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

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

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

Fig 10: Replacing Wiring Harnesses
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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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