General repair methods for wiring harness - AR00.19-P-0100A

MODEL 117, 124, 126, 129, 140, 156, 163, 164, 166, 168, 169, 170, 171, 172, 176, 190, 197, 199, 202, 203, 204, 205, 207, 208, 209, 210, 211, 212, 215, 216, 217, 218, 219, 220, 221, 222, 230, 231, 240, 242, 245, 246, 251, 414, 450, 451, 452, 454, 461, 463

	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
	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 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
	Notes on replacement of safety-relevant and special components		AH00.19-P-1000-08A
	Notes on soldering		AH00.19-P-1000-10A
	Notes on crimping		AH00.19-P-1000-09A
	Assessment of damage in wiring harnesses		AH00.19-P-1000-05A
	Notes on the use of paint scraping nuts on ground connections		AH00.19-P-1000-20A
	Evaluation of high-voltage components		AH54.00-P-6500-01SXH
	Notes on cable protection		AH00.19-P-1000-11A
	Notes on soft soldering		AH00.19-P-1000-07A
	Repair methods for wiring harnesses		AH00.19-P-1000-04A
	Advantages of repairing wiring harnesses		AH00.19-P-1000-03A
	Notes regarding plug connections		AH00.19-P-1000-06A
	Repair wiring harness
1.1	Removing contacts from plugs and connectors	MODEL 117, 124, 126, 129, 140, 156, 163, 164, 166, 168, 169, 170, 171, 172, 176, 190, 197, 199, 202, 203, 204, 205, 207, 208, 209, 210, 211, 212, 215, 216, 217, 218, 219, 220, 221, 222, 230, 231, 240, 242, 245, 246, 251, 414, 450, 451, 452, 454, 461, 463
		If required for wiring harness repair.	AR00.19-P-0120A
	Female contacts and contact pins, installation survey, as-built configuration	MODEL 124, 126, 129, 140, 163, 164, 168, 169, 170, 171, 199, 202, 203, 204, 208, 209, 210, 211, 215, 216, 219, 220, 221, 230, 240, 245, 251, 414, 461, 463 up to 5/31/12	GF00.19-P-7000A
	Plugs and couplings as-built configuration	MODEL 124, 126, 129, 140, 163, 164, 168, 169, 170, 171, 199, 202, 203, 204, 208, 209, 210, 211, 215, 216, 219, 220, 221, 230, 240, 245, 251, 414, 461, 463 up to 5/31/12	GF00.19-P-8000A
1.2	Repair wiring harness by means of solder connector sleeve	MODEL 117, 124, 126, 129, 140, 156, 163, 164, 166, 168, 169, 170, 171, 172, 176, 190, 197, 199, 202, 203, 204, 205, 207, 208, 209, 210, 211, 212, 215, 216, 217, 218, 219, 220, 221, 222, 230, 231, 240, 242, 245, 246, 251, 414, 450, 451, 452, 454, 461, 463 With soldering end sleeves.
			AR00.19-P-0100-09A
		Wiring harness repair kit, basic	Fig 28
		Welding bead catcher	Fig 5
		Wire stripper	Fig 27
		Reflector	Fig 26
		Adapter	Fig 29
		New passenger car wiring harness repair kit	Fig 3
1.3	Repair wiring harness by means of axial solder connectors	MODEL 117, 124, 126, 129, 140, 156, 163, 164, 166, 168, 169, 170, 171, 172, 176, 190, 197, 199, 202, 203, 204, 205, 207, 208, 209, 210, 211, 212, 215, 216, 217, 218, 219, 220, 221, 222, 230, 231, 240, 242, 245, 246, 251, 414, 450, 451, 452, 454, 461, 463 For axial solder connector and conductor cross section ≥ 0.35 mm² .
			AR54.18-P-0100-06A
1.4	Repair wiring harness with conductor cross section of 0.13 mm² using axial solder connector	MODEL 117, 124, 126, 129, 140, 156, 163, 164, 166, 168, 169, 170, 171, 172, 176, 190, 197, 199, 202, 203, 204, 205, 207, 208, 209, 210, 211, 212, 215, 216, 217, 218, 219, 220, 221, 222, 230, 231, 240, 242, 245, 246, 251, 414, 450, 451, 452, 454, 461, 463
		For axial solder connector and conductor cross section of 0.13 mm² .	AR00.19-P-0100-12A
		Wire stripper	Fig 25
1.5	Repair wiring harness by crimping	MODEL 117, 124, 126, 129, 140, 156, 163, 164, 166, 168, 169, 170, 171, 172, 176, 190, 197, 199, 202, 203, 204, 205, 207, 208, 209, 210, 211, 212, 215, 216, 217, 218, 219, 220, 221, 222, 230, 231, 240, 242, 245, 246, 251, 414, 450, 451, 452, 454, 461, 463 With round cable wiring harness.
			AR00.19-P-0100-03A
		Wiring harness repair kit, basic	Fig 28
		Fl. crimping set 6.3_/2.8	Fig 11
		MCP 2.8_crimping set	Fig 13
		MCP 2.8_crimping set	Fig 12
		JPT crimping set	Fig 8
		RK 2.5_crimping set	Fig 7
		Crimp set SLK 2.8	Fig 10
		Crimp pliers	Fig 22
		Wire stripper	Fig 27
		MLK 1.2_crimping set	Fig 17
		MQS crimping set	Fig 19
		MCP 1.2_crimping set	Fig 1
		New passenger car wiring harness repair kit	Fig 3
1.6	Repair flat conductor wiring harness by crimping	MODEL 117, 124, 126, 129, 140, 156, 163, 164, 166, 168, 169, 170, 171, 172, 176, 190, 197, 199, 202, 203, 204, 205, 207, 208, 209, 210, 211, 212, 215, 216, 217, 218, 219, 220, 221, 222, 230, 231, 240, 242, 245, 246, 251, 414, 450, 451, 452, 454, 461, 463 With flat conductor wiring harness.
		MODEL 164, 204, 211, 216, 219, 221, 251	AR00.19-P-0100-10A
		Wiring harness repair kit	Fig 4
1.7	Repair wiring harness by crimping with watertight connections	MODEL 117, 124, 126, 129, 140, 156, 163, 164, 166, 168, 169, 170, 171, 172, 176, 190, 197, 199, 202, 203, 204, 205, 207, 208, 209, 210, 211, 212, 215, 216, 217, 218, 219, 220, 221, 222, 230, 231, 240, 242, 245, 246, 251, 414, 450, 451, 452, 454, 461, 463 If the repair point has to be watertight.
			AR00.19-P-0100-04A
		Wiring harness repair kit, basic	Fig 28
		MCP 2.8_ELA crimping set	Fig 21
		SLK 2.8_crimping set/ELA	Fig 9
		SLK 2.8_ELA crimping set	Fig 23
		Crimp pliers	Fig 22
		Wire stripper	Fig 27
		MCP 2.8_ELA crimping set	Fig 14
		MCP 2.8_ELA crimping set	Fig 15
		JPT ELA crimp set	Fig 16
		MLK 1.2_ELA crimping set	Fig 18
		MQS ELA crimping set	Fig 20
		New passenger car wiring harness repair kit	Fig 3
		MCP 1.2_ELA crimping set	Fig 2
1.8	Repairing cable harness by soldering	MODEL 117, 124, 126, 129, 140, 156, 163, 164, 166, 168, 169, 170, 171, 172, 176, 190, 197, 199, 202, 203, 204, 205, 207, 208, 209, 210, 211, 212, 215, 216, 217, 218, 219, 220, 221, 222, 230, 231, 240, 242, 245, 246, 251, 414, 450, 451, 452, 454, 461, 463 With solder cups.
			AR00.19-P-0100-05A
		Wiring harness repair kit, basic	Fig 28
		Welding bead catcher	Fig 5
		Wire stripper	Fig 27
		New passenger car wiring harness repair kit	Fig 3
1.9	Repair cable harness using rapid connection technology	MODEL 117, 124, 126, 129, 140, 156, 163, 164, 166, 168, 169, 170, 171, 172, 176, 190, 197, 199, 202, 203, 204, 205, 207, 208, 209, 210, 211, 212, 215, 216, 217, 218, 219, 220, 221, 222, 230, 231, 240, 242, 245, 246, 251, 414, 450, 451, 452, 454, 461, 463 With rapid connection technology.
			AR00.19-P-0100-06A
1.10	Protect repair area after cable repairs	MODEL 117, 124, 126, 129, 140, 156, 163, 164, 166, 168, 169, 170, 171, 172, 176, 190, 197, 199, 202, 203, 204, 205, 207, 208, 209, 210, 211, 212, 215, 216, 217, 218, 219, 220, 221, 222, 230, 231, 240, 242, 245, 246, 251, 414, 450, 451, 452, 454, 461, 463
			AR00.19-P-0100-08A
1.11	Checking wiring harness	MODEL 117, 124, 126, 129, 140, 156, 163, 164, 166, 168, 169, 170, 171, 172, 176, 190, 197, 199, 202, 203, 204, 205, 207, 208, 209, 210, 211, 212, 215, 216, 217, 218, 219, 220, 221, 222, 230, 231, 240, 242, 245, 246, 251, 414, 450, 451, 452, 454, 461, 463
			AR54.18-P-0600-01A
		Electrical connection kit	Fig 6
		126-pin socket box	Fig 24

Fig 1: Identifying MCP 1.2 Crimping Set (220 589 04 99 11)

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Fig 2: Identifying MCP 1.2 ELA Crimping Set (220 589 04 99 10)

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

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Fig 4: Identifying Wiring Harness Repair Kit (211 589 01 99 00)

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Fig 5: Identifying Welding Bead Catcher (129 589 01 98 00)

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Fig 6: Identifying Electrical Connection Kit (220 589 00 99 00)

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Fig 7: Identifying RK 2.5 Crimping Set (220 589 01 99 06)

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Fig 8: Identifying JPT Crimping Set (220 589 01 99 05)

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Fig 9: Identifying SLK 2.8 Crimping Set/ELA (220 589 01 99 08)

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Fig 10: Identifying Crimp Set SLK 2.8 (220 589 01 99 07)

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Fig 11: Identifying Fl. Crimping Set 6.3/2.8 (220 589 01 99 01)

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Fig 12: Identifying MCP 2.8 Crimping Set (220 589 01 99 04)

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Fig 13: Identifying MCP 2.8 Crimping Set (220 589 01 99 03)

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Fig 14: Identifying MCP 2.8 ELA Crimping Set (220 589 01 99 80)

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Fig 15: Identifying MCP 2.8 ELA Crimping Set (220 589 01 99 81)

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Fig 16: Identifying JPT ELA Crimp Set (220 589 01 99 82)

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Fig 17: Identifying MLK 1.2 Crimping Set (220 589 01 99 83)

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Fig 18: Identifying MLK 1.2 ELA Crimping Set (220 589 01 99 84)

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Fig 19: Identifying MQS Crimping Set (220 589 01 99 85)

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Fig 20: Identifying MQS ELA Crimping Set (220 589 01 99 86)

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Fig 21: Identifying MCP 2.8 ELA Crimping Set (000 589 13 99 10)

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Fig 22: Identifying Crimp Pliers (220 589 01 99 10)

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Fig 23: Identifying SLK 2.8 ELA Crimping Set (220 589 01 99 09)

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Fig 24: Identifying 126-Pin Socket Box (129 589 00 21 00)

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Fig 25: Identifying Wire Stripper (000 589 30 37 00)

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Fig 26: Identifying Reflector (220 589 01 99 41)

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Fig 27: Identifying Wire Stripper (220 589 01 99 40)

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Fig 28: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)

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Fig 29: Identifying Adapter (220 589 01 99 42)

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