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 Wiring Harness Repair Kit (220 589 02 99 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)

Fig 7: Identifying Welding Bead Catcher (129 589 01 98 00)

Workshop equipment/MB testers

WE58.40-Z-1007-03A

Hot-air gun

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

Fig 8: Identifying Wiring Harness Offset Distance
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 cup as shown in table below.

Fig 9: Identifying Dimensions For Cutting Line

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 mm ²	9.0 mm	15 mm	Yellow

A maximum of seven individual cables maybe inserted into each solder connection.

Insert the cables into the corresponding solder connections (Z) according to the total cable cross-section.
Ensure that solder connection (Z) is fully rotated onto cables.
Approx. 5 mm (A) of the stripped line ends should be visible.

Fig 10: Rotating Solder Connection Onto Cables
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 line.

Fig 11: Heating Solder Connector Using Heat Gun
Check soldered point.
The soldering ring (1) of the solder connection (Z) must no longer be visible. The covering (2) must be resting smoothly against the cables.

Fig 12: Identifying Solder Connection - Correct/Incorrect
Fit solder connection onto cable and wrap fabric tape around repaired area.
Solder connections must not be positioned directly one above the other.

Fig 13: Identifying Solder Connection, Cable And Fabric Tape