Repair wiring harness by means of axial solder connectors - AR54.18-P-0100-06A

WARNING: This page is about a different car, the 2011 Mercedes-Benz C300, 2010 Mercedes-Benz C300, 2009 Mercedes-Benz C300, and 2008 Mercedes-Benz C300. However, it is still accessible from the selected car via links, so may be relevant.

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

Fig 1: Separating Cores In Wiring Harness
Courtesy of MERCEDES-BENZ USA
Cut new section of cable to match old cable.
Remove 15 mm of insulation at end of cables.
Pull cut-off insulation off the line while turning.

Fig 2: Identifying Cable Insulation End Removal Lengths
Courtesy of MERCEDES-BENZ USA
Select axial solder connector by means of cable cross-section.
Push the axial solder connector on line beyond the solder point.
Push on the thinner side of the axial solder connector first.

Fig 3: Pushing Axial Solder Connector On Line
Courtesy of MERCEDES-BENZ USA
Twist the line ends together.
Push back the axial solder connector on the transposition while turning.

Fig 4: Twisting Line Ends Together
Courtesy of MERCEDES-BENZ USA
Heat up axial solder connector with a preheated hot air blower (with electronic temperature control) to 400 °C.
Use welding bead catcher in the vehicle interior in order to avoid damage due to liquid solder.

Until the soldering ring has dissolved and the covering has positioned itself properly around the lines.

Fig 5: Heating Up Axial Solder Connector
Courtesy of MERCEDES-BENZ USA
Check soldered point.
It must not be possible to see the soldering ring of the axial soldered connector any more. The covering must contact the lines properly.

Fig 6: Identifying Correct And Incorrect Soldered Point
Courtesy of MERCEDES-BENZ USA
Apply axial solder connector to the lines and wrap repaired area round with fabric tape.
The axial solder connectors must not lie directly above one another.

Fig 7: Wrapping Repaired Area
Courtesy of MERCEDES-BENZ USA