Converting headlamp connector on wiring harness — AUDI

As of model year 1997, only headlamps with a 5-pin connector to wiring harness are available as replacement parts.

Vehicles up to model year 1997 feature a wiring harness with a 3-pin and a 4-pin connector.

Where appropriate, connector must be converted to appropriate 5-pin version.

Note:

Repairs to wiring harness and plug connectors for the Audi A8 may only be performed using repair set VAS 1978.

Detach both connectors at appropriate headlamp.
Note down contact assignments of both connectors based on cable colours.
Use releasing tools from wiring harness repair set VAS 1978 to release the two connectors.

=> Usage instructions for wiring harness repair set VAS 1978; Release and dismantling of connector housings; Socket housings

Remove the two grommets.
Detach earth cable from 3-pin connector in vicinity of wiring harness sheathing.
Detach contact 4 of 4-pin connector and then fit an appropriate yellow repair wire.

=> Usage instructions for wiring harness repair set VAS 1978; Release and dismantling of connector housings; Socket housings

Notes:

When selecting repair wire, use corresponding wire thickness and matching plug-in contact to headlamp connector.
Prior to connection, shorten wire so that it cannot subsequently become chaffed or trapped.
Always use insertion tools from wiring harness repair set VAS 1978 to route contacts/leads through grommet.

Use insertion tools to guide lead through grommet and then insert contact into receptacle 1 of 5-pin connector.

Use insertion tools to guide earth cable (contact 3 of 4-pin connector) through grommet and then insert contact into receptacle 2 of 5-pin connector.
Use insertion tools to guide contact 1 of 3-pin connector through grommet and then insert contact into receptacle 3 of 5-pin connector.
Use insertion tools to guide contact 2 of 4-pin connector through grommet and then insert contact into receptacle 4 of 5-pin connector.
Use insertion tools to guide contact 1 of 4-pin connector through grommet and then insert contact into receptacle 5 of 5-pin connector.
Engage secondary locking at 5-pin connector and then check tightness of contacts.
Slip grommet fully into connector.

=> Usage instructions for wiring harness repair set VAS 1978; Release and dismantling of connector housings; Installation of socket housings -B-.

Receptacle assignments:1)

5-pin connector at left headlamp · 5-pin connector at right headlamp
3-pin connector
Receptacle 1 · Receptacle T5h/3 · Receptacle T5i/3
4-pin connector
Receptacle 1 · Receptacle T5h/5 · Receptacle T5i/5
Receptacle 2 · Receptacle T5h/4 · Receptacle T5i/4
Receptacle 3 · Receptacle T5h/2 · Receptacle T5i/2
Receptacle 4 · Receptacle T5h/1 · Receptacle T5i/1

1)
If necessary, use appropriate current flow diagram to check assignments.