Driver door wiring harness replacement write-up (lots of pics) - AudiWorld Forums

Go Back   AudiWorld Forums > Audi Models > Audi A4 > A4 (B6 Platform) Discussion
Sign in using an external account
Register Forgot Password?


A4 (B6 Platform) Discussion Discussion forum for the B6 Audi A4 produced from 2002-2005

Driver door wiring harness replacement write-up (lots of pics)

Reply
 
 
 
 
LinkBack Thread Tools Search this Thread
Old 11-11-2007, 02:38 PM   #1
AudiWorld Super User
 
Join Date: Apr 2006
Posts: 2,962
Default Driver door wiring harness replacement write-up (lots of pics)

A few weeks ago, I noticed my dome light wouldn't go off when I closed the door, also all the switches on the driver door had stopped working. After inspecting the harness where is crosses from the door jamb to the door, I noticed quite a lot of damaged wires. I ordered a replacement harness and replaced it today.
Here is the part to be replaced.

Part number for those interested.

Picture of my original switches that don't work (notice the lack of peeling, my car is a 2002).

Here is a pic of why the non-peeling switches are so special!

So here we go, first remove the cap under the armrest (just pry off).

Remove the 2 screws seen in the hole.

With caution, unclip the door trim.

Remove the 4 screws exposed under the door trim.

Remove the screw at the bottom of the door.

This part here almost gave me a hernia. Unclip the top of the door from the edge of the window, just lift. I thought that the top part would seperate completely, it doesn't. I put a lot of effort into this before realizing that all I needed to do was unclip from the window's edge.

Now you can remove the whole inner door, before you go too far with it, unclip the door handle hook cable (seen in the center of the pic).

There are 2 more connections to unplug, one to the door control module and one to the speaker, then you can completely remove the inner door. Here is a pic of the inside of the door.

Start unplugging the harness (2 connections to the door controle module and one to the speaker).

Remove the plug where the harness enters the door.


For the next part, you'll have to peel the sound insulation from the door. Remove the rectangular plug by the door handle cable.


Unplug the connector to the latch area.

Next, unplug the connector at the door jamb (goddamn I hate those German connectors, they all seem to clip/unclip in their own little special way). In the second pic you can see the damaged wires.


See the little black plastic thingies, make sure you push them to unclip them or you won't be able to remove the old harness.

Unclip the harness from the door.

Remove the speaker to be able to remove the old harness and thread in the new one. There are a few white plastic pins that hold the harness in place that you'll have to cut/pull off.

Before plugging everything back in, I applied dielectric grease to all the connectors.

You can now insert the new harness (start at the door, obviously). Everything is just the reverse of the removal, make sure you insert the black and white plastic thingies in the holes so that the new harness doesn't rattle around.
Before re-installing the inner door, I tried the switches, they don't friggin' work, goddamn. A Vag-Com scan revealed the following DTC.
Address 09: Cent. Elect.
Control Module Part Number: 8E0 907 279 E
Component and/or Version: int. Lastmodul KAN 0305
Software Coding: 00014
Work Shop Code: WSC 63351
1 Fault Found:

01331 - Door Control Module; Driver Side (J386)
49-10 - No Communications - Intermittent

I guess I'll have to replace the door control module.

Oh well, it's not like I replaced the harness for nothing, the damage was pretty easy to see (the new harness didn't cause a speaker connection DTC to appear and the driver door speaker works now).
I'll drive a la Jet Jockey (no inner door) until the new door controle module arrives I guess.
x1rider is offline   Reply With Quote
Old 11-11-2007, 03:15 PM   #2
AudiWorld Super User
 
Join Date: Mar 2005
Posts: 6,154
Default

I saw a similar problem on an older B6, the 2 CAN wires sheared right in the hinge area
__________________

Current:1999 A4 1.8TQ
1988 Scirocco 16V project
2000 A6 2.8Q

Previous:1999 Passat 1.8T purple demon
2002 GTI 337
1998 A6 2.8
1993 Canadian S4
1997 Jetta GL
Aarononymous is offline   Reply With Quote
Old 11-11-2007, 03:29 PM   #3
AudiWorld Expert
 
Join Date: Jun 2000
Posts: 29,354
Default

Excellent write-up! How much did the harness run($)?
__________________


2004 A4 1.8t USP Quattro 6MT
K04-15/APR/TT 225 Injectors/Custom Stainless Exhaust/710N/RaceTec FMIC
034 HFC/Jet-Hot Cermi-coated & ported exhaust manifold
Spec Stage 3+ with OE DMFW!
Neuspeed TIP/Neuspeed Snub/Optima 75-35/AFE Pro-Dry/FSI Coils
AMS Short-shift @ %40 redux(Sweet!)
Bilstein Sport with H&R/ H-Sport Anti-Sway bars/E-codes
19x8.5 OEM Audi Skinny Fives with 235-35 Bridgestone 760 Sport Skins
B7 A4 brakes with StopTech Ceramic pads and Stop Tech rotors

Sirius Satellite Radio

Ross-Tech HEX-USB+CAN Equipped

Escort 9500ix
MikTip is offline   Reply With Quote
Old 11-11-2007, 04:05 PM   #4
AudiWorld Super User
 
Join Date: Apr 2006
Posts: 2,962
Default the harness cost me around $220.00 CAD (I can verify the exact price tomorrow if you want)...

I wonder how much the door control module will cost me?
x1rider is offline   Reply With Quote
Old 11-11-2007, 04:08 PM   #5
AudiWorld Super User
 
Join Date: Oct 2005
Posts: 6,127
Default I think the cause of the unusual wire damage in this case, is the result of ...

the extreme cold experienced, cracking the insultation, then the wires fatigued from the unsupported flexing at the locations of the cracked insulation. Are you sure the door control module is getting power via the door harness? If the power hot wire shorted to ground after breaking, maybe the circuit fuse is blown. Check the Power Window fuse #37.
diagnosticator1 is offline   Reply With Quote
Old 11-11-2007, 04:12 PM   #6
AudiWorld Super User
 
Join Date: Apr 2006
Posts: 2,962
Default I thought about that and I agree with you, the cracking was probably caused by the...

extreme cold the car has been exposed to over here. That is a good point about the fuse, would the control module fuse be found in the fusebox by the driver door? One reason I thought it might be a defective control module is the "intermittent" description found in the DTC. I'll check the fusebox nonetheless. Thanks for the advice.
x1rider is offline   Reply With Quote
Old 11-11-2007, 04:24 PM   #7
AudiWorld Super User
 
Join Date: Oct 2005
Posts: 6,127
Default

Check the Power Window fuse, #37.
diagnosticator1 is offline   Reply With Quote
Old 11-11-2007, 04:25 PM   #8
AudiWorld Super User
 
Join Date: Apr 2006
Posts: 2,962
Default

thanks, I'll check that tomorrow, I'd rather buy a fuse than a control module!
x1rider is offline   Reply With Quote
Old 11-11-2007, 04:28 PM   #9
AudiWorld Super User
 
Join Date: Oct 2005
Posts: 6,127
Default For sure! Hopefully thats the cause. If the passanger side window does not operate, ...

confirms the fuse as a quick check, both sides use the same fuse.
diagnosticator1 is offline   Reply With Quote
Old 11-11-2007, 06:31 PM   #10
AudiWorld Super User
 
Join Date: May 2004
Posts: 3,645
Default

i just checked world impex -- $176
__________________

GIAC FX ~ AWE exhaust ~ APR TIP w/ samco boost hoses ~ K&N ~ Koni/neuspeed suspension ~ 18" fliks/BF Gdrch SS A/S ~ APR snub mount ~ B&M SS ~ podi ~ RS4 pedals ~ 3.0 front brakes ~ hawk pads all around ~ european xenon headlights ~ black out grill trims ~ painted front bumper w/ zender add-ons ~ S4 door blades and rear bumper ~ ebay spoiler ~ 40% tint

<a href="http://www.dvagonline.com/forums/showthread.php?t=507">the history of my car
</a>
heateris is offline   Reply With Quote
Old 11-11-2007, 07:10 PM   #11
Audiworld Junior Member
 
Join Date: May 2007
Posts: 30
Default

Clean the electrical connections. Possibly too much grease.
stacks is offline   Reply With Quote
Old 11-11-2007, 07:12 PM   #12
AudiWorld Senior Member
 
Join Date: May 2005
Posts: 806
Default

Excellent Write-Up!
__________________
2002 Brilliant Black A4 3.0 QT
Almost as stock as the day she left .DE
Tech Articles: B6 Sound Deadening - Symphony II -&gt; II+ &amp; SAT Radio Upgrade
pr0digy30 is offline   Reply With Quote
Old 11-12-2007, 02:39 AM   #13
AudiWorld Super User
 
Join Date: Apr 2006
Posts: 2,962
Default Crap, the fuse is fine (turned out to be #22 in my car)...

Next step, I'll replace the door control module. I checked ETKA and it's the whole thing circled in red (It is integrated with the window regulator). It's going to cost an arm...

x1rider is offline   Reply With Quote
Old 11-12-2007, 03:20 AM   #14
AudiWorld Super User
 
Join Date: Apr 2006
Posts: 2,962
Default

I paid $217.67 CAD
x1rider is offline   Reply With Quote
Old 11-12-2007, 06:57 AM   #15
DWP
AudiWorld Super User
 
Join Date: Mar 2000
Posts: 5,494
Default

2nd - get it in the FAQ! Or the tech articles.
__________________
My Audis:
05 A4 Ultrasport 3.0 MT. Silver on ebony leather. Debadged, ClearBra, AMS Short Shifter, MagnaFlows, RS4 Reps, RS4 Rear Sway Bar, 4-ring valve caps, Premium, Bose, Sirius, Warm, Cold, other stuff.

02 2.7T Irish Green Sport Tip
Gone but never forgotten

2001 A4 1.8TQM w/ Bilsteins & Vogtland sport springs, TSB, APR Snub, 17" OEM Avus S4's, GIAC Chip, V&S Short Shifter, H-sport bars, APR Cat-back, A8 rotors, clear corners, PIAA Superwhites, sunglass holder mod.

'87 4KQ Bone Stock Gone after all these years

emailWPMR@YAHOOdotCOM
DWP is offline   Reply With Quote
Old 11-12-2007, 07:10 AM   #16
Member
 
Join Date: Jan 2003
Posts: 3,538
Default

Well done. Looked like a bit of a pain, I agree with you on the connectors.
__________________




Sprint Booster review 1
http://forums.audiworld.com/a4gen2/msgs/1014641.phtml

Sprint Booster review 2
http://forums.audiworld.com/a4gen2/msgs/1015112.phtml

REASON #1 NEVER TO VISIT A HOME DEPOT:
THERE'S ALWAYS A LOWES NEARBY.
QuattroFan02 is offline   Reply With Quote
Old 11-12-2007, 08:35 AM   #17
AudiWorld Super User
 
Join Date: Apr 2006
Posts: 2,962
Default

I know, every time I have to unplug one, I have to figure it out first... without breaking it!
x1rider is offline   Reply With Quote
Old 11-12-2007, 12:46 PM   #18
AudiWorld Super User
 
Join Date: Mar 2006
Posts: 12,794
Default Great write up

You should submit it to the tech section
__________________
-Matt



2004 Audi A4 1.8t 6MT Quattro

"Modding is like herpes; once you get the itch, it never leaves."- OpenSkye

Dahlback | Milltek | AWE | Vogtland | H-Sport | Oettinger | BFGoodrich | Thule | OEM+ | Dents

Wish List: Stasis Torsen Center Differential, S4 Recaros (Black leather), Affordable parking in Washington DC

KMD Tuning

Stock Dyno (w/ Milltek): 162.5 HP; 164.5 ft/lbs TQ

Dahlback Stage 2 Dyno (w/ AWE FMIC, Milltek): 244.8 HP; 312.8 ft/lbs TQ

2002 Audi 1.8t K04'd Tiptronic
Gone but not forgotten
quattrothatcould is offline   Reply With Quote
Old 11-12-2007, 12:52 PM   #19
AudiWorld Super User
 
Join Date: Apr 2006
Posts: 2,962
Default

I don't know how to do that
x1rider is offline   Reply With Quote
Old 11-12-2007, 04:34 PM   #20
AudiWorld Super User
 
Join Date: Mar 2006
Posts: 12,794
Default Lol I don't really either

I think you go to the feedback forum or something and ask for it to be submitted. You have a tendency to do really good write ups. I have a bunch bookmarked on my computer for future reference.
__________________
-Matt



2004 Audi A4 1.8t 6MT Quattro

"Modding is like herpes; once you get the itch, it never leaves."- OpenSkye

Dahlback | Milltek | AWE | Vogtland | H-Sport | Oettinger | BFGoodrich | Thule | OEM+ | Dents

Wish List: Stasis Torsen Center Differential, S4 Recaros (Black leather), Affordable parking in Washington DC

KMD Tuning

Stock Dyno (w/ Milltek): 162.5 HP; 164.5 ft/lbs TQ

Dahlback Stage 2 Dyno (w/ AWE FMIC, Milltek): 244.8 HP; 312.8 ft/lbs TQ

2002 Audi 1.8t K04'd Tiptronic
Gone but not forgotten
quattrothatcould is offline   Reply With Quote
Old 11-12-2007, 04:34 PM
AudiWorld
Audi R8




Paid Advertisement
 
 
 
Reply

Tags
2002, 2003, a4, audi, b7, door, drivers, harness, panel, removal, replacement, s8, tool, wire, wiring

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On



All times are GMT -8. The time now is 02:20 AM.


Copyright 2014 AudiWorld.com Audi Enthusiast Community