Flexray Wires, Repairing

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NOTE: Observe general notes for repairs on the vehicle electrical system, refer to VEHICLE ELECTRICAL SYSTEM, GENERAL REPAIR INFORMATION .

A two-layer wire -1 and 2- with a 0.35 mm ² profile is used as a FlexRay wire.

Fig 1: Identifying Repair In Twisted Wire Pairs

Courtesy of AUDI OF AMERICA, LLC

During repair work, both wires must have the same length.
When twisting the wires -1 and 2- together, the -A- = 30 mm routing length must be maintained.
While doing so, no section of wire may be greater than -B- = 50 mm without twisting the wires, for example in the area of crimp connectors -arrow-.
Maximum exposed wire length: -C- = 100 mm.

Fig 2: Identifying Exposed Wire
Courtesy of AUDI OF AMERICA, LLC
Protect the area being repairs from the environment. Use a crimp connector with heat-shrinkable tube over the untwisted location being repairs and waterproof insulation over the exposed wire.
Mark the location of the repair with something suitable, for example, with yellow tape.
Repairing both wires is identical to repair just one wire.
Position both repaired location -arrows- -A- = 30 mm opposite each other.
Crimp the cables with connectors.

1 -

Repair location in the area without insulation

2 -

Repair location with connectors

C -

Maximum exposed length = 100 mm