Repair Methods For Wiring Harnesses - AH00.19-P-1000-04A
Model all (4xWD, CAR, Light transporter, smart)
Repair method summary
The following methods are approved by Daimler for the repair of wiring harnesses on Mercedes-Benz cars:
Repair methods:
- Crimping
- End sleeve (Raychem)
- Axial solder connection (Raychem)
- Combination of Raychem and cable tail
- Soldering
- Rapid connection technology
- Flat conductor pliers
Application
Individual cases must be analyzed in detail to decide which repair methods can or should be used for wiring harnesses (lines, contacts and connector couplings).
Crimping repair method
In crimping, the cable that has been stripped to dimension (a) beforehand using a preformed die is crimped to the contact (PIN) in special pliers. Crimping is performed quickly and with ease. A special crimper is required.
Only lines up to 4 mm2
may be crimped.
Raychem repair method
Special end sleeves are used in this method. The end sleeves contain the solder and have insulation and a seal. A special heat gun, which is fitted with a special reflector, provides heat input for soldering and shrinking the insulation.
The temperature for this repair method is 400°C.
Raychem is the manufacturer of the end sleeves which are required for this method. The Raychem repair method is mainly used for integrating repair wiring harnesses (cable tails).
Combination of Raychem repair method and cable tail repair
Cable tails are prefabricated line part kits available as a Mercedes-Benz replacement part. They have the appropriate cable cross-sections and crimped contacts. The Raychem repair method is intended for the integration of cable tails into the wiring harnesses.
Soldering repair method
The strands of the cable (2) are soldered in the solder contact (axial or radial version) (1) using a soldering iron. Commercially available solder is used for the soldered connection. This method is only to be used for repairing connector couplings.
Repair method using rapid connection technology
This method uses special rapid-connection wire connector blocks. Mercedes-Benz permits the 2-, 4-, and 6-pin versions. They contain tin-plated rapid connection contacts, which are pressed together to touch the wires of the cables using pliers. The lines do not have to be separated or stripped.
Can be used for connecting to continuous lines with a cross-section of 0.35 to 0.75 mm2 and as an end-to-end cable connection.
The rapid connection method must only be used inside the vehicle or in the trunk because the connection is not watertight. They are not permissible for CAN lines.
Flat conductor cable repair method
Select crimp sleeves in wiring harness repair kit and insert into tool head of opened manual crimping pliers (2). The flat conductor cable (7) must make contact with the tool head, and the correct edge of the flat conductor cable (7) must make contact with the adjusting stop (3). The adjustment device (4) in the manual crimping pliers (2) must be visible between 2 conductor tracks. Press the manual crimp pliers (2) together all the way. After it has reached the end point, it can be opened again. Remove finished crimp connection.