Repairing 2.5 mm2, 4 mm2 or 6 mm2 aluminium wiring with single butt connector — AUDI

🧭 Before you start

Fits: Audi Q5 (8R, 2008–2017), Audi A5 Cabriolet (8F), Audi A1 (8X, 2010–2018), Audi A8 D4 (4H, 2010–2017), Audi A2 (8Z), Audi A4 B6/B7 (8E), Audi A6 C5 (4B), Audi A8 D3 (4E, 2002–2010), Audi A3 (8P, 2003–2012), Audi A6/A7 C7 (4G, 2011–2018), Audi Q7 (4M, 2015–), Audi R8 (4S, 2015–), Audi A4 B9 (8W, 2015–), Audi A4 Cabriolet B6/B7 (8H), Audi TT Mk1 (8N), Audi A6 C6 (4F, 2004–2011), Audi TT Mk2 (8J, 2006–2014), Audi A5 (8T, 2007–2016), Audi A4 B8 (8K, 2007–2015), Audi Q7 (4L, 2005–2015), Audi A3 (8V, 2012–2020), Audi Q3 (8U, 2011–2018); platform codes 42, 83, 84, 4X, 85, FV

• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: locking pin

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• Risk of damage to electrical wiring.Take care when releasing wiring from wrapped wiring harnesses. — If necessary, use a knife to remove wrapping of wiring harness.
• 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.
• Working from the front, insert end of wire as far as it will go into mounting in jaws of pliers (mounting must correspond to wire cross section).

📋 Procedure

1. Fit crimp anvil, crimp indentor and contact positioner with contact bar (items must correspond to wire cross section) to hand pliers as follows:
2. Open hand pliers from wiring harness repair setVAS 631 001.
3. Pull locking pin (1) out in direction of (arrow A) as far as stop.
4. Open mounting (2) in direction of (arrow B).
5. Fit crimp anvil (1) in hand pliers so that crimp anvil (1) is flush with front of pliers.

6. Secure crimp anvil with pins (2)(arrow A) and tighten knurled screw hand-tight.
7. Fit crimp indentor (3) (corresponding to crimp anvil) in mounting.
8. Secure crimp indentor with pins (4)(arrow B) and tighten knurled screw hand-tight.
9. Close adapter (1) in direction of (arrow A).
10. Push locking pin (2) in as far as stop (in direction of (arrow B)).
11. Insert contact bar (1) in contact positioner (2).
12. Position contact positioner with contact bar in hand pliers (5). To do so, slide hole in contact positioner (2) over knurled screw (4).
13. Screw in knurled screw (3) hand-tight.
14. Release a length of approx. 20 cm of the defective wire on both sides of the repair joint.
15. ⚠ Risk of damage to electrical wiring.Take care when releasing wiring from wrapped wiring harnesses. — If necessary, use a knife to remove wrapping of wiring harness.
16. Use wire strippers from wiring harness repair setVAS 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.]
17. Working from the front, insert end of wire as far as it will go into mounting in jaws of pliers (mounting must correspond to wire cross section).
18. Press pliers fully together.
19. Open wire stripper again and take out stripped end of wire.
20. For repair, take a suitable butt connector and heat-shrink hose from the wiring harness repair setVAS 631 001.
21. Slide heat-shrink hose onto one of the wires.
22. Insert butt connector (1) in contact positioner (2).
23. Slide contact bar (3) in direction of (arrow B) as far as stop. This will fix butt connector (1) in place.
24. Slide wire (2) (stripped at end) into butt connector (1) as far as stop (arrow).
25. Fully close hand pliers until they open again on their own.
26. Move contact bar (2) across as far as stop in direction of (arrow).
27. Remove butt connector (1) from contact positioner (3).
28. Turn hand pliers over for the second crimp.
29. Repeat crimping of wire with butt connector on other side, as described.
30. Pull locking pin (1) out in direction of (arrow A) as far as stop.
31. Open mounting (2) in direction of (arrow B).
32. Remove crimped butt connector.
33. Attach shrink element for hot air blowerVAS 1978/15A to hot air blower, 220 V/ 50 HzVAS 1978/14A.
34. ⚠ Risk of damage to surrounding components.When shrink-fitting butt connectors, take care not to damage any other pipes/wires, plastic parts or insulating material with hot nozzle of hot air blower.Always observe operating instructions for hot air blower. — Position heat-shrink hose (1) centrally above butt connector (2).
35. Working from centre outwards, use hot air blower to heat heat-shrink hose in longitudinal direction until it is completely sealed and adhesive emerges at ends. [Note: If several wires have to be repaired, make sure butt connectors are not directly adjacent to one another. Offset the butt connectors slightly to restrict the size of the wiring harness.If the repair location was previously wrapped, yellow adhesive tape must be wrapped around this location again on completion of repair.If necessary, secure the repaired wiring harness with a cable tie to prevent rattling noises when the vehicle is driven.]

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