QCRAZY

I know this has been done a few times but I just did this on my A6. The following is what I found.

<b>Purpose:</b>
I decided to investigate this area on my A6 and determine if a problem could be located and, if one was found, attempt a repair/patch. The date of the procedure was April 10, 2004. The procedure was preformed on a 99 A6 2.8 (sedan) with just over 104,000 miles.

Below is a report of what was noticed during the investigation and what was done to alleviate the problem found.

<b>Tools Needed:</b>
1/4" drive ratchet
1/4" extension
8mm socket
Rubber foam weather seal - 7/16" thick, 3/4" wide

<b>Assumption:</b>
I assume that anyone wanting to attempt this investigation/repair can find the five 8mm bolts that retain the driver's side kick panel.

<b>Procedure:</b>
The wires to the headlight switch run back over the auxiliary relay panel and below the metal support for the dash area. Here's what was seen:

<img src="http://pictureposter.audiworld.com/1889/existingcable.jpg">

In this picture you can see where the wiring loom runs below the dash support. The top of the wiring loom rests against the bottom of the support. On my car this metal piece was relatively smooth <B>EXCEPT</B> where the wiring loom touched the support. Where the two items where in contact the metal was slightly roughened, probably something that happened over time.

To get access to the area I simply undid the wiring holder that can be seen in the foreground. This allows the cable to be moved down and out of the way for closer inspection.

<img src="http://pictureposter.audiworld.com/1889/existingedge.jpg">

In this picture you can see the contact area. My wiring <b>ONLY</b> touched on the top and not on the sides. This is a good thing because the side support is <b>VERY</b> sharp. You can also see in this picture some wear on the top of the cable (note the white marks on the wiring wrap). These white marks were caused by the support starting to wear its way through the wiring wrap.

<B>The FIX:</B>
After seeing wear on the wrap I did not want to leave the wiring. To fix the area I decided to use some Rubber Foam Weather Seal (self stick tape). This has it's own adhesive to stick by itself, is a pretty stiff foam, readily available from the local hardware store, and very easy to install. I installed two pieces of this foam to the support; one to protect the top, and one to protect the side (just in case it shifts). With the tape in place the top of the wiring loom has a gap of about 1/4" from the metal support. I'm going to watch it over the next few months. Here are two pictures with the tape installed.

<img src="http://pictureposter.audiworld.com/1889/afterstrip.jpg">

<img src="http://pictureposter.audiworld.com/1889/afterfrombelow.jpg">

<b>Keywords:</b>
Dashboard, fires, headlight switch, relay panel, recall.

<b>Disclaimer:</b>
This is the procedure that I used to address the wiring on my 1999 A6 2.8. This procedure may be similar to other C5 A6's, as well. The previous was just a description of the procedure I used to repair my wiring. Attempt at your own risk.

Seattle Scott

So Audi has stolen the "Chariots of Fire" trademark from the Ford Pinto ??

paulroad

Great Post... can you cross it to the other forums? That share the problem?

JimR

Ummmmm - No.

eddie crawford

thanks, its no 1 to do next... 99 2.7t 94k a6

BasicSlvr

<center><img src="http://pictureposter.audiworld.com/24101/sig1.1.jpg"></center><p>

QCRAZY

AFAIK, this only effects the C5 A6/S6. I'm not sure if it effects the RS6's.

fkess

While in Palm Springs last month I passed a late model car parked at the curb with dark gray smoke eminating from the front of the car (hood closed). When I returned i5 minutes later it was a burned out hulk with lots of police and fire equipment around. No it was not an Audi.......Toyota I think.
Also last year the neighbor"s BMW 530(?) burst into flames 5 minutes after parking it. It was towed as junk. It happens to all makes.

ESN

Att: Stoney - good add to FAQs

PaulW

Nice job QCRAZY!