MERCEDES-BENZ ML350 1997 Complete Repair Manual

Fig. 394: Wrapping Insulating Tape Around Corrugated Hose At Both Ends
PROTECT REPAIR AREA AFTER CABLE REPAIRS - AR00.19-P-0100-08C
Protect repair area by wrapping fabric tape around it.
1. Wrap fabric tape around repair area as per original condition.
Fabric tape restores the appearan ce of the repair area and provides pr otection from chafing. In parts of
vehicle subject to high levels of st ress (e.g. engine compartment) fabric tape should only be used together
with other (watertight) protective measures.
REPAIRING WIRING HARN ESS USING SOLDER CONNECTORS - AR00.19-P-0100-09A
Fig. 395: Identifying New Passe nger Vehicle Wiring Harness Repair Kit (220 589 04 99 00)
Fig. 396: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:49 PMPage 276 © 2006 Mitchell Repair Information Company, LLC.

Fig. 397: Identifying Wiring Ha rness Repair Kit (220 589 02 99 00)
Fig. 398: Identifying Wi re Stripper (220 589 01 99 40)

Fig. 399: Identifying Reflector (220 589 01 99 41)

Fig. 400: Identifying Adapter (220 589 01 99 42)

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Fig. 401: Identifying Welding Bead Catcher (129 589 01 98 00)
Workshop equipment/MB testers
1. Expose damaged cable or plug/coupling in easily accessible position and cut off.
Separate cores in wiring harness offset by approx. 45 mm (B).
Fig. 402: Identifying Wiring Harness Offset Distance

2. Cut new section of cable to match old cable.
When cutting the line, add an allowance of approx. 50 mm (C) for loop formation (strain-relief).
3. Remove approx. 15 mm (D) of insulation at line ends.
4. Select solder cup as shown in table below.
Fig. 403: Identifying Dimensions For Cutting Line
WE58.40-Z-1007-03AHot-air gun

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Saturday, October 02, 2010 3:47:49 PMPage 278 © 2006 Mitchell Repair Information Company, LLC.

A maximum of seven individual cables maybe inserted into each solder connection.
5. Insert the cables into the corresponding solder connections (Z) according to the total cable cross-section.
6. Ensure that solder connection (Z) is fully rotated onto cables.
Approx. 5 mm (A) of the stripped line ends should be visible.
Fig. 404: Rotating Solder Connection Onto Cables

7. Heat solder connector using a heat gun (approx. 400°C).
Start at tapered end until soldering ring has dissolved and sleeve has correctly wrapped itself around
the line.
Fig. 405: Heating Solder Connector Using Heat Gun
Selection table for solder connector
Total copper cross-
section A
tot.
Overall diameter with
insulationLength stripped of
insulationColor code
0.7 to 2.4 mm2 3.3 mm15 mmgreen
2.0 to 4.0 mm2 4.5 mm15 mmred
3.5 to 8.0 mm2 7.0 mm15 mmblue
7.5 to 12 mm 2 9.0 mm15 mmYellow

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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8. Check soldered point.
The soldering ring (1) of the solder connection (Z)must no longer be visible. The covering (2) must be
resting smoothly against the cables.
Fig. 406: Identifying Solder Connection
- Correct/Incorrect
9. Fit solder connection onto cable and wrap fabric tape around repaired area.
Solder connections must not be positioned directly one above the other.
Fig. 407: Identifying Solder Connection

GENERAL REPAIR METHODS FOR WIRING HARNESS. - AR00.19-P-0100A
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
Figure/item, etc.Work instructions
Risk of injury to skin and
eyes caused by handling
hot or glowing objects.Wear safety gloves,
protective clothing and
safety glasses, if
necessary.AS00.00-Z-0002-01A
Risk of injury caused by
burns to skin and eyes. Work in well ventilated
rooms only. Wear safety AS00.19-Z-0001-01A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Saturday, October 02, 2010 3:47:49 PMPage 280 © 2006 Mitchell Repair Information Company, LLC.

Risk of poisoning caused
by inhaling fumes when
working with heat-
shrinkable tubing.glasses with side
protection and protective
gloves.
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
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, 211, 215,
216, 219, 220, 221, 230,
240, 245, 251, 414, 461
as of 1.4.94, 463AH00.19-P-1000-08A
Assessment of damage in
wiring harnesses AH00.19-P-1000-05A
Notes on crimping AH00.19-P-1000-09A
Notes on soldering AH00.19-P-1000-10A
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
Notes on soft soldering AH00.19-P-1000-07A
Notes on cable protection AH00.19-P-1000-11A
Removing contacts from
plugs and connectors AR00.19-P-0120A
Repairing wiring harness
using solder connectors AR00.19-P-0100-09A
Repair wiring harness by
crimping AR00.19-P-0100-03A
Repair flat conductor
wiring harness by
crimpingModel 164, 211, 216,
219, 221, 251AR00.19-P-0100-10A
Repair wiring harness by
crimping (with watertight
connections) AR00.19-P-0100-04A
Repairing cable harness AR00.19-P-0100-05A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Saturday, October 02, 2010 3:47:49 PMPage 281 © 2006 Mitchell Repair Information Company, LLC.

REMOVE CONTACTS FROM SENSOR SPADE- TYPE CONTACT PLUG - AR00.19-P-0120-01A
Fig. 408: Identifying Wiring Harness Repair Kit, Supplement Fo r Passenger Cars (220 589 04 99 00)
Fig. 409: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)
by soldering
Repair cable harness using
rapid connection
technology AR00.19-P-0100-06A
Protect repair area after
cable repairsHeat-shrinkable tubeAR00.19-P-0100-08A
Protect repair area after
cable repairsCorrugated tubeAR00.19-P-0100-08B
Protect repair area after
cable repairsFabric tapeAR00.19-P-0100-08C
Checking wiring harness AR54.18-P-0600-01A
Plugs and couplings as-
built configuration GF00.19-P-8000A
Female contacts and
contact pins, installation
survey, as-built
configuration GF00.19-P-7000A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Saturday, October 02, 2010 3:47:49 PMPage 282 © 2006 Mitchell Repair Information Company, LLC.

Fig. 410: Identifying Wiring Ha rness Repair Kit (220 589 02 99 00)
Fig. 411: Identifying Blad e Holder With Clamping Pliers (220 589 01 99 50)

Fig. 412: Identifying SLK 2.8
- 97 Blade (220 589 01 99 63)
Unpin contact pins from the plug (SLK design 97)
1. Insert blade holder with clamping pliers and SLK 2.8 - 97 blade fro m front side into contact cavity
of connector housing (4).
Both spring shackles on the contact pin (7) are pre ssed together and, simultaneously, the locking tab
(5) of the connector housing (4) is lifted.
2. Remove contact pin (7) from connector housin
g (4) by gently pulling the corresponding line.

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Fig. 413: Unpinning Contact Pins From Plug (SLK Design 97)
Rocking the contact pin back and forth, thus maki ng use of the full housing tolerance, may help to
unpin the contact.
REMOVE CONTACTS FROM SENSOR LAMINATED CONTAC T PLUG - AR00.19-P-0120-01B
Fig. 414: Identifying New Passenger Vehicle Wiring Harness Repair Kit (220 589 04 99 00)

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Saturday, October 02, 2010 3:47:49 PMPage 284 © 2006 Mitchell Repair Information Company, LLC.

Fig. 415: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)
Fig. 416: Identifying Wiring Ha rness Repair Kit (220 589 02 99 00)
Fig. 417: Identifying Blad e Holder With Clamping Pliers (220 589 02 99 50)

Fig. 418: Identifying SLK 2.8 Blade (220 589 02 99 62)

Secondary unlocking for versio n with contact retainer (SLK)
1. Using a suitable tool, push tabs of contact retainer (1) in direction of arrow out of locked position.
Shown on 2-pin SLK connector

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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