Repair wiring harness by crimping (with watertight connections) - AR00.19-P-0100-04A

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 Crimp Pliers (220 589 01 99 10)

Fig 5: Identifying Wire Stripper (220 589 01 99 40)

Fig 6: Identifying MQS ELA Crimping Set (220 589 01 99 86)

Fig 7: Identifying SLK 2.8 / ELA Crimping Set (220 589 01 99 08)

Fig 8: Identifying SLK 2.8 ELA Crimping Set (220 589 01 99 09)

Fig 9: Identifying MCP 2.8 ELA Crimping Set (220 589 01 99 80)

Fig 10: Identifying MCP 2.8 ELA Crimping Set (220 589 01 99 81)

Fig 11: Identifying JPT ELA Crimping Set (220 589 01 99 82)

Fig 12: Identifying MLK 1.2 ELA Crimping Set (220 589 01 99 84)

Fig 13: Identifying SLK 2.8 / ELA Crimping Set (220 589 01 99 08)

Fig 14: Identifying MCP 2.8 ELA Crimping Set (000 589 13 99 10)

Fig 15: Identifying MCP 1.2 ELA Crimping Set (220 589 04 99 10)

TABLE OF STRIPPING LENGTHS

Contact family	Single-strand sealing	Cable cross-section	Length stripped of insulation
All		up to 1.5 mm²	4 mm ± 0.3
All		1.5 up to 4 mm²	5 mm ± 0.3

Select crimp contact according to assignment table in wiring harness repair kit , wiring harness repair kit basic or wiring harness repair kit as supplement to passenger cars .
Push single-strand insulation (1) over cable (2) with lip at the front.
Strip line (2) using wire stripper according to assignment table.
Damaged wire strands can lead to changes in the line cross-section and an impermissible strength of the crimped connection.
Align single-strand insulation (1) with line (2) ensuring that dimension (b) = maximum 1 mm.

Fig 16: Aligning Single-Strand Insulation With Line
Select crimping set (1, 2) for crimp pliers (3) .
Select crimping set (1, 2) according to the crimp contact type and single-strand insulation used. See table.
Insert crimping set (1, 2) into crimp pliers (3) .

Fig 17: Identifying Crimping Set And Crimp Pliers
1. Screw positioner onto crimp pliers (arrow).
2. Fit positioner with quick-release fitting on crimp pliers .
  Positioners with screw fitting can be exchanged for positioners with quick-release fitting.
  
  Fig 18: Identifying Positioner Screwed Onto Crimp Pliers
Insert crimp contact (1) all the way into crimp nest (2) and into positioner (3) of die sets (4, 5).
Select crimp nest (2) according to cable cross section. Crimp contact (1) must be vertical between the die sets (4, 5).

Fig 19: Identifying Crimp Contact, Crimp Nest, Positioner And Die Sets
Close crimp pliers until crimp contact (2) is fixed in crimp nest (3).
Make sure that the crimp contact (2) is inserted correctly in the positioner (5).

Do not yet deform the crimp contact (2), as otherwise the line (1) cannot be inserted correctly into the crimp contact (2).
Guide cable (1) with single-strand insulation (4) into inserted crimp contact (2) (arrow).

Fig 20: Identifying Cable, Positioner, Single-Strand Insulation And Crimp Contact
Squeeze crimp pliers until stop is reached remove crimped connection.
The crimp pliers must be squeezed until stop is reached before they will open again.

Fig 21: Squeezing Crimp Pliers
Check crimped connection for deformation and ensure that the wires fill the crimp tab correctly
(cross-section of enclosed wires).

Correct crimped connection (A):

The strands of the cable are evenly enclosed. The crimp tab is evenly shaped.

Incorrect crimped connections (B, C, D)

The crimp shackle has the wrong cross-section. The crimp tab is not filled properly.

Individual wire strands are outside the crimp shackle. The crimp tab is too full.

The crimp claws touch the bottom of the crimped fitting. The crimp tab is too full. The crimp tab is deformed incorrectly and therefore damaged.

Fig 22: Identifying Correct And Incorrect Crimped Connection (1 Of 3)
Check crimped connection to ensure that all wires are enclosed correctly.
Insulation and single-strand insulation must be positioned in the center and enclosed completely by the crimp tab and they must be able to take up tensile force.

Single-strand insulation must not be pinched otherwise galvanic corrosion can occur if the connection is penetrated by water.

Correct crimped connection (A):

Wire strands are enclosed correctly by the shackle. Insulation and single-strand insulation are enclosed correctly by the large tab. All parts can withstand the required tensile force.

Incorrect crimped connections (B, C):

The single-strand insulation is not enclosed by the shackle because it was inserted incorrectly during the crimping procedure.

The crimped area of the single-strand insulation is damaged because the wrong die set or wrong single-strand insulation was used.

Fig 23: Identifying Correct And Incorrect Crimped Connection (2 Of 3)
Check crimped connection for correct length and distance of strands and insulation, as well as position and condition of seal.
Correct crimped connection (A):

Insulation and wires are of the correct length in the shackles. Correct distance between the single-strand insulation and the end of the insulation.

Incorrect crimped connections (B, C):

The single-strand insulation is damaged because the distance between seal and end of insulation is too small.

Stripped strands are too long, single-strand insulation is therefore not crimped.

Fig 24: Identifying Correct And Incorrect Crimped Connection (3 Of 3)