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
177
ID.4 2021 ➤
Electrical system - Edition 02.2021
•
The crimp connector -1- must be flush -arrow A- with the
contact positioner -2-.
– Push contact locking device -3- to stop in direction of
-arrow B- until crimp connector -1- is fixed.
•
Lugs -4- on crimp connector -1- must engage in groove -5-
on contact locking device -3-.
– Insert stripped end of electrical wire -2- to stop in direction of
-arrow- into crimp connector -1-.
•
•
All single wires must be pushed into the crimp connector -1-.
The end of insulation of the electrical wire -2- should reach
no further than to the front edge of the insulation crimp.
– Close crimping pliers until crimping pliers open again auto‐
matically.
– Push contact locking device -2- to stop in direction of
-arrow-.
178
Rep. gr.97 - Wiring
ID.4 2021 ➤
Electrical system - Edition 02.2021
– Remove crimp connector -1- from contact positioner -3-.
– Turn crimping pliers over.
– 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.
– Open adapter -2- in direction of arrow -B-.
– Remove crimped crimp connector.
– Inspect crimped crimp connector.
•
•
Dimension -a- = 0.1 mm …. 1.0 mm
The end of insulation -arrow- should reach no further than to
the front edge of the insulation crimp.
– Position heat-shrink hose -1- centrally over crimp connector
-2-.
4. Repairing wiring harnesses
179
ID.4 2021 ➤
Electrical system - Edition 02.2021
•
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 -1- must be entirely shrunk.
Adhesive must come out at the ends.
180
Rep. gr.97 - Wiring
2024 VW ID.4 Owner's Manual
