Repair wiring harness by crimping - AR00.19-P-0100-03A

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 Fl. Crimping Set 6.3/2.8 (220 589 01 99 01)

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Fig 6: Identifying MQS Crimping Set (220 589 01 99 85)

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Fig 7: Identifying MLK 1.2 Crimping Set (220 589 01 99 83)

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Fig 8: Identifying MCP 2.8 Crimping Set (220 589 01 99 03)

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Fig 9: Identifying MCP 2.8 Crimping Set (220 589 01 99 04)

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Fig 10: Identifying JPT Crimping Set (220 589 01 99 05)

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Fig 11: Identifying RK 2.5 Crimping Set (220 589 01 99 06)

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Fig 12: Identifying SLK 2.8 Crimping Set (220 589 01 99 07)

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Fig 13: Identifying MCP 1.2 Crimping Set (220 589 04 99 11)

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TABLE OF STRIPPING LENGTHS

Contact family	Cable cross-section	Length stripped of insulation
All	up to 1.5 mm ²	4 mm ± 0.3
All	1.5 to 4 mm ²	5 mm ± 0.3

The following work procedure is shown on a circular conductor.

Select crimp contact based on table in wiring harness repair kit, basic wiring harness repair kit or new passenger car wiring harness repair kit.
Strip line in accordance with table using wire stripper.
Damaged wire leads can cause changes of the line cross-section and result in an unreliable strength of the crimp connection.

Fig 14: Identifying Crimping Distance
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Select crimping kit (1, 2) for manual crimp pliers (3).
Select crimping kit (1, 2) based on the crimp contact model used in the wiring harness repair kit,

basic wiring harness repair kit or new passenger car wiring harness repair kit. 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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5.1 Screw positioner onto manual crimp pliers (arrow).
With manual crimp pliers with screw cap.
5.2 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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6 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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7 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 crimp contact (2) is seated correctly in positioner (4).

6 Guide cable (1) into inserted crimp contact (2) (arrow).

Fig 18: Guiding Cable Into Crimp Contact
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9 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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