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)

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

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Fig 3: Identifying Crimp Pliers (220 589 01 99 10)

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

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Fig 5: Identifying MQS ELA Crimping Set (220 589 01 99 86)

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Fig 6: Identifying SLK 2.8/ELA Crimping Set (220 589 01 99 08)

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Fig 7: Identifying SLK 2.8/ELA Crimping Set (220 589 01 99 09)

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Fig 8: Identifying MQS 2.8 ELA Crimping Set (220 589 01 99 80)

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Fig 9: Identifying MCP 2.8 ELA Crimping Set (220 589 01 99 81)

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Fig 10: Identifying JPT ELA Crimping Set (220 589 01 99 82)

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Fig 11: Identifying MLK 1.2 ELA Crimping Set (220 589 01 99 84)

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Fig 12: Identifying MCP 1.2 ELA Crimping Set (220 589 04 99 10)

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

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TABLE OF STRIPPING LENGTHS

Contact family	Cable cross-section	Length stripped of insulation
All	up to 1.5 mm²	4 mm ±0.3
All	1.5 to 4 mm²	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.
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 leads can cause changes of the line cross-section and result in an unreliable strength of the crimp connection.
Align single-strand insulation (1) with line (2) ensuring that dimension (b) = maximum 1 mm.

Fig 14: Aligning Single-Strand Insulation With Line
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Select crimping kit (1, 2) for manual crimp pliers (3).
Select crimping set (1, 2) according to the crimp contact type and single-strand insulation used. See table.
Insert crimping kit (1, 2) into manual crimp pliers (3).

Fig 15: Inserting Crimping Kit Into Manual Crimp Pliers
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7.1 Screw positioner onto manual crimp pliers (arrow).
With manual crimp pliers with screw cap.
7.2 Attach positioner with quick-release coupling to manual crimp pliers.
With manual crimp pliers with quick-release coupling.

Positioners with screw cap can be replaced with positioners with quick-release coupling.

Fig 16: Locating Screw Positioner On Manual Crimp Pliers
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8 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 17: Identifying Die Sets, Crimp Contact And Positioner
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9 Close crimp pliers until crimp contact (2) is fixed in crimp nest (3).
Do not deform the crimp contact (2) otherwise the cable (1) cannot be inserted correctly into the crimp contact (2).

Ensure that the crimp contact (2) is correctly seated in the positioner (5).
10 Guide cable (1) with single-strand insulation (4) into inserted crimp contact (2) (arrow).

Fig 18: Guiding Cable Into Crimp Contact
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11 Squeeze crimp pliers until stop is reached remove crimped connection.
The manual crimp pliers must be squeezed until stop is reached before they will open again.

Fig 19: Crimping Connection
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12 Check crimp connection for correct deformation and filling.
Correct crimp connection (A): The strands of the line are evenly enclosed. The crimp tab is evenly shaped.

Incorrect crimp connections (B, C, D): The crimp tab has an incorrect 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 and therefore damaged.

Fig 20: Identifying Correct & Incorrect Crimped Connections
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13 Check crimped connection to ensure that all wires are enclosed correctly.
Single-strand insulation must not be pinched otherwise contact corrosion can occur if the connection is penetrated by water.

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.

Correct crimp connection (A): The leads are enclosed correctly by the tab. Insulation and single-strand insulation are enclosed correctly by the large tab. All parts can withstand the required tensile force.

Incorrect crimp connections (B, C): The single-strand insulation is not enclosed by the tab due to incorrect insertion when crimping. The crimped area of the single-strand insulation is damaged because the wrong die set or wrong single-strand insulation was used.

Fig 21: Identifying Correct & Incorrect Crimped Connections
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14 Check crimped connection for correct length and distance of strands and insulation, as well as position and condition of seal.
Correct crimp connection (A): Insulation and leads are of the correct length in the tab. Correct distance between the single-strand insulation and the end of the insulation.

Incorrect crimp connections (B, C): The single-strand insulation is damaged due to an insufficient distance between the seal and the end of the insulation. Stripped strands are too long, single-strand insulation is therefore not crimped.

Fig 22: Identifying Correct & Incorrect Crimped Connections
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