Repair method summary - AH00.19-P-1000-04A

Repair methods for wiring harnesses 

The following methods have been approved by Daimler for repairing wiring harnesses in Mercedes-Benz passenger cars:

Repair methods: 

• Crimping
• Solder connection (Raychem)
• Axial solder connection (Raychem)
• Combination of Raychem and cable tail
• Soldering
• Rapid connection technology
• Flat conductor pliers

Application 

Individual cases must be analyzed in detail to decide which method can and cannot be used to repair wiring harnesses (wires, contacts and connectors).

Crimping repair method 

In crimping, the insulation is first stripped off an appropriate distance (a) from the end of the wire. Then the contact pin is placed over the stripped end of the wire and pinched "crimped" in place by means of a special pliers-like crimping tool. Crimping is performed quickly and with ease. A special crimper is required.

Only lines up to 4 mm² shall be crimped.

Fig 1: Identifying Crimping Distance Of Insulation

Courtesy of MERCEDES-BENZ USA

Raychem repair method 

With this method, special solder connectors are used. The solder connections contain the solder and they also feature insulation and a seal. A special hot air blower provides the heat required for soldering and shrinking the insulation. A special reflector is fitted to the hot air blower.

The temperature for this repair method is 400°C.

Raychem is the manufacturer of the solder connectors that are required for this method. The Raychem repair method is mainly used for integrating repair wiring harnesses (cable tails).

Fig 2: Identifying Raychem Repair Method

Courtesy of MERCEDES-BENZ USA

Combination of Raychem repair method and cable tail repair 

Cable tails are prefabricated partial wiring harness kits available as Mercedes-Benz replacement parts. They have the appropriate cable cross-sections and crimped contacts. The Raychem repair method is used to integrate the cable tails into the wiring harnesses.

Only use cable tails for lines between 4 and 10 mm² . Starting at 10 mm² the wiring harnesses must be replaced.

Soldering repair method 

The strands of the cable (2) are soldered in the solder contact (axial or radial version) (1) using a soldering iron. Commercially available solder is used for the soldered connection. This method is only used for repairing connectors.

Fig 3: Identifying Strands Of Cable And Solder Contacts

Courtesy of MERCEDES-BENZ USA

Repair method using rapid connection technology 

This method uses special rapid-connection wire connector blocks. Mercedes-Benz permits the 2-, 4-, and 6-pin versions. They contain tin-plated rapid connection contacts, which are pressed together to touch the wires of the cables using pliers. The lines do not have to be separated or stripped.

This method can be used for connection to cables with a cross section of 0.35 to 0.75 mm² and for wire end connections.

The rapid connection method must only be used inside the vehicle or in the trunk because the connection is not watertight. They are not permissible for CAN lines.

Fig 4: Pressing Together Tin-Plated Rapid Connection Contacts

Courtesy of MERCEDES-BENZ USA

Flat conductor cable repair method 

Select crimp contacts in the wiring harness repair kit and insert into the tool head of the open manual crimp pliers (2). The flat conductor cable (7) must make contact with the tool head, and the correct edge of the flat conductor cable (7) must make contact with the adjusting stop (3). The optical adjusting device (4) in the manual crimp pliers (2) must be fully visible between 2 conductor tracks. Press the manual crimp pliers (2) together all the way. After it has been pressed down all the way, it can be opened again. Remove the finished crimp connection.

Fig 5: Identifying Adjusting Stop, Flat Conductor Cable And Manual Crimp Pliers

Courtesy of MERCEDES-BENZ USA