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
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ID.4 2021 ➤
Electrical system - Edition 02.2021
•
Dimension -a- must be even on both sides.
– Turn quick-action lever -3- in direction of -arrow- until crimp
connector -1- is fixed.
– Insert stripped end of electrical wire -2- in direction of -arrow-
to stop into crimp connector -1-.
•
All single wires must be pushed into the crimp connector.
– Close and open the crimping pliers several times until the
crimping anvil moves downwards automatically to the start
position.
•
The insulation on the electrical wire -2- must not be crimped.
– Proceed in the same way to crimp electrical wire with crimp
connector -1- on the other side.
– Pull out locking pin -1- in direction of arrow -A- as far as it
will go.
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Rep. gr.97 - Wiring
ID.4 2021 ➤
Electrical system - Edition 02.2021
– Open adapter -2- in direction of arrow -B-.
– Remove crimped crimp connector.
– Inspect crimped crimp connector.
♦ -A- – 10 mm², star-shaped crimp
♦ -B- – 16 mm², F-crimp
NOTICE
Risk of damage to the crimp connector due to overheating.
– The heat-shrink hose must be heat-shrunk to prevent the
ingress of moisture.
– 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.
4. Repairing wiring harnesses
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ID.4 2021 ➤
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– Inspect completed repair section -3-.
•
•
The heat-shrink hose must be entirely shrunk.
Adhesive must come out at the ends.
Premature release
NOTICE
Risk of damage to crimp connector.
– Do not use the crimp connector after premature release.
– Release release lever -1- in direction of -arrow A-.
– Turn quick-action lever -2- in direction of -arrow B- until
crimping anvil is in the start position.
If premature release is not possible by hand:
– Release release lever -1- in direction of -arrow A-.
– Turn quick-action lever -3- in direction of -arrow C- until
crimping anvil is in the start position.
176
Rep. gr.97 - Wiring
ID.4 2021 ➤
Electrical system - Edition 02.2021
4.3
Repairing 2.5 mm, 4 mm or 6 mm alu‐
minium wire with a single crimp con‐
nector
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-
•
Copper wire pieces are available for repairs.
Removing
– Install crimping anvil, crimping die and contact positioner
with contact locking device 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.
– Insert end of wire from front to stop into appropriate recess
in wire stripper from wiring harness repair set -VAS 631
001-.
– Press together wire stripper completely, and then open it
again.
– Remove stripped wire.
•
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.
– Strip end of other electrical wire in the same way.
– Push heat-shrink hose ⇒ Electronic parts catalogue (ETKA)
onto electrical wire.
– Insert crimp connector -1- in contact positioner -2-.
4. Repairing wiring harnesses
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2024 VW ID.4 Owner's Manual
