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PointedThree : Sedan Forums : W140 S Class : Wire "Micro"-Connector Repair, Mercedes-Method

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Wire "Micro"-Connector Repair, Mercedes-Method

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Posted 10/11/2014 6:05 PM

G-AMG
G-Class DIY Host

Date registered: May 2006
Location: South Texas
Vehicle(s): '04 G55, '80 280GE, '99 S420, '98 E320, 2011 E350
1000

Wire "Micro"-Connector Repair, Mercedes-Method

I know many will think this overly "Esoteric"...

"Ahh, why don't you just grab a pair of Needle-Nose Pliers, and crimp the Connector", or the process of RELEASING the Connectors, "Just take a PaperClip and prise the Connector Out!!"'

Well, being a Noob at Wiring Repair, I did a bit of research, trying to find a method "As close to Factory as Possible".

The following post is as close to what I have found to be the "Factory" method of Wire Connector Repair.

The M-B system of Repair is a rather KLUNKY, and non-intuative system.

First, you need to Find the Connector Housing Part within EPC, then Navigate to the "Connector" position.

Sometimes, the part# contains the Wire Size, sometimes NOT. If "Not" you might have to go to the Wire Diagram to determine this. The "Chart" per below can also help.

You then refer to the "Chart" to determine the Crimp Set#, System Release Tool for that Connection.

The repair then proceeds per below.

I am showing the Crimping Process OUTSIDE of the Vehicle. The Dark interior of the Car, and the Short wire I had to work with? Yielded lousy photos.

The Profile of the "Factory" Crimp is quite a bit more COMPLEX than I realized. Here is a Reference, showing a Good-vs-Bad Crimp:

http://www.digikey.com/Web%20Export/Supplier%20Content/Tyco_8004/PD...

For a more Detailed Explanation:

http://www.shearwaterresearch.com/wp-content/uploads/2012/08/qual_c...

I am posting this on various sub-forums, as the procedure is M-B Generic. Obviously there are an entire SPECTRUM of different Micro-Connectors, including the "ELA" version, which has a WeatherSeal Protection on the non-connecting end of the connector.

Hopefully, this will help others "Learn along with me">

"G"