Remove contacts from 2.5 round plug contact plug - AR00.19-P-0120-16A

WARNING: This page does not describe the selected car, but rather 42 other vehicles, including the 1999 Mercedes-Benz S600, 1999 Mercedes-Benz S500, 1999 Mercedes-Benz S420, 1999 Mercedes-Benz S320, and 1999 Mercedes-Benz CL600. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Wiring Harness Repair Kit, Supplement For Passenger Cars (220 589 04 99 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Wiring Harness Repair Kit (220 589 01 99 30)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Release Tool With RK 2.5 Ejector (220 589 01 99 30)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Secondary release on version with slide valve (RK 2.5)

Using a suitable tool (1), push the slide valve (2) out of the last detent in direction shown by arrow.

Shown on a 1-pin RK 2.5 plug

Fig 5: Pushing Slide Valve - Shown On A 1-Pin RK 2.5 Plug

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Secondary release on version with contact retainer (RK 2.5)

Using a suitable tool (1), open the contact retainer (2).

Shown on a 2-pin RK 2.5 plug

Fig 6: Opening Contact Retainer - Shown On A 2-Pin RK 2.5 Plug

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Secondary release on version with secondary retainer (RK 2.5)

Using a suitable tool, slide the secondary retainer (1) to the pre-locking position.

Shown on a 12-pin RK 2.5 plug

Fig 7: Locating Secondary Retainer - Shown On A 12-Pin RK 2.5 Plug

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Secondary release on version with lock tab (RK 2.5)

Using a suitable tool, slide the lock tab to the pre-locking position.
Shown on an 8-pin RK 2.5 plug

Fig 8: Sliding Lock Tab - Shown On An 8-Pin RK 2.5 Plug

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Unpin contact pins from the plug (RK 2.5)

Insert release tool with RK 2.5 ejector into the contact cavity of the plug (1) from the front end.
In this step, the sleeve (4) of the release tool compresses the spring shackles on the contact-pin (2).
Press the plunger (3) on the release tool with RK 2.5 ejector to apply spring pressure to force the contact pin (2) from its seat in the connector housing.

Fig 9: Contact Pins From Plug (RK 2.5)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Gently pull the respective line to remove the contact pin (2) from the plug (1).