Installing adapter harnesses for gear detection sensors (G604, G616) — AUDI

🧭 Before you start

Fits: platform code 42

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• (Items 2 and 3) can be disregarded.
• If several wires have to be repaired, make sure the crimp connectors are not directly adjacent to each other. Stagger the crimp connectors slightly so that the harness does not become too thick.
• If the repaired wiring was originally taped, wrap it again with yellow insulating tape.If necessary, secure the repaired wiring harness with a cable tie to prevent it from rattling or chafing when the vehicle is driven.

📋 Procedure

1. Remove rear bumper cover General body repairs, exterior63.
2. ⚠ The pressure in the hydraulic system can be as high as 50 bar – danger of injury!The system pressure must always be released before working on the hydraulic system for R tronic . — Remove air cleaner housing Injection and ignition system24.
3. Remove bolts (1) and detach heat shield (arrow).
4. Unplug electrical connector (1) on gear detection sensor 2G616. [Note: (Items 2 and 3) can be disregarded.]
5. Unplug electrical connector (1) on gear detection sensor G604. [Note: (Items 2 and 3) can be disregarded.]

6. Remove cable tie and push protective hose (1) back towards the right.
7. ⚠ Risk of malfunctionWhen making the repair, the harness (3) for gear detection sensor 2G616 must not be interchanged by mistake with the harness (2) for gear detection sensor G604. — First connect the twisted pair of signal wires (1) and (2) on adapter harness420 971 164 with the twisted pair of signal wires in the vehicle wiring harness. [Note: The signal wires are already twisted on the existing vehicle wiring harness and on the adapter harness420 971 164 as supplied. Carefully note the pin assignment of the wires on the »old« connector and connect the new wiring accordingly.]
8. ⚠ Risk of malfunctionKeep exactly to the required procedure for repairs to electrical wiring Electrical system; General information97Repairing wiring harnesses and electrical connectors.Observe any particular national requirements. — Connect adapter harness to wiring harness in vehicle; ensure a watertight joint and keep exactly to required procedure for repairs to electrical wiring Electrical system; General information97Repairing wiring harnesses and electrical connectors. [Note: If several wires have to be repaired, make sure the crimp connectors are not directly adjacent to each other. Stagger the crimp connectors slightly so that the harness does not become too thick.]
9. After connecting and twisting the signal wires, shorten the third wire (3) as required and connect it. [Note: If the repaired wiring was originally taped, wrap it again with yellow insulating tape.If necessary, secure the repaired wiring harness with a cable tie to prevent it from rattling or chafing when the vehicle is driven.]
10. Pull protective sleeve of adapter harnesses420 971 164(2 and 3) over repaired joints.
11. Connect electrical connector (1) to gear detection sensor 2G616. [Note: (Items 2 and 3) can be disregarded.]
12. Connect electrical connector (1) to gear detection sensor G604. [Note: (Items 2 and 3) can be disregarded.]
13. Position wiring (2 and 3) as illustrated and secure with cable ties as required.
14. Align wiring harness so that repaired joints are located at the required position (arrow) and secure with cable tie as required.
15. Install heat shield „Heat shield above gearshift actuator for R tronic, tightening torque“.
16. Install air cleaner housing Injection and ignition system24.
17. Install rear bumper cover General body repairs, exterior63.
18. Perform basic setting for gear actuator .

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