W210 (and others) insulation breaks off
 

Last weekend I changed the high and low beams on my '02 W210. Easy Peasy.
but alas the 20 year old wire insulation broke off.

Considering tape solves all, I attempted to tape the wires. Futile.

Today, I coated the wires with Hot Glue, formed instant wire insulation, cooled quickly and saved me from burning another fuse.

Success

So simple, coat wires with hot glue. (may not be pretty, but functions as an insulator.)

Good idea on the hot glue, thanks for the heads up.

You know, they make liquid electrical tape in a can, with a brush, for just such a situation.

Probably not the best idea for that location. The engine bay will get hot enought to melt the glue eventually.

The wires are in an even hotter location, the wires in question are the ones inside the headlamp housing. They get real toasty.

I have found the best way to insulate them is to use multicolored heat shrink tubings after depinning the connectors one by one.

Recently replaced the headlamp assemblies due to this wire issue and lens discoloration.

Good luck!!!