Repair A Wiring 0.35 Mm 2 Or Greater With Intermediate Wire Section

WARNING: This page is about a different car, the 2023 Audi SQ8, 2023 Audi RS Q8, and 2023 Audi Q8. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

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

For the repair use repair wires with a cross section of 0.35 mm² through 6.0-mm² .

Procedure

-- Free up the wire to be repaired at two places approximately 20 cm (7.87 in.) 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.

-- Route the yellow repair wire next to the damaged wiring harness and cut the repair wire to the required length using the Wiring Harness Repair Set - Wire Strippers:VAS1978/3 .

Fig 1: Cutting Wire

Courtesy of AUDI

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

-- Adjust the sliding stop in the Wiring Harness Repair Set - Wire Strippers:VAS1978/3 pliers jaws to 6 to 7 mm for the wire to be stripped.

Fig 2: Identifying Stripping Pliers To Strip Wiring Insulation

Courtesy of AUDI

-- 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.

-- Repeat the procedure on the other end of the vehicle-specific individual wire.

-- For the repair, use two suitable crimp connectors from the Wiring Harness Repair Set:VAS1978B .

NOTE:

Always be sure to use the corresponding crimp connector and the correct crimping slot for the crimping connection used. Refer to CRIMPING PLIERS WITH INSERT .

Do not crimp wire insulation.

-- Use the Wiring Harness Repair - Crimping Plier - Base Tool:VAS1978/1-2 to press the crimp connector.

Fig 3: Crimping Pliers

Courtesy of AUDI

The following exchangeable heads are available for the Wiring Harness Repair - Crimping Plier - Base Tool:VAS1978/1-2 :

Wiring Harness Repair - Crimping Head -.35-2.5mm:VAS1978/1-1
Wiring Harness Repair Set - Crimping Head - 4-6mm:VAS1978/2A

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

-- Crimp the crimp connection at both wire ends using crimp pliers.

Fig 4: Crimping A Single Break Point

Courtesy of AUDI

-- Repeat this procedure on the other wire ends.

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

-- 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 hot air gun lengthwise from center outward until it is sealed completely and adhesive comes out the ends.

Fig 6: Identifying Wire Break With Dual Repair Point

Courtesy of AUDI

This is how the completed repair location with the inserted wire and two crimp connectors should look.

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

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.