General Repair Methods For Wiring Harness - Ar00.19-D-0100A

MODEL ALL 

	Risk of injury  caused by burns to skin and eyes, risk of poisoning caused by inhaling fumes during soldering.	Wear protective gloves, protective clothing and safety glasses. Ensure that the work area is adequately ventilated. Secure power supply cables. Avoid sources of fire in working area.	AS00.19-Z-0002-01A
	Risk of injury  caused by burns to skin and eyes. Risk of poisoning  caused by inhaling fumes when working with heat-shrinkable tubing.	Work in well ventilated rooms only. Wear safety glasses with side protection and protective gloves.	AS00.19-Z-0001-01A
	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
	Notes on replacement of safety-relevant and special components		AH00.19-D-1000-08A
	Repair wiring harness
1	Expose repair point	Remove insulating tubing, corrugated hose or fabric tape. Disassemble electrical connector and remove contact if necessary.
2.1	Repair wiring harness using connector sleeve	Where several lines are connected.
			AR00.19-D-0100-09A
		Adapter	Fig 11
		Reflector	Fig 8
		Wire stripper	Fig 9
		Welding bead catcher	Fig 3
2.2	Repair wiring harness by means of axial solder connectors	When replacing or inserting line sections.
			AR54.18-D-0100-06A
		Adapter	Fig 11
		Reflector	Fig 8
		Wire stripper	Fig 9
		Welding bead catcher	Fig 3
2.3	Repair wiring harness by crimping	For example, for damaged or oxidized contacts.
			AR00.19-D-0100-03A
		JPT crimping set listed representative for all crimping sets.
		JPT crimping set	Fig 7
		Crimping set overview	Fig 1
		Wire stripper	Fig 9
		Crimp pliers	Fig 5
		Crimp set overview	Fig 6
		New passenger car wiring harness repair kit	Fig 2
		Wiring harness repair kit, basic	Fig 10
2.4	Repair wiring harness by crimping with watertight connections	For damaged or oxidized contacts in wet environments.
			AR00.19-D-0100-04A
		JPT crimping set listed representative for all crimping sets.
		JPT crimping set	Fig 7
		Crimping set overview	Fig 1
		New passenger car wiring harness repair kit	Fig 2
		Wire stripper	Fig 9
		Crimp pliers	Fig 5
		Crimp set overview	Fig 6
		Wiring harness repair kit, basic	Fig 10
2.5	Repairing cable harness by soldering	When using soldering eyes.
			AR00.19-D-0100-05A
		Wire stripper	Fig 9
		Welding bead catcher	Fig 3
3	Protect repair area after cable repairs		AR00.19-D-0100-08A
		If necessary.
4	Checking wiring harness	Checking wiring harness	AR54.18-D-0600-01A
		Electrical connection kit	Fig 4
5	Connect diagnostic system
6	Perform system test in accordance with diagnosis specifications.

Fig 1: Crimping Set Overview (220 589 04 99 01)

Fig 2: New Passenger Car Wiring Harness Repair Kit (220 589 04 99 00)

Fig 3: Welding Bead Catcher (129 589 01 98 00)

Fig 4: Electrical Connection Kit (220 589 00 99 00)

Fig 5: Crimp Pliers (220 589 01 99 10)

Fig 6: Crimp Set Overview (000 589 13 99 01)

Fig 7: JPT Crimping Set (220 589 01 99 05)

Fig 8: Reflector (220 589 01 99 41)

Fig 9: Wire Stripper (220 589 01 99 40)

Fig 10: Wiring Harness Repair Kit, Basic (000 589 13 99 00)

Fig 11: Adapter (220 589 01 99 42)