Repairing wiring harness using solder connectors - AR00.19-P-0100-09A

Fig 1: Identifying New Passenger Vehicle Wiring Harness Repair Kit (220 589 04 99 00)

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

Fig 3: Identifying Welding Bead Catcher (129 589 01 98 00)

Fig 4: Identifying Wire Stripper (220 589 01 99 40)

Fig 5: Identifying Reflector (220 589 01 99 41)

Fig 6: Identifying Adapter (220 589 01 99 42)

Expose damaged cable or plug/coupling in easily accessible position and cut off.
Separate strands in wiring harness approx. 45 mm (B) offset to each other.

Fig 7: Identifying Strands In Wiring Harness Offset To Each Other
Cut new section of cable to match old cable.
When cutting the line, add an allowance of approx. 50 mm (C) for loop formation (strain-relief).
Remove approx. 15 mm (D) of insulation at line ends.

Select solder connectors in line with following table.

Fig 8: Identifying New Cable Measurements

Selection table for solder connector
Total copper cross-section A_tot.	Overall diameter with insulation	Length stripped of insulation	Color code
0.7 to 2.4 mm²	3.3 mm	15 mm	green
2.0 to 4.0 mm²	4.5 mm	15 mm	red
3.5 to 8.0 mm²	7.0 mm	15 mm	blue
7.5 to 12 mm²	9.0 mm	15 mm	yellow

Insert the lines into the corresponding solder connector (Z) according to the total line cross-section.
No more than seven individual leads may be inserted into each solder connector (Z).
Ensure that solder connector (Z) is fully rotated onto lines.
Approx. 5 mm (A) of the stripped line ends should be visible.

Fig 9: Inserting Lines Into Corresponding Solder Connector
Heat solder connector using a heat gun (approx. 400 °C).
Start at tapered end until soldering ring has dissolved and sleeve has correctly wrapped itself around the lines.

Heat gun refer to GOTIS

http://gotis.aftersales.daimlerchrysler.com

Fig 10: Heating Solder Connector Using Heat Gun
Check soldered point.
The soldering ring (1) of the solder connector (Z) must no longer be visible. The covering (2) must contact the lines as shown.

Fig 11: Identifying Soldering Ring And Solder Connector
Fit solder connector onto line and wrap fabric tape around repaired area.
Solder connectors must not be positioned directly one above the other.

Fig 12: Identifying Solder Connector Onto Fabric Tape Repaired Area