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D2 - Lights Headlights, xenons, foglights. Everything outside the car that glows

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Old 27th August 2016, 10:59 AM
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notorious notorious is offline
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Default D2 Xenon range control wiring renewal

Hello D2 lovers. One more day, one more job.

Problem:

As your car is getting older the range control sensors attached to suspension on the left hand side of your car will start to fail.
You will purchase new sensors and remove the wheel only to discover that the wiring connector is so weak that it basically falls into pieces when you try remove it.

Another good sign of failing wiring is errors like below due to poor contact, etc. followed by a beep and a yellow headlight range control icon on your dashboard.

00774 - Level Control System Sensor; Rear Left (G76)
28-10 - Short to Plus - Intermittent

In my personal opinion Audi OEM wiring of xenon range control sensors is inadequate for what I expect to find **under** the car.
Here's how existing wiring looks on my car:

Front:



Rear:


Attempt to remove the connector will result in broken connector since old plastic is so brittle:



Solution:

Replace both front and rear connectors by installing the following kit.
(order quantity x part number)

3 x 000 979 009 EA -- repair wires, (A suffix = gold plated core contact, important for outdoor), -40C/+125C Note: Audi/TPS may only sell these in quantities of 5.
2 x 7M0 973 119 -- electric connector
2 x 4А0 906 102 -- rubber housing
6 x 357 972 740 D -- connector wire seal, yellow
6 x 3C0 972 841 -- connector cavity plug, orange

Expect to pay 50 to 60 for it.


Since repair wires will be crimped from both sides you cut them in half so you will have 3 crimped ends per connector. Then dress the wires with yellow seals as shown on picture:


Then slide green latches on connector and place wires into pins 1, 4 and 5 until they click. Unused cavities seal with orange plugs. Slide green latches back in place.




Then you need to cut off old connector and solder each of 3 wires one by one. Then insulate the area. I use 3M series super 88 insulation tape and then Certoplast cloth tape. No pictures, sorry. But this is a very basic wiring skill.

Additionally, you can put some silicone grease into rubber housing before you slide it onto connector.

End result front:


End result rear:


And front again:


Any questions -- shout
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Last edited by notorious; 27th August 2016 at 02:51 PM.
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Old 27th August 2016, 02:46 PM
MikkiJayne MikkiJayne is offline
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Nicely done Good find on the boots.
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Old 30th August 2016, 07:19 PM
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David's8 David's8 is offline
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As always Sergei a neat, professional job. When I had to repair my sensors I could not believe the "open to the elements" plug unit. However, it hasnt failed yet. Neither has my repair which comprised cutting an arm out of sheet aluminium and supergluing it to the broken plastic arm. You would be ashamed of me Sergei.
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Old 31st August 2016, 06:35 AM
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The_Laird The_Laird is offline
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Serge

If your car is ever for sale, please let me have first option. I think it's probably better than new!
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Planned mods: auto-dimming rear view mirror, dash cam (as steamship's), fit the ski hatch, refit philips drl's (or maybe not).
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Old 31st August 2016, 06:46 AM
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Adrian E Adrian E is offline
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No probably about it - it IS better than new!
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