Repairing a wire with cross-section 0.22 mm 2 or 0.35 mm 2

WARNING: This page does not describe the selected car, but rather 16 other vehicles, including the 2009 Audi S4, 2009 Audi A4, 2008 Audi S4, 2008 Audi RS 4, and 2008 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Procedure

NOTE:

Wiring harness repair set VAS 1978 contains repair wires of three different cross-sections (0.5 mm ² , 1.5 mm ² , 4.0 mm ² ) and the corresponding crimp connectors.
0.5 mm ² repair wire must be used for repairing 0.35 mm ² wire.

Perform the repair as follows:

Fig 1: Stripping Insulation At Wiring Using Stripping Pliers

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Strip the ends of the 0.22 mm ² and 0.35 mm ² wires to a length of 12... 14 mm using the stripping pliers VAS 1978/3.
Fold back half of the stripped wire ends.
Strip the ends of the 0.5 mm ² repair wire to a length of 6 to 7 mm using the stripping pliers VAS 1978/3.

Fig 2: Crimping On Both Sides With Crimping Pliers

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Slip crimp connector over ends of wires and crimp on both sides using crimping tool VAS 1978/1.

NOTE:

Be sure to select the correct red crimp insert VAS 1978/24 for 0.5 mm ² wires.
Do NOT crimp the insulation on the wires.

Fig 3: Heating Crimp Connection Using Hot Air Gun

Courtesy of VOLKSWAGEN UNITED STATES, INC.

After crimping, you must shrink-fit the crimp connector using the hot-air blower, 220 V/ 50 Hz VAS 1978/14 and hot-air blower shrink fitting VAS 1978/15.

Crimp connector must be heated working outwards from center until it is completely sealed and adhesive emerges.
Set the hot air blower to the correct temperature; refer to operating manual for VAS 1978.

When shrink-fitting, ensure no other wires, plastic components or insulating materials are damaged by the hot nozzle.
If repair wire was previously wrapped, yellow insulating tape must again be wound around this point; reattach wire with a cable tie if necessary.
Reconnect battery. Required steps Audi A4 S4 Reconnecting . Required steps Audi RS4 Connecting .