Electrical System General Information
Electrical System General Information
Repair Group
27 - Starter, current supply, CCS
92 - Windscreen wash/wipe system
94 - Lights, bulbs, switches - exterior
96 - Lights, bulbs, switches - interior
97 - Wiring
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
A005AA00420
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Electrical system; General information - Edition 08.2015
Contents
Contents i
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Electrical system; General information - Edition 08.2015
97 - Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1 Vehicle diagnostic, testing and information systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.1 Connecting vehicle diagnostic tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2 Repairing wiring harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.1 General information on repairs to the vehicle electrical system . . . . . . . . . . . . . . . . . . . . . . 94
2.2 Wiring harness repair set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.3 Description of tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.4 Repairing wiring harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.5 Repairing fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.6 Repairing aerial wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.7 Repairing connector housings and electrical connectors . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.8 Releasing and dismantling connector housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
3 Contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3.1 Using contact surface cleaning set VAS 6410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4 ESD (electrostatic discharge) workplace VAS 6613 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
4.1 Using ESD workplace VAS 6613 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
ii Contents
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Electrical system; General information - Edition 08.2015
Note
Caution
WARNING
Caution
1. Battery 1
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Caution
Do not remove any labels and do not top up with distilled water.
Perform only a visual check. Note the chapter on checking the
battery ⇒ page 7 .
WARNING
Caution
Do not remove any labels and do not top up with distilled water.
Perform only a visual check. Note the chapter on checking the
battery.
WARNING
Note
1. Battery 3
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WARNING
WARNING
WARNING
1. Battery 5
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Caution
2 Checking battery
⇒ “2.1 Test sequence”, page 7
⇒ “2.2 Visual check”, page 9
⇒ “2.3 Checking colour indicator of magic eye”, page 10
⇒ “2.4 Checking battery using vehicle diagnostic tester”,
page 11
⇒ “2.5 Battery tester with printer VAS 6161 ”, page 13
⇒ “2.6 Battery tester with printer VAS 5097 A ”, page 18
⇒ “2.7 Current draw test”, page 23
⇒ “2.8 Checking no-load voltage of battery, stock vehicles”, page
25
Caution
2. Checking battery 7
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WARNING
WARNING
Caution
WARNING
WARNING
Note
In the near future, battery tester with printer - VAS 5097 A- will no
longer be used for testing the battery; only battery tester with
printer - VAS 6161- will be used.
WARNING
Caution
2. Checking battery 9
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WARNING
Note
WARNING
WARNING
Note
WARNING
2. Checking battery 11
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WARNING
Note
2. Checking battery 13
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WARNING
Procedure
WARNING
Note
– Switch off ignition and all electrical equipment and remove ig‐
nition key.
– Check colour indicator on batteries - A- with magic eye
⇒ page 7 .
– Switch on battery tester with printer - VAS 6161- ⇒ page 14 .
– Connect red clamp (+) to positive terminal of battery - A- .
– Connect black clamp (-) to negative terminal of battery - A- .
Note
Note
WARNING
Procedure
– Select “maintenance test” from the menu.
– Connect scanner.
2. Checking battery 15
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Note
WARNING
Procedure
– Select “service test” from the menu.
– Select “On battery terminal” or “On jump-start point”.
– Select vehicle model.
– Determine temperature above battery - A- by holding temper‐
ature sensor approx. 5 cm over one of the battery terminals
until temperature is constant.
– Select type of battery (normal, AGM, 2*6 V or gel).
– Select standard (CCA, JIS, DIN, SAE, IEC or EN).
– Start test.
– Print test report.
WARNING
Procedure
– Select “warranty test” from the menu.
– Select “In vehicle” or “Out of vehicle”.
– Select “On battery terminal” or “On jump-start point”.
– Select vehicle model.
– Determine temperature above battery - A- by holding temper‐
ature sensor approx. 5 cm over one of the battery terminals
until temperature is constant.
– Select type of battery (normal, AGM, 2*6 V or gel).
– Select battery capacity.
– Start test.
– Print test report.
Note
– Charge battery - A-
⇒ page 26 and repeat test.
Replace battery - A- – Disconnect battery - A- and
repeat test.
Poor contact of the cables can
be responsible for the result
“Replace battery”.
2. Checking battery 17
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WARNING
Note
9- Printer
WARNING
2. Checking battery 19
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WARNING
Note
Caution
Note
Note
Note
– Use the sliding switch to select the connection point for the test
clamps ⇒ page 19 .
1- Direct connection to battery - A-
2- Connection to jump start terminal
– Check whether low temperature test current indicated on bat‐
tery - A- matches value set on battery tester with printer - VAS
5097 A- .
– Press Start button ⇒ page 19 .
The green LED will light up ⇒ page 19 . The test program runs
through automatically. The test result will be printed out
⇒ page 22 . If battery tester with printer - VAS 5097 A- does not
start up (no LED lights, no printout), battery - A- must be charged
⇒ page 26 .
– Switch off battery tester with printer - VAS 5097 A-
⇒ page 19 .
– Remove test clamps.
Note
2. Checking battery 21
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Note
WARNING
Check that the correct charging mode is set on the battery charger
to ensure that the results of the current draw test are accurate.
♦ Battery charger - VAS 5095 A- ⇒ page 27
♦ Battery charger - VAS 5900- ⇒ page 31
♦ Battery charger - VAS 5903- ⇒ page 43
By checking the current draw of the battery - A- during charging,
it is possible to quickly determine the condition of a discharged
battery - A- (whether it must be renewed or fully charged).
2. Checking battery 23
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Note
When using the battery tester with printer - VAS 6161- , always
perform a current draw test when the test result “Perform current
draw test” appears on the display.
WARNING
Note
Test conditions
Battery - A- must not have been charged or discharged within last
2 days.
Procedure
– Measure no-load current of battery - A- using hand-held mul‐
timeter - V.A.G 1526 B- .
Test result
No-load voltage Charge state Condition of battery - A-
11.60 V 0% Discharged, no capacity. Totally discharged ⇒ page 59 .
2. Checking battery 25
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3 Charging battery
⇒ “3.1 Battery charger VAS 5095 A ”, page 26
⇒ “3.2 Battery charger VAS 5900 ”, page 31
⇒ “3.3 Battery charger VAS 5903 ”, page 43
⇒ “3.4 Battery charger VAS 5906 ”, page 55
⇒ “3.5 Solar panel VAS 6102 A ”, page 58
⇒ “3.6 Totally discharged batteries”, page 59
WARNING
WARNING
Note
The battery is charged without current and voltage peaks; the ve‐
hicle electronics are not affected by the charging process. The
battery - A- can remain in the vehicle during charging and does
not need to be disconnected from the vehicle electrical system.
Battery charger - VAS 5095 A-
1- ON/OFF switch (0 = OFF)
WARNING
Caution
Note
3. Charging battery 27
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WARNING
Procedure
– Switch off ignition and all electrical equipment and remove ig‐
nition key.
– Check battery type set on Battery type selector switch
⇒ page 26 . Battery type switch must be set to 2.4 V/C
(volts/cell).
– Connect red charger clamp (+) to positive terminal of battery
- A- .
Note
WARNING
Note
WARNING
Procedure
– Charge battery - A- ⇒ page 27 .
WARNING
WARNING
3. Charging battery 29
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Procedure
Caution
Caution
Note
WARNING
WARNING
WARNING
WARNING
3. Charging battery 31
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Note
Overview - controls
1- Display
2- ↑ button: up
3- ↓ button: down
4- START/STOP button
5- INFO button
WARNING
WARNING
Note
Procedure
– Switch off ignition and all electrical equipment and remove ig‐
nition key.
– Connect battery charger - VAS 5900- to electrical system. The
last mode selected will be shown on display ⇒ page 32 .
– Set battery type with INFO button.
Symbol -1- for “Standard charging of wet batteries” or symbol
-2- for “Standard charging of gel/absorbent glass mat batteries”
will be shown on display.
– Use ↑ button or ↓ button to set battery capacity (Ah) of battery
- A- being charged.
– Connect red charger clamp (+) to positive terminal of battery
- A- .
Note
3. Charging battery 33
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When the charge is 100 % all the bars appear on the display
-1-.
Note
WARNING
Caution
WARNING
Caution
Note
Procedure
– Switch off ignition and all electrical equipment and remove ig‐
nition key.
3. Charging battery 35
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Note
Note
WARNING
WARNING
Caution
3. Charging battery 37
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Note
Procedure
– Switch off ignition and all electrical equipment and remove ig‐
nition key.
– Connect battery charger - VAS 5900- to electrical system. The
last mode selected will be shown on display ⇒ page 32 .
Note
Note
The battery charger - VAS 5900- returns to the main menu (op‐
erating mode selection) if no button is pressed within 5 seconds.
3. Charging battery 39
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WARNING
WARNING
Procedure
Caution
Caution
Note
Note
The battery charger - VAS 5900- returns to the main menu (op‐
erating mode selection) if no button is pressed within 5 seconds.
3. Charging battery 41
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Note
WARNING
WARNING
Procedure
– Proceed in the same way as when charging the battery - A-
⇒ page 32 .
When the charge is 100 % all the bars appear on the display
-1-.
WARNING
WARNING
Note
3. Charging battery 43
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Overview - controls
1- Display
2- ↑ button: up
3- ↓ button: down
4- START/STOP button
5- INFO button
WARNING
WARNING
Note
Procedure
– Switch off ignition and all electrical equipment and remove ig‐
nition key.
– Connect battery charger - VAS 5903- to electrical system. The
display shows the last mode selected ⇒ page 44 .
– Set battery type with INFO button.
Symbol -1- for “Standard charging of wet batteries” or symbol
-2- for “Standard charging of gel/absorbent glass mat batteries”
will be shown on display.
– Use ↑ button or ↓ button to set battery capacity (Ah) of battery
- A- being charged.
– Connect red charger clamp (+) to positive terminal of battery
- A- .
Note
3. Charging battery 45
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When the charge is 100 % all the bars appear on the display
-1-.
Note
WARNING
WARNING
Caution
Caution
Note
Procedure
– Switch off ignition and all electrical equipment and remove ig‐
nition key.
3. Charging battery 47
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Note
Note
WARNING
WARNING
Caution
3. Charging battery 49
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Note
Procedure
– Switch off ignition and all electrical equipment and remove ig‐
nition key.
– Connect battery charger - VAS 5903- to electrical system. The
display shows the last mode selected ⇒ page 44 .
Note
Note
The battery charger - VAS 5903- returns to the main menu (op‐
erating mode selection) if no button is pressed within 5 seconds.
3. Charging battery 51
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WARNING
WARNING
Procedure
Caution
Caution
Note
Note
The battery charger - VAS 5903- returns to the main menu (op‐
erating mode selection) if no button is pressed within 5 seconds.
3. Charging battery 53
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Note
WARNING
WARNING
When the charge is 100 % all the bars appear on the display
-1-.
WARNING
WARNING
Note
3. Charging battery 55
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Overview - controls
1- Charge level display 25 %
2- Charge level display 50 %
3- Charge level display 75 %
4- Charge level display 100 %
5- "Ready" indicator
6- START/STOP button and Setup button for interrupting and
resuming charging process. Press for 10 seconds to access
setup menu and select characteristic curve type.
7- Malfunction indicator
WARNING
WARNING
Procedure
– Place charger - VAS 5906- in engine compartment or under
vehicle.
– Connect battery charger - VAS 5906- to electrical system.
Battery charger - VAS 5906- is in no-load operation; “ready” in‐
dicator will light up.
WARNING
Caution
Note
Caution
3. Charging battery 57
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Note
Procedure
– Secure solar panel - VAS 6102 A- to interior mirror -1-.
– Place underside on dash panel -2-.
Note
WARNING
WARNING
3. Charging battery 59
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Caution
Note
Procedure
– Check no-load voltage of battery - A- ⇒ page 26 .
– Charge battery - A- :
♦ Battery charger - VAS 5095 A- ⇒ page 28
♦ Battery charger - VAS 5900- ⇒ page 37
♦ Battery charger - VAS 5903- ⇒ page 49
♦ Battery charger - VAS 5906- ⇒ page 56
4 Alternator
4. Alternator 61
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1 - Bolts
❑ 1 Nm
2 - Cover
❑ With three retaining tabs
3 - Bolts
❑ 2 Nm
4 - Voltage regulator
❑ Removing:
– Unscrew bolts -item 1-
and detach protective
cap -item 2-
Note
1 - Alternator
2 - Voltage regulator
❑ Removing and installing
⇒ page 64
❑ Checking carbon brush‐
es ⇒ page 66
3 - Bolt
❑ 2.5 Nm
4 - Cover
5 - Nut
❑ 12 Nm
6 - Nut
❑ 30 Nm
7 - Bolt
❑ 3 Nm
8 - Bolt
❑ 1.5 Nm
4. Alternator 63
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Note
1 - Nut
❑ 65 Nm
2 - Poly V-belt pulley
3 - Alternator
4 - Voltage regulator
❑ Removing and installing
⇒ page 65
❑ Checking carbon brush‐
es ⇒ page 66
5 - Bolt
❑ 1.5 Nm
6 - Cover
7 - Bolt
❑ 3 Nm
8 - Bolt
❑ 2.5 Nm
4. Alternator 65
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1 - Alternator
2 - Voltage regulator
❑ Removing:
– Remove nuts -item 5-
and detach cover
-item 4-
4. Alternator 67
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Note
1 - Alternator
2 - Voltage regulator
❑ Removing and instal‐
ling: Up to 2007
⇒ page 69 ; from 2007
onwards ⇒ page 70
❑ Checking carbon brush‐
es: Up to 2007
⇒ page 69 ; from 2007
onwards ⇒ page 70
3 - Bolt
❑ 2 Nm
4 - Cover
5 - Protective cap
6 - Bolt
❑ 2 Nm
Installing
– Press protective cap -2- off voltage regulator -1- in direction of
-arrow-.
– When positioning voltage regulator, ensure carbon brushes
are positioned correctly on contact surfaces.
– Refit protective cap when voltage regulator has been installed.
Further installation is carried out in the reverse order; note the
following:
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
Removing and installing alternator .
• Tightening torque ⇒ page 68
4. Alternator 69
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Installing
– Insert 0.3 mm feeler gauge -item 4- between protective cap
-2- and carbon brushes -3-.
– Pull protective cap off only as far as point where projection on
protective cap keeps carbon brushes pressed down.
– After installing voltage regulator, press protective cap on as
far as stop.
Further installation is carried out in the reverse order; note the
following:
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
Removing and installing alternator .
• Tightening torque ⇒ page 68
Procedure
– Remove voltage regulator ⇒ page 70 .
– Insert 0.3 mm feeler gauge -item 3- between protective cap
-2- and carbon brushes.
– Pull protective cover off voltage regulator -1- -arrow-.
4. Alternator 71
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♦ Socket - 3310-
Caution
-B- Large poly V-belt pulley with free-wheel; special tool to use:
adapter - 3400-
Note
The poly V-belt for the large pulley with free-wheel must be longer
to accommodate the larger diameter.
♦ Adapter - 3400-
4. Alternator 73
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4. Alternator 75
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Electrical system; General information - Edition 08.2015
Note
Note
♦ Hot air blower - VAS 1978/14A- from wiring harness repair set
- VAS 1978 B-
Note
Procedure
– Cut washer fluid hose at point of damage using cutting pliers
- VAS 6228- .
– Select appropriate connecting pieces -2- and -3- and appro‐
priate heat-shrink hose (refer to ⇒ Electronic parts catalogue
(ETKA) ).
– Heat end of corrugated pipe -1- with hot air blower - VAS
5179- .
– Push connecting piece -2- into corrugated pipe -1- -arrow A-.
– Heat end of corrugated pipe -4- with hot air blower - VAS
5179- .
– Push connecting piece -3- into corrugated pipe -4- -arrow B-.
WARNING
WARNING
WARNING
Caution
♦ Do not touch the glass part of the gas discharge bulb with
bare hands. The remaining fingerprint would be evapora‐
ted by the heat of the bulb when it is switched on, become
deposited on the reflector and thus impair the brightness
of the headlight. Wear clean fabric gloves when fitting the
gas discharge bulb.
♦ Only replace defective gas discharge bulbs with gas dis‐
charge bulbs of the same type. The type can be found on
the base of the bulb or on the glass part of the bulb.
♦ When installing, make sure connectors engage properly
and are securely attached.
1. Immobiliser 83
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Electrical system; General information - Edition 08.2015
2 Towing bracket
Version 1:
– Release retaining tabs -arrows- and then release the clips
-1- and -3 ... 5-.
– Remove frame from connectors -2-.
2. Towing bracket 85
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Electrical system; General information - Edition 08.2015
Version 2:
– Release retaining tabs -arrows- and then release clips
-1, 2, 3, 4, 6, 7-.
– Remove frame from multi-pin connector -5-.
Installing
Installation is carried out in the reverse order; note the following:
Note
Make sure that seals -1- and -3- are not damaged.
– Insert connectors -4- into frame -2- until they audibly engage.
Note
Note
2. Towing bracket 87
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Electrical system; General information - Edition 08.2015
Installing
Installation is carried out in the reverse order; note the following:
– Frame -1- can only be fitted onto multi-pin connector -3- in one
position.
• Guide pins -4- can be inserted in frame in one position only
(the contacts -2- must be in the frame).
– Slide frame into multi-pin connector until it engages audibly.
Note
Installing
Installation is carried out in the reverse order; note the following:
– Frame -1- can only be fitted onto multi-pin connector -3- in one
position.
• Guide pins -4- can be inserted in frame in one position only
(the contacts -2- must be in the frame).
– Slide frame into multi-pin connector until it engages audibly.
Note
2. Towing bracket 89
Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 08.2015
Note
Installing
Installation is carried out in the reverse order; note the following:
– Frame -1- can only be fitted onto multi-pin connector -3- in one
position.
• Guide pins -4- can be inserted in frame -1- in one position only
(the contacts -2- must be in the frame).
– Slide frame into multi-pin connector until it engages audibly.
2. Towing bracket 91
Audi A1 2011 ➤ , Audi A2 2001 ➤ , Audi A3 2004 ➤ , Audi A3 2013 ➤ , Au ...
Electrical system; General information - Edition 08.2015
97 – Wiring
1 Vehicle diagnostic, testing and infor‐
mation systems
WARNING
WARNING
Note
Caution
WARNING
Note
Additional information:
Note
Additional information:
Caution
Note
Additional information:
Note
Additional information:
Note
WARNING
– Working from the front, insert end of wire into jaws of wire
stripper as far as it will go and press stripper together com‐
pletely.
– Open wire stripper again and take out stripped end of wire.
Caution
Caution
– Working from centre outwards, use hot air blower to heat crimp
connector in longitudinal direction until it is completely sealed
and adhesive emerges at ends.
• A wire repaired using a single crimp connector must look as
shown in illustration.
Note
WARNING
Note
♦ Wiring for airbag and belt tensioner wiring harness may only
be repaired using wiring harness repair set - VAS 1978 B- and
previous versions.
♦ Observe general information on repairs to the vehicle electri‐
cal system ⇒ page 94 .
♦ Do not repair wiring for the airbag and belt tensioner system
at more than two repair locations. Repair locations increase
the resistance in wiring and can be the cause of faults in the
system's self-diagnosis.
♦ To avoid corrosion, the crimp connectors must always be
shrink-fitted when repairing the airbag wiring harness or belt
tensioner wiring harness.
♦ Do not incorporate the repaired wiring back in the wiring har‐
ness in the vehicle, and mark the repair location clearly with
yellow insulating tape.
♦ Repairs in the area around airbags or belt tensioners should
not be performed more than 30 cm from the nearest connector
housing. Following this method and marking the repair with
yellow insulating tape ensures that previous repairs can be
easily identified.
♦ The original wires going to the airbag igniters have a twist
length specification of 20 ± 5 mm. The wiring pairs have stand‐
ard part numbers that ensure this twist length in series pro‐
duction, and it must always be observed when repairing
twisted wires.
♦ When performing repairs both wires to the airbag igniters must
be of the same length. When twisting wires -1- and -2-, it is
very important to ensure that twist length A = 20 ±5 mm.
♦ There must be no untwisted section of wire which is longer
than B = 100 mm, e.g. in the vicinity of crimp connectors
-arrow-.
♦ Repair operations must be recorded in the Audi Service
Schedule under “Workshop entries” with a brief outline of the
repair work completed, company stamp and signature.
♦ Any warranty claims made under the AUDI AG factory war‐
ranty are invalid if airbag wiring harness repairs have not been
performed using genuine replacement parts and wiring har‐
ness repair set - VAS 1978 B- .
Note
Note
Caution
Note
If cutting out the damaged section of wiring makes the two ends
of the original vehicle wire too short for repair with a single crimp
connector, insert a corresponding length of repair wire with two
crimp connectors ⇒ page 113 .
Note
Caution
– Working from centre outwards, use hot air blower to heat crimp
connector in longitudinal direction until it is completely sealed
and adhesive emerges at ends.
• A wire repaired using a single crimp connector must look as
shown in illustration.
Note
Caution
Note
If cutting out the damaged section of wiring makes the two ends
of the original vehicle wire too short for repair with a single crimp
connector, insert a corresponding length of repair wire with two
crimp connectors ⇒ page 116 .
Note
– Use crimping pliers (base tool) - VAS 1978/1-2- for fitting crimp
connectors.
The following head adapters are available for the crimping pliers
(base tool) - VAS 1978/1-2- :
♦ Head adapter 0.35 mm² - 2.5 mm² - VAS 1978/1-1-
♦ Head adapter 4.0 - 6.0 mm² - VAS 1978/2 A-
Note
Caution
– Working from centre outwards, use hot air blower to heat crimp
connector in longitudinal direction until it is completely sealed
and adhesive emerges at ends.
• A wire repaired using a single crimp connector must look as
shown in illustration.
Note
Note
To repair a 0.22 mm2 wire, a repair wire with a 0.35 mm2 or 0.5
mm2 cross section can be used as the additional wire.
Procedure
– Release a length of approx. 20 cm of the defective wire at two
points on both sides of the repair joint.
Caution
Note
Caution
– Working from centre outwards, use hot air blower to heat crimp
connector in longitudinal direction until it is completely sealed
and adhesive emerges at ends.
• A wire repaired using inserted repair wire and two crimp con‐
nectors must look as shown in illustration.
Note
Note
Repair wires with a cross section of 0.35 mm2 to 6.0 mm2 can be
used for repairs.
Procedure
– Release a length of approx. 20 cm of the defective wire at two
points on both sides of the repair joint.
Caution
Note
– Use crimping pliers (base tool) - VAS 1978/1-2- for fitting crimp
connectors.
The following head adapters are available for the crimping pliers
(base tool) - VAS 1978/1-2- :
♦ Head adapter 0.35 mm² - 2.5 mm² - VAS 1978/1-1-
♦ Head adapter 4.0 - 6.0 mm² - VAS 1978/2 A-
– Slide crimp connector over original vehicle wire on one side
and over repair wire on the other.
Note
Caution
– Working from centre outwards, use hot air blower to heat crimp
connector in longitudinal direction until it is completely sealed
and adhesive emerges at ends.
• A wire repaired using inserted repair wire and two crimp con‐
nectors must look as shown in illustration.
Note
♦ Shrink element for hot air blower - VAS 1978/15A- from wiring
harness repair set - VAS 1978 B-
♦ Wiring harness repair set - VAS 631 003-
Note
Procedure
– Fit crimp anvil and crimp indentor to crimping pliers as follows
(items must correspond to the wire cross section):
– Open crimping pliers from wiring harness repair set - VAS 631
003- .
– Pull locking pin -1- out in direction of -arrow A- as far as stop.
– Open adapter -2- in direction of -arrow B-.
Caution
Note
– Slide wire -2- (stripped at end) into butt connector -1- as far as
stop -arrow-.
• All strands must be inserted in the butt connector
– Fully open and close crimping pliers several times until the
crimp anvil moves into the starting position on its own.
Note
After crimping, hot air blower must be used to shrink-fit butt con‐
nector to prevent moisture from ingressing.
– Attach shrink element for hot air blower - VAS 1978/15A- to
hot air blower, 220 V/ 50 Hz - VAS 1978/14A- .
Caution
Note
Releasing early
– Press lever -1- downwards -arrow A-.
– Turn handle -2- clockwise -arrow B- until crimp anvil is in start‐
ing position.
If it is not possible to release early by hand, proceed as follows:
– Press lever -1- downwards -arrow A-.
– Fit key from wiring harness repair set - VAS 631 003- on bolt
-3- on reverse side.
– Turn key anti-clockwise -arrow C- until crimp anvil is in starting
position.
Caution
♦ Shrink element for hot air blower - VAS 1978/15A- from wiring
harness repair set - VAS 1978 B-
♦ Wiring harness repair set - VAS 631 001-
Note
Procedure
– Fit crimp anvil, crimp indentor and contact positioner with con‐
tact bar (items must correspond to wire cross section) to hand
pliers as follows:
– Open hand pliers from wiring harness repair set - VAS 631
001- .
– Pull locking pin -1- out in direction of -arrow A- as far as stop.
– Open mounting -2- in direction of -arrow B-.
– Fit crimp anvil -1- in hand pliers so that crimp anvil -1- is flush
with front of pliers.
– Secure crimp anvil with pins -2- -arrow A- and tighten knurled
screw hand-tight.
– Fit crimp indentor -3- (corresponding to crimp anvil) in mount‐
ing.
– Secure crimp indentor with pins -4- -arrow B- and tighten
knurled screw hand-tight.
Caution
– Use wire strippers from wiring harness repair set - VAS 631
001- to cut out damaged section of wiring.
Note
If cutting out the damaged section of wiring makes the two ends
of the original vehicle wire too short for repair with a single butt
connector, insert a corresponding length of yellow copper repair
wire with two butt connectors.
– Slide wire -2- (stripped at end) into butt connector -1- as far as
stop -arrow-.
• All strands must be inserted in the butt connector
• End of insulation must extend no further than front edge of
insulating crimp
– Fully close hand pliers until they open again on their own.
After crimping, hot air blower must be used to shrink-fit butt con‐
nector to prevent moisture from ingressing.
– Attach shrink element for hot air blower - VAS 1978/15A- to
hot air blower, 220 V/ 50 Hz - VAS 1978/14A- .
Caution
Note
Caution
Note
♦ You can use the “Guided Fault Finding” to find out where (be‐
tween which components) the fibre optic cabling is damaged.
♦ A fibre optic cable that has already been repaired is coloured
“yellow”.
Preparing pliers for fibre optic cable - VAS 6223/1- for use
– Release transport safeguard on cutter by slackening off hex‐
agon socket head bolt -arrow-.
Stripping
– Open pliers for fibre optic cable - VAS 6223/1- .
• Stripping lever must be in lower position -arrow-.
– Insert fibre optic cable -1- in stripper unit.
• Fibre optic cable must be flush with back of cutting pliers.
– Close pliers for fibre optic cables - VAS 6223/1- as far as fixed
stop and keep closed.
– Swivel up stripping lever -arrow-.
– Open cutting pliers and take out fibre optic cable -1-.
– Detach separated section of insulation from fibre optic cable.
Note
– Slide fibre optic cable -2- into brass pin contact -1- as far as
spring-loaded stop.
– Push in fibre optic cable further as far as fixed stop and close
pliers for fibre optic cable - VAS 6223/2- .
– Open pliers for fibre optic cable and take out fibre optic cable
with brass pin contact.
Caution
Note
Caution
Mounting tool head for pliers for fibre optic cable - VAS 6223/1-
Stripping
– Open pliers for fibre optic cable - VAS 6223/1- .
– Bring stripping lever into lower position -arrow-.
– Insert fibre optic cable into stripping point.
• Fibre optic cable must be flush with back of cutting pliers.
– Close pliers for fibre optic cables as far as fixed stop and keep
closed.
– Swivel stripping lever upwards -arrow- and remove fibre optic
cable.
– Close pliers for fibre optic cable - VAS 6223/1- and remove
cable.
– Perform a visual check of cable -1- to ensure that it has been
cut correctly and that there is no burr on end face.
Note
– Slide fibre optic cable into brass pin contact -arrow- as far as
spring-loaded stop and close pliers for fibre optic cable .
– Open pliers for fibre optic cable and remove fibre optic cable
with brass pin contact.
Caution
Note
– Insert fibre optic cable into pliers for corrugated tube installa‐
tion - VAS 6223/10- , as shown in illustration.
– Apply pliers for corrugated tube installation at slot in corruga‐
ted tube.
– Slide pliers for corrugated tube installation along slot on cir‐
cumference of corrugated tube. This will insert the fibre optic
cable into the corrugated tube.
– Pull basic module -2- for fibre optic cable out of connector
housing -1-.
Caution
Note
♦ Seal off open connector plug -2- for fibre optic cable with pro‐
tective cap for cable connector - VAS 6223/9- -item 1-.
♦ Protective cap prevents contamination of or mechanical dam‐
age to end face of fibre optic cable which would impair light
transmission.
Note
– Release both locking pins -arrows- from grips of pliers and pull
them out.
– Push blade holder -1- against shaft of rotary cutter until it en‐
gages. The gap -2- beneath the blade holder is now com‐
pletely closed.
– Hold aerial wire securely so that it cannot turn.
– Turn rotary cutter -3- approximately 2 times in direction of ar‐
row until it rotates easily.
– Pull release pin -1-. The blade holder will be released and will
detach from aerial wire.
– Push locating pin -2- into rotary cutter as far as stop. The aerial
wire will be pressed out of rotary cutter.
– Remove screening from aerial wire.
– Remove any pieces of insulation remaining in rotary cutter.
Stripping outer sleeve:
– Insert aerial wire -2- in retainer -3- into tool head as far as stop
-1-.
– Close tool and open it again.
– Pull out aerial wire -4-.
Stripping inner insulation:
– Insert aerial wire -2- in retainer -1- into tool head as far as stop.
– Close tool and open it again.
– Pull out aerial wire -3-.
Crimping central wire:
– Insert aerial wire -1- into inner contact -2- in tool head (hold
adjustable positioner in place).
– Close tool until it opens by itself.
– Open positioning piece -3- and pull out aerial wire.
Crimping outer wire:
– Push sleeve -2- and outer contact -1- over central wire. The
knurled contact part must be pushed under shielding -3- but
over the aluminium foil.
– Push outer contact -4- on all the way, ensuring that socket/pin
is seated correctly.
Note
Note
Note
– Cut old connector off original vehicle wiring harness (if appli‐
cable with wire seal).
– Take yellow repair wire with correct connector out of wiring
harness repair set - VAS 1978 B- .
– Release a length of approx. 20 cm of the defective wire on both
sides of the repair joint.
Caution
– Use wire stripper - VAS 1978/3- to shorten repair wire and wire
of original vehicle wiring harness as required.
– Strip ends of repair wire and original vehicle wire and crimp
stripped ends of repair wire and wire of original vehicle wiring
harness using crimping pliers and a crimp connector
⇒ “2.4.5 Repairing a wire of 0.22 mm2 section with a single
crimp connector”, page 109 or
⇒ “2.4.6 Repairing a wire of 0.35 mm2 section or thicker with
a single crimp connector”, page 111 .
Note
♦ Wire seals prevent water and dirt from ingressing into the con‐
nector housing. They are fitted e.g. in the engine compartment
and must always be re-installed after completing a repair.
♦ As a standard, wire seal is crimped to wire together with con‐
nector. This is not the case with repair wires. Wire seal must
be slipped onto wire before crimping repair wire.
♦ Wire seals must always match the wire cross section of the
repair wire used. The outer diameter of the wire seal depends
on the diameter of the connector housing slot. Always use the
appropriate assembly tool when fitting.
– Slide wire seal -A- over repair wire as far as connector housing
and then as far as it will go into connector housing using an
appropriate fitting tool -B-.
– Use wire stripper - VAS 1978/3- to shorten repair wire and wire
of original vehicle wiring harness as required.
– Crimp stripped ends of repair wire and wire of original vehicle
wiring harness using crimping pliers and a crimp connector
⇒ “2.4.5 Repairing a wire of 0.22 mm2 section with a single
crimp connector”, page 109 , or
⇒ “2.4.6 Repairing a wire of 0.35 mm2 section or thicker with
a single crimp connector”, page 111 .
Note
Note
Example 2:
Release housing securing element by opening “flap” -arrow-.
Example 3:
Release housing securing element by disengaging a “slide”
-arrow-.
Note
Note
Note
Note
Note
Asymmetrical:
– Insert appropriate release tool for connector housing in re‐
lease slot at connector housing.
– Take hold of connector at wire and press it slightly into con‐
nector housing -arrow-.
Note
Note
Fast-on contacts:
– Insert appropriate release tool for connector housing in re‐
lease slot at connector housing.
– Take hold of connector at wire and press it slightly into con‐
nector housing.
Note
GT 150/280 connectors:
– Insert appropriate release tool for connector housing beneath
retaining tab into connector housing.
– Press tool -arrow- in connector housing as far as it will go.
Note
Note
WARNING
– Disconnect battery.
– Loosen cap nut and remove wiring lug from screw connection.
– Check wiring lug for corrosion, dirt, etc.
– Select appropriate adapter and corresponding sanding pad.
Note
Caution
Do not sand away the tin plating to such an extent that the
copper layer underneath becomes visible. This could produce
a galvanic cell which destroys metal and causes faulty repair.
Note
– Apply adapter to wiring lug and sand corrosion and dirt off by
rotating adapter.
– Check wiring lug and if necessary re-sand.
Note
WARNING
Note
WARNING
– Disconnect battery.
– Loosen cap nut and remove wiring lug from screw connection.
– Check screw connection for corrosion, dirt, etc.
– Select appropriate adapter and corresponding sanding pad for
screw connection.
Caution
Do not sand away the tin plating to such an extent that the
copper layer underneath becomes visible. This could produce
a galvanic cell which destroys metal and causes faulty repair.
Note
Note
WARNING
♦ VAG 1331
Note
WARNING
– Disconnect battery.
– Check battery terminal clamp and battery terminal for corro‐
sion or dirt.
– Clean battery terminal clamp with wire brush of battery termi‐
nal cleaner (rotary motion).
WARNING
Note
Caution
Note
– Hold injector underneath wiring lug and spray all around ter‐
minal.
– Hold injector above wiring lug and spray terminal and wiring
lug (all around).
Caution