MERCEDES-BENZ ML350 1997 Complete Repair Manual

REPAIR WIRING HARNESS AS PER SPECIFIED REPAIR METHOD - AR00.19-P-0001A
MODEL 124, 126, 129, 140, 163, 164, 168, 169, 170, 171, 202, 203, 208, 209, 210, 211, 215, 216, 219, 220,
221, 230, 240, 245, 251, 414, 461, 463
Fig. 335: Repair Wiring Harness As Per Specified Repair Method

Repair wiring harness as
per specified repair methodMODEL 124, 126, 129,
140, 163, 164, 168, 169,
170, 171, 202, 203, 208,
209, 210, 211, 215, 216,
219, 220, 221, 230, 240,
245, 251, 414, 461, 463...AR00.19-P-0001A
General repair methods for
wiring harness.MODEL 124, 126, 129,
140, 163, 164, 168, 169,
170, 171, 199, 202, 203,
208, 209, 210, 211, 215,
216, 219, 220, 221, 230,
240, 245, 251, 414, 461,
463...AR00.19-P-0100A
Removing contacts from
plugs and connectorsMODEL 124, 126, 129,
140, 163, 164, 168, 169,
170, 171, 199, 202, 203,
208, 209, 210, 211, 215,
216, 219, 220, 221, 230,
240, 245, 251, 414, 461,
463...AR00.19-P-0120A
Performing basic
programmingMODEL 163AR00.19-P-0200GH
Raising, jacking up vehicleMODEL 163AR00.60-P-1000GH
Figure/item, etc.Work instructions
Notes on replacement of
safety-relevant and
special componentsModel 124, 126, 129, 140,
163, 164, 168, 169, 170, 171,
199, 202, 203, 208, 209, 210, AH00.19-P-1000-08A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 246 © 2006 Mitchell Repair Information Company, LLC.

211, 215, 216, 219, 220, 221,
230, 240, 245, 251, 414, 461
as of 1.4.94, 463
Assessment of damage
in wiring harnessesModel 124, 126, 129, 140,
163, 164, 168, 169, 170, 171,
199, 202, 203, 208, 209, 210,
211, 215, 216, 219, 220, 221,
230, 240, 245, 251, 414, 461,
463AH00.19-P-1000-05A
Assessment of airbag
and belt tensioner units
in accident vehiclesModel 129, 202 up to 30.6.93
Model 124, 126, 140AH91.00-P-0006-01A
Assessment of airbag
and belt tensioner units
in accident vehiclesModel 129 as of 1.7.93, 163,
164, 168, 169, 170, 171, 199,
202 as of 1.7.93, 203, 208,
209, 210, 211, 215, 216, 219,
220, 221, 230, 240, 245, 251,
414, 461 as of 1.4.94, 463,
638, 901, 902, 903, 904, 905,
906, WD1, WD2, WD3, WD6,
WD7, XD1, XD2, XD3, XD4,
XD5, XD6, XD7, YD1, YD2,
YD3, YD4, YD5, YD6, YD7AH91.00-P-0006-01B
Notes regarding plug
connections AH00.19-P-1000-06A
Advantages of repairing
wiring harnesses AH00.19-P-1000-03A
Repair methods for
wiring harnesses AH00.19-P-1000-04A
Repair supplemental
restraint system (SRS)
squib wiring harnessModel 124, 129, 140, 163,
164, 168, 169, 170, 171, 202,
203, 208, 209, 210, 211, 215,
216, 219, 220, 221, 230, 240,
245, 251, 414, 461 as of
1.4.94, 463
Model 126 with code 291
Airbag for driver and front
passenger (for front passenger
only if driver airbag standard)
Model 126 with code 442
Airbag in steering wheelAR54.18-P-0600A
Repairing wiring
harnessModel 168.031 ## up to
180747 with engine 166.940
Engine wiring harness at body
side
Model 168.033 ## up to AR54.18-P-0100GF

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 247 © 2006 Mitchell Repair Information Company, LLC.

180747 with engine 166.960
Engine wiring harness at body
side
Repairing wiring
harnessModel 168.007 with engine
668.941
Engine wiring harness at body
side
Model 168.008 with engine
668.940
Engine wiring harness at body
sideAR54.18-P-0100GD
Repairing wiring
harnessModel 168.007 with engine
668.941
Engine wiring harness
Model 168.008 with engine
668.940
Engine wiring harnessAR54.18-P-0100GC
Install left front repair
wiring harnessModel
168.007/008/031/032/033
Only vehicles with one-piece
wiring harnessAR54.18-P-0700GC
Install right front repair
wiring harnessModel
168.007/008/031/032/033
Only vehicles with one-piece
wiring harnessAR54.18-P-0701GC
Install left rear repair
wiring harnessModel
168.007/008/031/032/033
Only vehicles with one-piece
wiring harnessAR54.18-P-0702GC
Install right rear repair
wiring harnessModel
168.007/008/031/032/033
Only vehicles with one-piece
wiring harnessAR54.18-P-0703GC
General repair method
for wiring harness. AR00.19-P-0100A
Checking wiring harness AR54.18-P-0600-01A

Electrical connection setFig. 336
126-pin socket boxFig. 337

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 248 © 2006 Mitchell Repair Information Company, LLC.

Fig. 336: Identifying Electrical Connection Kit (220 589 00 99 00)
Fig. 337: Identifying 126
-Pin Socket Box (129 589 00 21 00)
REPAIR WIRING HA RNESS BY CRIMPING - AR00.19-P-0100-03A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 249 © 2006 Mitchell Repair Information Company, LLC.

Fig. 338: Identifying New Passe nger Vehicle Wiring Harness Repair Kit (220 589 04 99 00)
Fig. 339: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)

Fig. 340: Identifying Wiring Ha rness Repair Kit (000 589 02 99 00)

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 250 © 2006 Mitchell Repair Information Company, LLC.

Fig. 341: Identifying Crimp Pliers (220 589 01 99 10)
Fig. 342: Identifying Wi re Stripper (220 589 01 99 01)

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 251 © 2006 Mitchell Repair Information Company, LLC.

Fig. 343: Identifying FL. Crim ping Kit 6.3/2.8 (220 589 01 99 83)
Fig. 344: Identifying MQS Crimping Set (220 589 01 99 85)

Fig. 345: Identifying MLK 1.2 Crimping Set (220 589 01 99 83)

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 252 © 2006 Mitchell Repair Information Company, LLC.

Fig. 346: Identifying MCP 2.8 Crimping Set (220 589 01 99 03)
Fig. 347: Identifying MCP 2.8 Crimping Set (220 589 01 99 04)

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 253 © 2006 Mitchell Repair Information Company, LLC.

Fig. 348: Identifying JPT Cr imping Set (220 589 01 99 05)
Fig. 349: Identifying RK 2.5 Crimping Set (220 589 01 99 06)

Fig. 350: Identifying SLK 2.8 Crimping Set (220 589 01 99 07)

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 254 © 2006 Mitchell Repair Information Company, LLC.

Fig. 351: Identifying MCP 1.2 Crimping Set (220 589 04 99 11)
Table of stripping lengths
1. Select crimp contact based on table in wiring harness repair kit, basic wiring harness repair kit or new
passenger car wiring harness repair kit .
2. Strip cable in accordance with table using wire stripper .
Damaged wire leads can cause changes of the line cross-section and result in an unreliable strength of
the crimp connection.
Shown with circular conductor
Contact familySingle-strand insulationCable cross-section
Length stripped of
insulation
All up to 1.5 mm 24 mm 0.3
All 1.5 to 4 mm 25 + mm 0.3

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 255 © 2006 Mitchell Repair Information Company, LLC.