Notes regarding plug connections - AH00.19-P-1000-06A

Model 124, 126, 129, 140, 163, 164, 168, 169, 170, 171, 199, 202, 203, 208, 209, 210, 211, 215, 216, 219, 220, 221, 230, 240, 245, 251, 414, 461, 463 

Terminology of plug connections: 

The coupling and the plug form a plug connection. The female contact and the contact pin form the contact pair.

Illustrated: SLK family, coding A (with circular conductor) 

Plugs and couplings 

The plugs and couplings are grouped into families in the same way as the contact groups (e.g. SLK, JPT). The type and shape of the receptacle chambers in the housing is the major differentiating characteristic. Different contact families may be installed in the same housing. In addition, different codings (e.g. A, B, C) may exist within the same plug/coupling family.

Codings are special profiles or teeth on the housings of the coupling and the plug, which may be marked in different colors (e.g. black, white, violet).

These ensure that connector pairings can only be made with the same codings.

• Safety and restraint systems (airbag, emergency tensioning retractor, roll bar) have yellow, orange, or red plug connections for easy identification.

Part number assignments 

The housings are assigned according to the part numbers on the housings. On housings made up of several components, the number on the external housing is critical. (When ordering, all the individual part numbers must be ascertained.)

This method of identification by means of part numbers can be used when referring to the literature.

Contacts 

A distinction is made between the contact pin and the female contact. Each contact pin and each female contact can be clearly assigned to one group or "family" (e.g. SLK, JPT). Within these families distinctions are made according to the cable cross section and whether there is single-strand insulation for watertight connections. The contacts are also distinguished by their coating (tin, gold or silver).

The contacts are fastened to the cables by means of crimping. ↓

Crimp connections 

These are used to attach the female contacts or contact pins to the cable. Each contact type must be crimped with the aid of specifically assigned die sets using a pair of pliers. Determining factors: contact family, size of cable cross section, with or without single-strand insulation.

Only lines up to 4 mm shall be crimped.

Unpinning 

This requires a release tool appropriate to the contact family in order to remove female contacts and contact pins from plugs and couplings.

On some plugs and couplings the housings must first be disassembled and unlocked (secondary release) according to the instructions before the actual unpinning.

Contact materials 

The contacts used in the interior of the vehicle are primarily tin/tin combinations. Those used on the exterior and in the splash zone are generally silver/silver. Safety systems (particularly the airbag) are equipped with gold/gold contacts.

Only "identical" contact pairings are permitted for repair work.