tubing - 4 -.

Fig 8: Binding Transition Of Seat Side Of Corrugated Tubing And Wiring Harness With Self-Adhesive Fabric Tape

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Bind transition of seat side of corrugated tubing - 1 - and wiring harness - 2 - with self-adhesive fabric tape - arrow -.

Fig 9: Ensuring First Pins On Cover Engage Correctly In Mounts On Connector Station

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Ensure that first the pins - A arrows - on cover - 1 - engage correctly in mounts - B arrows - on connector station - 2 -.
They can only lock in the connector station when the cover is engaged correctly.

Tightening torques → Modular wiring routing, vehicles from 08.05, assembly overview