General repair methods for wiring harness

AR00.19-P-0100A

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