Repair wiring harness by crimping - AR00.19-P-0100-03A

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 (000 589 02 99 00)

Fig 4: Identifying Crimp Pliers (220 589 01 99 10)

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

Fig 6: Identifying FL. Crimping Kit 6.3/2.8 (220 589 01 99 83)

Fig 7: Identifying MQS Crimping Set (220 589 01 99 85)

Fig 8: Identifying MLK 1.2 Crimping Set (220 589 01 99 83)

Fig 9: Identifying MCP 2.8 Crimping Set (220 589 01 99 03)

Fig 10: Identifying MCP 2.8 Crimping Set (220 589 01 99 04)

Fig 11: Identifying JPT Crimping Set (220 589 01 99 05)

Fig 12: Identifying RK 2.5 Crimping Set (220 589 01 99 06)

Fig 13: Identifying SLK 2.8 Crimping Set (220 589 01 99 07)

Fig 14: Identifying MCP 1.2 Crimping Set (220 589 04 99 11)

Table of stripping lengths

Contact family	Single-strand insulation	Cable cross-section	Length stripped of insulation
All		up to 1.5 mm 2	4 mm 0.3
All		1.5 to 4 mm 2	5 + mm 0.3

Select crimp contact based on table in wiring harness repair kit, basic wiring harness repair kit or new passenger car wiring harness repair kit .
Strip cable in accordance with table using wire stripper .
Damaged wire leads can cause changes of the line cross-section and result in an unreliable strength of the crimp connection.

Shown with circular conductor

Fig 15: Identifying Repair Methods For Wiring Harnesses - Crimping Repair Method
Select crimping kit (1, 2) for crimp pliers (3) .
Select crimping kit (1, 2) based on the crimp contact model used in the wiring harness repair kit , basic wiring harness repair kit or new passenger car wiring harness repair kit . See table.
Insert crimping kit(1, 2) into crimp pliers (3) .

Fig 16: Identifying Crimping Kit And Crimp Pliers
1. Screw positioner onto crimp pliers (arrow).
2. Fit positioner with quick-release fitting on crimp pliers .
Positioner with screw cap can be replaced with positioner with quick-release fitting.

Fig 17: Locating 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 18: Identifying Crimp Contact, Crimp Nest, Positioner And Die Sets
Close crimp pliers until crimp contact (2) is fixed in crimp nest (3).
Ensure that the crimping contact (2) is correctly seated in the positioner (4).

Do not deform the crimp contact (2) otherwise the cable (1) cannot be inserted correctly into the crimp contact (2).
Guide cable (1) into inserted crimp contact (2) (arrow).
Shown with circular conductor

Fig 19: Identifying Guide Cable, Crimp Contact And Crimp Nest - Shown With Circular Conductor
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.

Shown with circular conductor

Fig 20: Squeezing Crimp Pliers - Shown With Circular Conductor