Repair Wiring Harness By Crimping (With Watertight Connections) - Ar00.19-D-0100-04A

MODEL ALL

Fig 1: Wiring Harness Repair Kit (220 589 01 99 00)

Fig 2: Crimping Set Overview (220 589 04 99 01)

Fig 3: New Passenger Car Wiring Harness Repair Kit (220 589 04 99 00)

Fig 4: Crimp Pliers (220 589 01 99 10)

Fig 5: Crimp Set Overview (000 589 13 99 01)

Fig 6: JPT Crimping Set (220 589 01 99 05)

Fig 7: Wire Stripper (220 589 01 99 40)

Fig 8: Wiring Harness Repair Kit, Basic (000 589 13 99 00)

Select crimp contact (1) in EPC.
Strip wire (2) using wire stripper.
Do not damage the wire strands.

Damaged wire strands can change the wire cross-section and result in an insufficient crimp connection strength.

With wire cross-sections of up to 1.5 mm² , the stripping length (a) is 4 mm, and with wire cross-sections of 1.5 mm² to 4 mm² , the stripping length (a) is 5 mm.
Push on the single-wire insulation (3) with the sealing lips at the front onto the wire (2) and align to dimension (b) = maximum 1 mm.
Select crimping set (4) for manual crimp pliers (5).
Select crimping set (4) according to crimping set overview in basic wiring harness repair kit or crimping set overview in wiring harness repair kit supplement for passenger cars.
Install crimping set (4) in manual crimp pliers (5).
Fit positioner (6) to manual crimp pliers (5).
Insert crimp contact (1) as far as it will go into the positioner (6) and the die set (4).
Close crimp pliers (5), until crimp contact (1) is fixed in die set (4).
The crimp contact (1) must not yet be deformed.

Otherwise, the line cannot be correctly inserted into the crimp contact (1).
Insert line (2) with single-wire insulation (3) into crimp contact (1) (arrow).
Make sure that all wire strands of the line (2) and the single-strand insulation (3) are lying neatly in the crimp contact (1).
Squeeze crimp pliers (5) until the end pressure point is reached and remove finished crimped connection.
The manual crimp pliers (5) must be squeezed until the end pressure point is reached before they will open again.
Check crimp connection for correct deformation and filling.
Correct crimp connection (A): The strands of the line are evenly enclosed. The crimp tab is evenly shaped.

Incorrect crimp connection (B): The crimp tab has the wrong cross-section and is not completely filled.

Incorrect crimp connection (C): The individual strands are partially outside the crimp tab. The crimp tab is too full.

Incorrect crimp connection (D): The crimping claws are touching the crimping base, crimp tab is deformed and damaged.
Check crimp connection for proper enclosure.
Single strand insulation must not be pinched. Otherwise water ingress can cause contact corrosion.

Insulation and single-strand insulation must be positioned in the center and enclosed completely by the crimp tab and they must be able to take up tensile force.

Correct crimp connection (A): The strands are correctly enclosed by the tab. Insulation and single-strand insulation are enclosed correctly by the large shackle. All parts can withstand the required tensile force.

Incorrect crimp connection (B): The single-strand insulation is not enclosed by the tab due to incorrect insertion when crimping.

Incorrect crimp connection (C): The crimping surface of the single-strand insulation is damaged because the wrong die set or wrong single-strand insulation was used.
Check crimped connection for correct length and spacing of strands and insulation, as well as position and condition of seal.
Correct crimp connection (A): Insulation and strands are of the correct length in the tabs. Correct distance between the single-strand insulation and the end of the insulation.

Incorrect crimp connection (B): The single-strand insulation is damaged due to insufficient spacing between the seal and the end of the insulation.

Incorrect crimp connection (C): Stripped strands are too long, single-strand insulation has therefore not been crimped.