Wire, 0.25 mm with Intermediate Wire Section, Repairing

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.

NOTE:

Only 0.5 mm ² repair wires are available for repairing a 0.25 mm ² wire.

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.

Free up wrapped wiring harnesses carefully.

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

Fig 1: Cutting Wire Using Side-Cutter Function Of Wire Stripper

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Route yellow repair wire next to damaged wiring harness and cut repair wire to the required length using wire stripper VAS 1978/3.

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

Fig 2: Stripping Insulation At Wiring Using Stripping Pliers

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Adjust the sliding stop in the Wire Stripper VAS 1978/3 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.

Fig 3: Stripping Insulation At Wiring Using Stripping Pliers

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Adjust the sliding stop in the Wire Stripper VAS 1978/3 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 0.25 mm ² wire, use a small yellow crimp connector from the Wiring Harness Repair Set VAS 1978A.

Fig 4: Crimping Pliers

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To press the crimp connector, use the Crimping Pliers (Base Tool) VAS 1978/1-2 from the Wiring Harness Repair Set VAS 1978A with the Exchangeable Head, 0.35 mm-2.5 mm VAS 1978/1-1.

Slide the small yellow crimp connector onto the vehicle-specific single wire at one side and onto the repair wire at the other side.

Fig 5: Crimping Single Break Point

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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.

Fig 6: Heating Crimp Connection Using Hot Air Gun

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

Put Shrink Tip For Hot Air Gun VAS 1978/15 on to Hot Air Gun, 220 V/ 50 Hz VAS 1978/14.

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 gun.
Always observe operating instructions of heat gun.

Fig 7: Wire Break With Dual Repair Point

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Heat crimp connection using hot air gun 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.

Fig 8: Offsetting Crimp Connections

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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.