Repairing Wiring Harness Using Solder Connectors - Ar00.19-D-0100-09A

AR00.19-D-0100-09A	Repairing wiring harness using solder connectors
	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

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Fig 1: Reflector (220 589 01 99 41)

Fig 2: Welding Bead Catcher (129 589 01 98 00)

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

Fig 4: Adapter (220 589 01 99 42)

Expose damaged line or plug/connector on wiring harness and separate.
Separate lines in wiring harness offset approx. 45 mm (B).
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 insulation at line ends to approx. 15 mm (D) using wire stripper.
Select connector sleeve based on cable cross-section.
Insert lines into the corresponding connector sleeve (Z) according to the total cable cross-section.
A maximum of seven individual lines may be inserted into each connector sleeve (Z).
Ensure that the connector sleeve (Z) is fully attached to the lines.
Approximately 5 mm, dimension (A), of the stripped line ends should be visible.
Heat up connector sleeve using a heat gun (approx. 400 °C), reflector, adapter, and welding pearl catcher.
Start at tapered end until soldering ring dissolves and covering has completely wrapped itself around the lines.
Check soldered point.
The soldering ring (1) of the connector sleeve (Z) must no longer be visible. The jacketing (2) must make contact with the lines as shown.
Position connector sleeve on line and attach a heat-shrinkable tube or corrugated hose in repair area or wrap with duct tape.
Connector sleeves must not lie directly above one another. Duct tape is used for visual harmonization of the repair point and to protect against chafing. In vehicle areas with higher loads (e.g. engine compartment), duct tape should only be used in combination with other (watertight) safety precautions.

When using heat-shrinkable tubes or corrugated hoses, they may have to be slid over the lines beforehand, depending on the position of the repair point.