ID.4 2021 ➤
Electrical system - Edition 02.2021
4
Repairing wiring harnesses
4.1
Repairing a 0.13 mm²/
0.35 mm²/0.5 mm² wire
Special tools and workshop equipment required
♦ crimping pliers (main tool) -VAS 1978/1-2-
♦ hot air blower -VAS 1978/14A-
♦ interchangeable head for crimping pliers 0.13 – 0.5 mm²
-VAS 1978/1-3-
♦ shrink element for hot air blower -VAS 1978/15A-
– Install interchangeable head for crimping pliers 0.13 –
0.5 mm² -VAS 1978/1-3- to crimping pliers (main tool) -VAS
1978/1-2-.
– Cut out the damaged section of the electrical wire.
•
If, after the damaged wire section has been cut out, both
ends of the electrical wire have become too short for a repair
using just one crimp connector, use a piece of yellow repair
wire of the appropriate length with two crimp connectors.
– Insert end of wire -2- to stop -arrow- into appropriate recess
on interchangeable head for crimping pliers 0.13 – 0.5 mm²
-VAS 1978/1-3--1- according to the respective wire cross
section.
– Press together crimping pliers (main tool) -VAS 1978/1-2-
completely, and keep it pressed.
– Pull end of wire -2- out of interchangeable head for crimping
pliers 0.13 – 0.5 mm² -VAS 1978/1-3--1- to strip it.
– Open crimping pliers (main tool) -VAS 1978/1-2-.
•
The insulation must be properly cut off and removed from
the electrical wire.
•
•
Do not leave any insulation on the stripped electrical wire.
Single wires must not be damaged.
170
Rep. gr.97 - Wiring
ID.4 2021 ➤
Electrical system - Edition 02.2021
– Strip end of other electrical wire -2- in the same way.
0.13 mm² wires
– Push heat-shrink hose ⇒ Electronic parts catalogue (ETKA)
onto electrical wire.
All vehicles (continued)
– Push crimp connector -2- to stop in direction of -arrow A- in‐
to crimp opening on interchangeable head for crimping pliers
0.13 – 0.5 mm² -VAS 1978/1-3-.
– Push stripped electrical wire -1- in direction of -arrow B- into
crimp connector -2-.
•
•
All single wires must be pushed into crimp connector -2-
The insulation on the electrical wire -arrow C- must not be
crimped.
– Press together crimping pliers (main tool) -VAS 1978/1-2-
completely, and then open it again.
– Remove electrical wire -1- with crimp connector -2-.
– Crimp electrical wire -1- with crimp connector -2- on other
side as described.
– Pull out locking pin -1- to stop in direction of -arrow A-.
– Swing upper part on interchangeable head for crimping
pliers 0.13 – 0.5 mm² -VAS 1978/1-3--2- in direction of
-arrow B-.
4. Repairing wiring harnesses
171
ID.4 2021 ➤
Electrical system - Edition 02.2021
– Removed crimped crimp connector.
NOTICE
Risk of damage to the crimp connector due to overheating.
– Crimp connectors must be heat-shrunk to prevent the in‐
gress of moisture.
– Use hot air blower -VAS 1978/14A--A- and shrink element
for hot air blower -VAS 1978/15A--B- to heat-shrink crimp
connector -1-.
0.13 mm² wires
– Position heat-shrink hose -1- centrally over crimp connector
-2-.
•
Dimension -a- must be even on both sides.
– Use hot air blower -VAS 1978/14A- and shrink element for
hot air blower -VAS 1978/15A- to shrink heat-shrink hose -1-
from the middle towards outside.
– Inspect completed repair section -3-.
•
•
The heat-shrink hose must be entirely shrunk.
Adhesive must come out at the ends.
All vehicles (continued)
Premature release
NOTICE
Risk of damage to the crimp connector if released to early.
– Do not use the crimp connector after premature release.
– Release release lever -1- in direction of -arrow A-.
172
Rep. gr.97 - Wiring
ID.4 2021 ➤
Electrical system - Edition 02.2021
– At the same time, press together crimping pliers (main tool)
-VAS 1978/1-2- slightly, and then open it again.
4.2
Repairing a 10 mm² or 16 mm² wire
Special tools and workshop equipment required
♦ hot air blower -VAS 1978/14A-
♦ shrink element for hot air blower -VAS 1978/15A-
♦ wiring harness repair set -VAS 631 003-
Removing
– Install crimping anvil and crimping die matching the wire
cross-section to crimping pliers from wiring harness repair
set -VAS 631 003-.
– Cut out the damaged section of the electrical wire.
•
If, after the damaged wire section has been cut out, both
ends of the electrical wire have become too short for a repair
using just one crimp connector, use a piece of yellow repair
wire of the appropriate length with two crimp connectors.
– Strip required length of electrical wires according to cross-
section.
♦ 10 mm² wires: 14 mm
♦ 16 mm² wires: 16.5 mm
•
The insulation must be properly cut off and removed from
the electrical wire.
•
•
Do not leave any insulation on the stripped electrical wires.
Single wires must not be damaged.
– Push heat-shrink hose onto one of the electrical wires
⇒ Electronic parts catalogue (ETKA).
– Position crimp connector -1- with first crimping point centrally
on crimping anvil -2-.
4. Repairing wiring harnesses
173
2024 VW ID.4 Owner's Manual
