2021-2022 Audi Wiring Harness Repair Guidelines

Symptoms of Wiring Harness Issues

Owners of 2021-2022 Audi vehicles, including the Audi e-tron, may experience a general "A warning or malfunction is present" message in the instrument cluster. This often indicates an underlying electrical problem. Technicians frequently identify a wiring issue as the root cause of such failures.

Technical Background

Audi has observed that when wiring issues are diagnosed as the root cause of vehicle failures, warranty claims often lack critical information. Details regarding symptoms, specific findings, affected circuits, and the exact location of the damage are frequently unclear. This Technical Service Bulletin (TSB) aims to improve the identification and documentation of wiring repairs to help identify common issues and enhance future product designs.

Repair Procedure Summary

When a wiring issue is identified, technicians are required to thoroughly document their findings and take photos of the damage. These photos must be retained for at least one month after warranty claim approval for potential review.

For issues related to pins or coaxial connector ends, approximately 10-20 mm of the original wire should be retained where space allows. Repairs for these components must be performed using the VAS1978B wiring harness repair set.

If the problem stems from high resistance or a short circuit in the wiring, overlays may be used for diagnosis. The affected section of faulty wire that is removed must be retained. Faulty sections of wire are to be repaired using the VAS1978B tool.

Detailed notes are crucial for any Audi e-tron wiring harness repair. Technicians must include:

• The specific circuit affected.
• Pin identification of the main circuit involved.
• Results of circuit checks, including resistance and/or voltage values.
• The exact location where the damaged pin or circuit was found.
• Any other relevant details that support and describe the findings.

An example provided in the TSB describes a Flexray circuit that measured 0.6 ohms to ground, indicating a short circuit. The damage was found on the green FlexRay wire between the J743 Dual Clutch T23/1 and J533 Data Bus on Board Diagnostic Interface T54/27, located underneath the driver's seat along the frame rail.

Photos are essential for accurate location and findings. These should include:

• A perspective view showing the general area and surroundings.
• A photo of the original wiring routing before disturbance.
• A clear close-up of the damaged circuit, in focus, with a date stamp and VIN reference.

Required Tools or Parts

Technicians performing wiring harness repairs will utilize specific tools:

• VAS 1978B: Wiring harness repair set
• VAS 6160/VAS 6150: VAS tester with the current version of ODIS (Windows 10)

Warranty Information

Proper documentation of wiring repairs is critical for warranty claims. While PID 9709 (Central Wiring Harness) is often used as a default, using the correct PID helps differentiate the affected harness. The TSB provides examples of PIDs for specific locations:

PID	Description	Notes
9709	Central Wiring Harness	For main body harness only. Not for sub-harnesses that are replaceable separately (e.g., door, bumper, or engine harness).
9713	Engine compartment wiring harness	Any repair made to harness sections in the engine bay NOT connected to the main body harness. Claim notes should specify a location.
9732	Door harness	Use for any door. Claim notes should state which door.
9757	Seat harness	Use for any location. Claim notes should specify the location.
9779	Roof wiring harness	Any repairs made to harness sections in the roof. Claim notes should specify a location.
9759	Bumper harness	Use for front or rear. Claim notes should specify the location.
9781	Transmission wiring harness	Any repair made to the harness that is separate from the main body harness and connects to the transmission.

Additional Resources for Technicians

Further information on wiring diagnosis, circuit identification, and repair is available through:

• Audi academy: Accessaudi >> App links >> Academy site CRC >> videos >> Technical >> Electrical, networking and vehicle lighting.
• Elsa: damage code catalog >> Electrical >> 97 Wiring.
• Self-Study Program (SSP) 973003: How to Read Wiring Diagrams, Symbols, Layout, and Navigation.
• Self-Study Program (SSP) 971003: Wiring Harness Inspection and Repair.