Wiring diameter of the G62 sensor

FSIer

New Member
Hello everyone,
Im new here. Currently not holding an Audi but a VW POLO 1.4 FSI which is very similar to the A2 1.6 FSI AUA.

After a tone of money thrown into this car...problems keep coming but Im very stubborn to make it run smoothly again.

Ive got a lot of electric problems, tomorrow morning I plan to remove my harness and inspect it in my house, repair any damaged wires or connectors.

Could anyone please advise what is the diameter of the G62 sensors wiring? Mine completely broke, they sectioned right near the connector which makes it impossible for me to solder them so I need to change the whole connector plug.
I dont have a crimping tool so Im looking to get the connector with 10-20cm of wire and solder them but the only connectors Ive found have a 0.75mm diameter wires and I suspect that the ones from the G62 sensors are 0.50mm.
Anyone could confirm if im right or advise otherwsie?

Thank you very much!
 

PlasticMac

Member
Hello everyone,
Im new here. Currently not holding an Audi but a VW POLO 1.4 FSI which is very similar to the A2 1.6 FSI AUA.

After a tone of money thrown into this car...problems keep coming but Im very stubborn to make it run smoothly again.

Ive got a lot of electric problems, tomorrow morning I plan to remove my harness and inspect it in my house, repair any damaged wires or connectors.

Could anyone please advise what is the diameter of the G62 sensors wiring? Mine completely broke, they sectioned right near the connector which makes it impossible for me to solder them so I need to change the whole connector plug.
I dont have a crimping tool so Im looking to get the connector with 10-20cm of wire and solder them but the only connectors Ive found have a 0.75mm diameter wires and I suspect that the ones from the G62 sensors are 0.50mm.
Anyone could confirm if im right or advise otherwsie?

Thank you very much!
This is for A2, shows wire size, 0.5 mm and 0.3 mm. You'll be fine with 0.5 mm for all.
Screenshot 2022-08-17 17.40.45.png


Mac.
 

PlasticMac

Member
This is for A2, shows wire size, 0.5 mm and 0.3 mm. You'll be fine with 0.5 mm for all.
View attachment 98186

Mac.
You might find something like this on ebay.
Mac.
 

FSIer

New Member
Hello! Thank you!

My car has 2 wires, not 4.
connector PN is 1j0 973 702.

Ive found some on ebay/Aliexpress but it takes really long until they arrive.

Im searching for the pins terminals at this moment. If i manage to find some I will just clamp them on the remaining wire which is long enough and problem solved. Just that those pins are not easely to be found
 

PlasticMac

Member
Hello! Thank you!

My car has 2 wires, not 4.
connector PN is 1j0 973 702.

Ive found some on ebay/Aliexpress but it takes really long until they arrive.

Im searching for the pins terminals at this moment. If i manage to find some I will just clamp them on the remaining wire which is long enough and problem solved. Just that those pins are not easely to be found
Try your local vw spares dept, they do genuine repair kits for most vag connectors.
Mac.
 

FSIer

New Member
Sadly,
1660760948578.png


However, just when I started to get depressed...after months of searching online, I ve managed to find both the wiring diagram and the repair manual of my car.
My cables are 0.35 and 0.5 diameter.
1660761054618.png


Mac, just a short question, for the Audi cars do you also use VCDS for the diagnostics?

Edit: Thank you very much for the help, really appreciated!
 

PlasticMac

Member
Sadly,
View attachment 98191

However, just when I started to get depressed...after months of searching online, I ve managed to find both the wiring diagram and the repair manual of my car.
My cables are 0.35 and 0.5 diameter.
View attachment 98192

Mac, just a short question, for the Audi cars do you also use VCDS for the diagnostics?

Edit: Thank you very much for the help, really appreciated!
Yes, VCDS is the correct diagnostic tool for all VAG cars. VCDS Lite for cars from around 1998 to 2005/6, MK1 TTs, A2, MK1 A3, etc. Golf MK 3 (I think) and MK4, Polo's etc.
Mac.
 

Evripidis

Member
Just use the closest wire gauge that you can find so long as the insulation can withstand the temperature and has a high copper content (usually bright reddish coloured strands). Use heatshrink, preferably glue-lined to make it waterproof. If you cannot find the same wire gauge go one size up on the thickness. The loom on many of the cars that I service has been repaired in the manner above without any issues, including critical components such as ABS units, alarms and immobilisers. Try and join the wires in line rather than twisting them to keep the diameter close to original where the wire will be soldered so that you can fit the heatshrink over it nicely and without any danger of it ripping through, You can achieve this by tinning both ends to be soldered and then joining them together. I'd buy a roll of black cable from RS/farnell/etc and be done with it.

Source: I design and build electronics for a living.
 

FSIer

New Member
Good morning!
Thank you very much Mac for the help!

Evripidis, thanks.
Given that the size is bigger on the one I've found, i'll go for the 0.75mm one whilst the original ones have 0.35 and 0.5
I believe this should not be a problem since its a bigger cable. The composition of the wires are Copper Tin alloy.

I'll join them togheter with a thermocontractable/ heat shrink solder tube.
 
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