Repair methods for wiring harnesses - AH00.19-P-1000-04A
Model 124, 126, 129, 140, 163, 164, 168, 169, 170, 171, 199, 202, 203, 208, 209, 210, 211, 215, 216, 219, 220, 221, 230, 240, 245, 251, 414, 461, 463
Repair method summary
The following methods have been approved by DaimlerChrysler 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
- Insulation displacement method
- 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.
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 minimum temperature for this repair method is 400°C.
Raychem is the manufacturer of the solder connections that are required for this method. The Raychem repair method is mainly used for integrating repair wiring harnesses (cable tails): ↓
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 plug connections.
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 mm 2 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.
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.
| Crimping | Raychem/cable tail repair method | Soldering | Rapid connection technology | |
|---|---|---|---|---|
| Applications | Repair cables Replace damaged contacts Repair connectors Additional line connection |
Repair cables Cable extension Integrate repaired cables (cable tails, replacement wires) in the wiring harness |
Replace soldered contacts (special applications) | Repair cables Additional line connection Wire end connection |
| Equipment and tools required | Side cutting pliers Wire stripper Crimper with special die sets |
Side cutting pliers Wire stripper Hot air blower with special reflector Raychem connection Cable tails Heat shield mat |
Side cutting pliers Wire stripper Soldering iron with accessories Heat shield mat as drip protection |
Side cutting pliers Water-pump pliers |
| Type of contact | clamped | soldered | soldered | clamped |
| Heat source | None | Hot air gun with special reflector (400°C) | Soldering iron (400°C) | None |
| Advantages | Quick repair, no mains power connection required Strain relieved by clamping the insulation Simple visual inspection of connection |
Insulation occurs automatically Sealing occurs automatically Avoids taut wires by introducing additional wires |
Replace soldered contacts (special applications) | No wire stripping or cutting required Relatively short set-up time No special tool required |
| Disadvantages | Special crimping components required | Mains power connection required Accessibility for hot air gun must be ensured Measures for heat protection required |
Extensive preparation and post-working required | No watertight versions, therefore only suitable for use inside the vehicle or in the trunk area Use limited to certain cable cross-sections Not permissible for CAN lines |