0.22 Mm 2 Wire, Repairing With Individual Crimp Connector

WARNING: This page does not describe the selected car, but rather 13 other vehicles, including the 2017 Audi SQ5, 2017 Audi Q5, 2016 Audi SQ5, 2016 Audi Q5, and 2015 Audi SQ5. However, it is still accessible from the selected car via links, so may be relevant.

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.

Fig 1: Cutting Wire

Courtesy of AUDI OF AMERICA, LLC

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 REPAIRING A 0.22 MM .

-- 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.

Fig 2: Identifying Stripping Pliers To Strip Wiring Insulation

Courtesy of AUDI OF AMERICA, LLC

-- 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.

-- Twist bare strands one-half turn.

-- For the repair of a 0.22 mm ² wire, use a small transparent crimp connector from the Wiring Harness Repair Set VAS1978B.

-- To press the crimp connector, use the Wiring Harness Repair - Crimping Plier - Base Tool VAS1978/1-2 with Wiring Harness Repair - Crimping Head -.35-2.5mm VAS1978/1-1.

Fig 3: Crimping Pliers

Courtesy of AUDI OF AMERICA, LLC

-- Slide the small transparent crimp connector onto both stripped, non-insulated wire ends on the vehicle-specific single wire and crimp them using crimp pliers.

Fig 4: Crimping A Single Break Point

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Do not crimp wire insulation.

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

Fig 5: Heating Crimp Connection Using Hot Air Gun

Courtesy of AUDI OF AMERICA, LLC

-- 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.

-- Heat crimp connection using the hot air blower lengthwise from center outward until it is sealed completely and adhesive comes out the ends.

Fig 6: Identifying Single Crimp Connection

Courtesy of AUDI OF AMERICA, LLC

This is how the completed repair location with individual crimp connector should appear.

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.

Fig 7: Identifying Offset Positions Of Crimped Connections

Courtesy of AUDI OF AMERICA, LLC

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.