Audi Q5: Repair Kit for FlexRay Wires with Coating
Note
- The repair of FlexRay wires with coating can only take place
using FlexRay wires with coating from the Parts Catalog.
- Observe general notes for repairs on the vehicle electrical
system. Refer to
→ Chapter "Vehicle Electrical System, General Repair
Information".
A two-layer wire -1 and 2- with
a 0.35 mm 2 profile is used as a
FlexRay wire.
- During repair work, both wires must have the same length.
- When twisting the wires -1 and 2-
together, the -A- = 30 mm routing
length must be maintained.
- While doing so, no section of wire may be greater than
-B- = 50 mm without twisting the
wires, for example in the area of crimp connectors
-arrow-.
- Maximum exposed wire length: -C-
= 100 mm.
- Protect the area being repairs from the environment. Use a
crimp connector with heat-shrinkable tube over the untwisted
location being repairs and waterproof insulation over the
exposed wire.
- Mark the location of the repair with something suitable, for
example, with yellow tape.
- Repairing both wires is identical to repair just one wire.
- Position both repaired location
-arrows--A- = 30 mm opposite each other.
- Crimp the cables with connectors.
1 - Repair location in the area without insulation
2 - Repair location with connectors
C - Maximum exposed length = 100 mm
Repair Kit for FlexRay Wires without Coating
Note
- The repair of FlexRay wires without coating can only take
place using FlexRay wires without coating from the Parts
Catalog.
- Observe general notes for repairs on the vehicle electrical
system. Refer to
→ Chapter "Vehicle Electrical System, General Repair
Information".
Unshielded, twisted two-wire lines -1
and 2- with a cross section of 0.35 mm
2 can be used as FlexRay wires.
- During repair work, both FlexRay wires must have the same
length.
- When twisting the wires -1 and 2-
together, the -A- = 20 mm routing
length must be maintained.
- While doing so, no section of wire may be greater than
-B- = 40 mm without twisting the
wires, for example in the area of crimp connectors
-arrow-.
- Mark the location of the repair with something suitable, for
example, with yellow tape.
- Repairing both FlexRay wires is identical to repairing just
one wire.
- Position both repaired locations -A-
= 20 mm opposite each other.
- Crimp the cables with connectors.
1 - Repair location in wiring harness
2 - Repair location with connectors
0.22 mm 2 Wire, Repairing with Individual
Crimp Connector
Procedure
- Free up the wire to be repaired approximately 20 cm 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 using a
knife.
- Cut out the damaged section of wire using the Wiring Harness
Repair Set - Wire Strippers -VAS1978/3-.
Note
If, by cutting out the damaged wire section, both ends of
the vehicle-specific single wire are too short for a repair
using a single crimp connector, insert a repair wire section of
matching length with two crimp connections. Refer to
→ Chapter "Repairing a 0.22 mm 2
Wire with Intermediate Wire Section".
- Adjust the sliding stop in the Wiring Harness Repair Set -
Wire Strippers -VAS1978/3- pliers jaws to 12 to 14 mm for the
wire to be stripped.
- Insert wire end from front up to stop into jaws of pliers
and squeeze the pliers completely.
- Open pliers again and remove the stripped wire end.
- Twist bare strands one-half turn.
- For the repair of a 0.22 mm 2
wire, use a small transparent crimp connector from the Wiring
Harness Repair Set -VAS1978B-.
- To press the crimp connector, use the Wiring Harness Repair
- Crimping Plier - Base Tool -VAS1978/1-2- with Wiring Harness
Repair - Crimping Head - .35-2.5mm -VAS1978/1-1-.
- Slide the small transparent crimp connector onto both
stripped, non-insulated wire ends on the vehicle-specific single
wire and crimp them using crimp pliers.
Note
Do not crimp wire insulation.
After crimping, crimp connections must be heat-shrunk using
hot air gun to prevent moisture penetration.
- 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 the hot air blower lengthwise
from center outward until it is sealed completely and adhesive
comes out the ends.
- This is how the completed repair location with individual
crimp connector should appear.
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.
- 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.
READ NEXT:
Procedure
- Free up the wire to be repaired approximately 20 cm on both
sides of the repair point.
Caution
Risk of damaging the electrical wires.
Expose wrapped wiring harnesses careful
Note
For repairing a 0.222 a repair
wire can be used as the intermediate wire with a cross section
of 0.35-mm2 or 0.5-mm2.
Procedure
- Free up the wire to be repaired at two places appr
Note
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 on both sides of the
SEE MORE:
WARNING
Risk of injury. Follow all warning messages and
safety precautions. Refer to
→ Chapter "Warnings and Safety Precautions".
Special tools and workshop equipment
required
Battery Charger -VAS5095A-
Caution
While charging, always set the battery type to 2.4
V/C (V
Impact Absorber, Removing and Installing, Vehicles through MY 2012
Removing
Note
During installation, all cable ties must be installed at the
same location.
- Remove the front bumper cover. Refer to
→ Chapter "Bumper Cover, Removing and Installing".
- Disconnect the electr