General repair methods for wiring harness

AR00.19-P-0100A

General repair methods for wiring harness

09.12.2019

Model

117, 124, 126, 129, 140, 156, 163, 164, 166, 167, 168, 169, 170, 171, 172, 176, 177, 190, 197, 199, 202, 203, 204, 205, 207, 208, 209, 210, 211, 212, 213, 215, 216, 217, 218, 219, 220, 221, 222, 223, 230, 231, 238, 240, 242, 245, 246, 251, 253, 257, 290, 292, 293, 414, 450, 451, 452, 453, 454, 461, 463

 Warning

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

 Caution

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

 Caution

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

Topical note

General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system

AH00.00-Z-0300-01A

Topical note

Assessment of damage in wiring harnesses

AH00.19-P-1000-05A

Topical note

Notes on replacement of safety-relevant and special components

AH00.19-P-1000-08A

Topical note

Notes on crimping

AH00.19-P-1000-09A

Topical note

Notes on soldering

AH00.19-P-1000-10A

Topical note

Notes on the use of paint scraping nuts on ground connections

Model 117, 156, 166, 167, 172, 176, 177, 190, 205, 213, 217, 222, 223, 238, 242, 246, 253, 257, 290, 292, 293
Model 463
as of model year 2019

AH00.19-P-1000-20A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on battery

AH54.10-P-0001-01A

Advantages of repairing wiring harnesses

AH00.19-P-1000-03A

Repair methods for wiring harnesses

AH00.19-P-1000-04A

Notes regarding plug connections

AH00.19-P-1000-06A

Notes on soft soldering

AH00.19-P-1000-07A

Notes on cable protection

AH00.19-P-1000-11A

Repair wiring harness

1

Remove contacts from plugs, couplings.

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

2

Repair wiring harness by soldering end sleeves.

With soldering end sleeves.

AR00.19-P-0100-09A

 Wiring harness repair kit, basic

*000589139900

 Welding bead catcher

*129589019800

 Wire stripper

*220589019940

 Reflector

*220589019941

 Adapter

*220589019942

 New passenger car wiring harness repair kit

*220589049900

3.1

Repair wiring harness by means of axial solder connectors.

For axial solder connectors and conductor cross-section  0.35 mm2.

AR54.18-P-0100-06A

3.2

Repair wiring harness by means of axial solder connectors.

For axial solder connectors and conductor cross-section 0.13 mm2.

AR00.19-P-0100-12A

 Wire stripper

*000589303700

4

Repair wiring harness by crimping.

With round cable wiring harness.

AR00.19-P-0100-03A

 Wiring harness repair kit, basic

*000589139900

 Fl. crimping set 6.3_/ 2.8

*220589019901

 MCP 2.8_crimping set

*220589019903

 MCP 2.8_crimping set

*220589019904

 JPT crimping set

*220589019905

 RK 2.5_crimping set

*220589019906

 Crimp set SLK 2.8

*220589019907

 Crimp pliers

*220589019910

 Wire stripper

*220589019940

 MLK 1.2_crimping set

*220589019983

 MQS crimping set

*220589019985

 MCP 1.2_crimping set

*220589049911

 New passenger car wiring harness repair kit

*220589049900

5

Repair flat conductor wiring harness by crimping.

Model 164, 204, 211, 216, 219, 221, 251
With flat conductor wiring harness.

AR00.19-P-0100-10A

 Wiring harness repair kit

*211589019900

6

For watertight connections, repair wiring harness by crimping.

If the repair point has to be watertight.

AR00.19-P-0100-04A

 Wiring harness repair kit, basic

*000589139900

 MCP 2.8_ELA crimping set

*000589139910

 SLK 2.8_crimping set / ELA

*220589019908

 SLK 2.8_ELA crimping set

*220589019909

 Crimp pliers

*220589019910

 Wire stripper

*220589019940

 MCP 2.8_ELA crimping set

*220589019980

 MCP 2.8_ELA crimping set

*220589019981

 JPT ELA crimp set

*220589019982

 MLK 1.2_ELA crimping set

*220589019984

 MQS ELA crimping set

*220589019986

 New passenger car wiring harness repair kit

*220589049900

 MCP 1.2_ELA crimping set

*220589049910

7

Repair wiring harness by soldering.

With solder cups.

AR00.19-P-0100-05A

 Wiring harness repair kit, basic

*000589139900

 Welding bead catcher

*129589019800

 Wire stripper

*220589019940

 New passenger car wiring harness repair kit

*220589049900

8

Repair wiring harness by means of rapid connection technology.

With cut&clamp connector.

AR00.19-P-0100-06A

9

Protect repair point after line repair.

AR00.19-P-0100-08A

10

Check wiring harness.

AR54.18-P-0600-01A

 Electrical connection kit

*220589009900

 126-pin socket box

*129589002100