Repairing wiring harness using solder connectors - AR00.19-P-0100-09A

WARNING: This page does not describe the selected car, but rather 11 other vehicles, including the 2014 Mercedes-Benz C63 AMG, 2013 Mercedes-Benz C63, 2012 Mercedes-Benz C63, 2011 Mercedes-Benz C63, and 2011 Mercedes-Benz C350. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying New Passenger Vehicle Wiring Harness Repair Kit (220 589 04 99 00)

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Fig 2: Identifying Wiring Harness Repair Kit Basic (000 589 13 99 00)

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Fig 3: Identifying Welding Bead Catcher (129 589 01 98 00)

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Fig 4: Identifying Wire Stripper (220 589 01 99 40)

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Fig 5: Identifying Reflector (220 589 01 99 41)

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Fig 6: Identifying Adapter (220 589 01 99 42)

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Expose damaged line or connector/coupling and separate.
Separate line in wiring harness offset approx. 45 mm (B).

Fig 7: Identifying Wiring Harness Offset
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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 connector according to table below.

Fig 8: Identifying Cutting Line Allowance

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Selection table for solder connector
Entire copper cross section	Overall diameter with insulation	Length stripped of insulation	Color code
0.7 to 2.4 mm ²	3.3 mm	15 mm	green
2.0 to 4.0 mm ²	4.5 mm	15 mm	red
3.5 to 8.0 mm ²	7.0 mm	15 mm	blue
7.5 to 12 mm ²	9.0 mm	15 mm	Yellow

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

Fig 9: Rotating Solder Connection
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Heat solder connector with hot air gun (approx. 400°C).
Hot air blower

Start at tapered end until soldering ring dissolves and covering has completely wrapped itself around the lines.

Fig 10: Heating Solder Connector With Hot Air Gun
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Check soldered point.
The soldering ring (1) of the solder connection (Z) must no longer be visible. The jacketing (2) must make contact with the lines as shown.

Fig 11: Identifying Soldering Ring And Jacketing
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Position solder connector on line and attach heat-shrinkable tube or corrugated hose in repair area or wrap with fabric tape.
solder connections must not be positioned directly one above the other. Primarily fabric tape is used for the visual adaptation of the repair point and to protect against chafing. In vehicle areas with higher loads (e.g. engine compartment), fabric tape should only be used in combination with other (watertight) safety measures.

Fig 12: Positioning Solder Connector On Line
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