Repair Wiring Harness By Means Of Axial Solder Connectors - AR54.18-D-0100-06A

Model All 

Risk of injury  . Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

Fig 1: Identifying Welding Bead Catcher (129 589 01 98 00)

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Fig 2: Identifying Reflector (220 589 01 99 41)

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Fig 3: Identifying Wire Stripper (220 589 01 99 40)

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Fig 4: Identifying Adapter (220 589 01 99 42)

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1. Expose damaged line, plug or coupling at an easily accessible position and cut off.

   Separate cores in wiring harness offset by approx. 45 mm.

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2. Cut new section of cable to match old cable.
3. Strip 15 mm of insulation from ends of lines using wire stripper.

   Twist the cut-off insulation off the end of the line.

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4. Select axial solder connector according to line cross section.
5. Push axial solder connector onto line beyond solder point.

   Push on the thin side of the axial solder connector first.

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6. Twist the line ends together.
7. Push axial solder connector back to center of connection.

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8. Heat up axial solder connector using heat gun (approx. 400°C), reflector, adapter and welding pearl catcher until soldering ring has fully dissolved and covering has wrapped itself around line.

   Use welding pearl catcher in vehicle interior.

   In order to prevent damage caused by molten solder.

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9. Check soldered point.

   The soldering ring of the axial solder connector must be fully dissolved and the covering must have fully wrapped itself around the line.

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10. Wrap axial solder connectors and lines in repaired area with fabric adhesive tape.

    The axial solder connectors must not lie directly above one another. The fabric adhesive 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 adhesive tape should only be used in combination with other (watertight) safety precautions.

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