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 Wiring Harness Repair Kit (220 589 02 99 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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Fig 7: Identifying Welding Bead Catcher (129 589 01 98 00)

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Workshop equipment/MB testers

WE58.40-Z-1007-03A

Hot-air gun

Expose damaged cable or plug/coupling in easily accessible position and cut off.
Separate cores in wiring harness offset by approx. 45 mm (B).

Fig 8: Identifying Wiring Harness Offset Distance
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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 cup as shown in table below.

Fig 9: Identifying Dimensions For Cutting Line

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Selection table for solder connector
Total copper cross-section A_tot.	Overall diameter with insulation	Length stripped of insulation	Color code
0.7 to 2.4 mm²	3.3 mm	15 mm	green
2.0 to 4.0 mm²	4.5 mm	15 mm	red
3.5 to 8.0 mm²	7.0 mm	15 mm	blue
7.5 to 12 mm ²	9.0 mm	15 mm	Yellow

A maximum of seven individual cables maybe inserted into each solder connection.

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

Fig 10: Rotating Solder Connection Onto Cables
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Heat solder connector using a heat gun (approx. 400°C).
Start at tapered end until soldering ring has dissolved and sleeve has correctly wrapped itself around the line.

Fig 11: Heating Solder Connector Using Heat Gun
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Check soldered point.
The soldering ring (1) of the solder connection (Z) must no longer be visible. The covering (2) must be resting smoothly against the cables.

Fig 12: Identifying Solder Connection - Correct/Incorrect
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Fit solder connection onto cable and wrap fabric tape around repaired area.
Solder connections must not be positioned directly one above the other.

Fig 13: Identifying Solder Connection
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