TSB's

Sporadic Audi DTC

When experiencing sporadic fault memory entries on 2000-2010 Audi vehicles, Audi suggests inspecting/correcting connections.

Contacts may be widened (over 0.63mm) by using incorrect pins or incorrect methods for current flow tests. Either action may cause intermittent electrical connections. This may cause sporadic DTCs to be stored in various control modules.

Check the contacts on the control module and connector. Verify that all pins and terminals are securely clipped into the connectors. Verify that no pins are bent or deformed. Verify proper crimping as described and illustrated in Figure 1.

 

Figure 1.  The male pin must be 0.63mm in width. The pin and terminal must be crimped onto the wire at (A) and crimped again onto the wire sheathing at (B).
<p>Figure 1.  The male pin must be 0.63mm in width. The pin and terminal  must be crimped onto the wire at (A) and crimped again onto the wire  sheathing at (B).</p>

Mechanically check the contacts on the control module and connector. Test the individual terminals by using the standard 0.63mm male pin (see Figure 1 and Parts Table) to verify proper contact. Make sure that the test pin is not twisted and is inserted correctly into the female terminal. The contact must be tight, but it must still allow the pin to slide into the terminal of the control module connector. Only use the 0.63mm male pins, because the female terminals are designed for these pins, which are the only terminals found in the connectors for the control modules.

If the pin/terminal is deformed, improperly crimped or does not contact properly, the contact must be replaced with the VAS 1978A repair kit or ordered in sets.

 PARTS TABLE

 Part number                    Part description                         Qty

000 979 007                     Male pin                                       1*

000 979 012                     Male pin                                        1*

000 979 409                     Male pin                                       1**

 *An order of 1 will provide a bag of 5 wires with like connectors on each end.

** An order of 1 will provide a bag of 3 wires with like connectors on each end.

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