MERCEDES-BENZ ML430 1997 Complete Repair Manual

Soft soldering materials
The alloy (mainly lead and tin) of the solder determines its melting point and thus the working temperature for
the soft soldering process. Additives modify the properties. Silver components improve e.g. the surface and the
joining properties.
The identification of the soft solders is according to DIN 1707.
Example:
L-Sn60PbCu2.
This solder consists of 60 % tin (Sn 60), max. 2 % copper
(Cu 2), the remainder is lead (Pb).
The melting point range is between 183°C and 190°C.
In the electrical system/electronic sector for vehicles, fast solders with a melting point range of approx. 180°C
to 200°C should used. These solders are available in the form of wires. They have flux from resins dissolved in
alcohol (e.g. colophonium) in their hollow center.
Soldering equipment
Soldering equipment with soldering tips that can reach a temperature of 250°C to 300°C are suitable for the
repairs specified by DaimlerChrysler. The aim is to use automatic temperature-regulated equipment (e.g.
soldering stations).
Preparation, general
Use suitable work clothing.
Use safety glasses.
Use any available soldering fume extractors, aeration.
Verify clamping devices and work surfaces.
Clean soldering tips with small wet sponge.
Protect surrounding working area from heat damage.
Preconditions for soldering
Soldering points must be clean, free of grease and oxides.
NOTES ON REPLACEMENT OF SAFETY-RELEVANT AND SPECIAL COMPONENTS - AH00.19-P-1000-08A
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 as of 1.4.94, 463

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Plugs and couplings. with yellow, orange or red housing colors are reserved for safety and restraint systems
(SRS) and roll bars.
Observe the following when repairing couplings for squibs (SRS systems):
The repair area must be between 100 mm and 1000 mm behind the squib. Cables which have already been
repaired are provided with a yellow marking. This is to be applied retroactively to repair lines without color
marking.
Carry out the first repair as close to the plug as possible. In the case of subsequent repairs the old soldered
connectors should be removed and the new ones should be attached behind them, the wiring harness should be
replaced if necessary.
Before cutting through the lines it is absolutely essential to assign the lines to the corresponding pins in
accordance with the wiring diagram. Do not mix up the pin assignment.
The line colors of the repair kit may deviate from the original fitting
Screened lines and light plastic-sheathed cable must never be repaired
In general the following applies to cable repair:
If more than ten lines per branch-off line are damaged, the wiring harness module must be replaced.
Overview (lines/contacts)
Overview (lines/contacts to components)
Lines/contacts (Function)Scope affected
CableContact
Radio antenna linesExchange wiring harness/lineExchange wiring harness/line
Navigation antenna linesExchange wiring harness/lineExchange wiring harness/line
Emergency call system antenna
linesExchange wiring harness/lineExchange wiring harness/line
Telephone antenna linesExchange wiring harness/lineExchange wiring harness/line
Radio antenna linesExchange wiring harness/lineExchange wiring harness/line
TV-antenna linesExchange wiring harness/lineExchange wiring harness/line
D2B (fiber optic cable)Exchange wiring harness/lineExchange wiring harness/line
MOST (fiber optic cable)Exchange wiring harness/lineExchange wiring harness/line
Telephone handset linesExchange wiring harness/lineExchange wiring harness/line
ESP/SBC cablesExchange wiring harness/lineExchange wiring harness/line
Lines/contacts for the following
componentsScope affected
CableContact
Airbag control unit couplingExchange wiring harnessExchange wiring harness
Squibs coupling (SRS systems)Install repair wiring harnessInstall repair wiring harness

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Saturday, October 02, 2010 3:47:44 PMPage 27 © 2006 Mitchell Repair Information Company, LLC.

NOTES ON CRIMPING - AH00.19-P-1000-09A
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
1. Check crimped connection for deformation and ensure that the wires fill the crimp tab correctly (cross-
section of enclosed wires).
Correct crimped connection (A):
The strands of the cable are evenly enclosed.
The crimp tab is evenly shaped.
Incorrect crimped connection (B):
The crimp tab has an incorrect cross-section and is not full enough.
Incorrect crimped connection (C):
Individual wire strands are outside the crimp shackle.
The crimp tab is too full.
Incorrect crimped connection (D):
The crimp claws touch the bottom of the crimped fitting.
The crimp tab is too full.
The crimp tab is deformed and therefore damaged.
Shown with circular conductor

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Saturday, October 02, 2010 3:47:44 PMPage 28 © 2006 Mitchell Repair Information Company, LLC.

Fig. 12: Cross-Section Of Enclosed Wires - Correct And Incorrect
2. Check crimped connection (ensure all wires are enclosed correctly).
Correct crimped connection (A):
Leads (3) enclosed correctly by the tab (2).
Insulation is enclosed correctly by the tab (1).
Incorrect crimped connection (B, C):
Leads (3) are damaged due to deformed tab (2).
Insulation is pinched by deformed tab (1) and damaged.
Shown with circular conductor

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Saturday, October 02, 2010 3:47:44 PMPage 29 © 2006 Mitchell Repair Information Company, LLC.

Fig. 13: Identifying Crimped Connection - Correct And Incorrect (1 Of 2)
3. Check crimped connection (ensure that wires and insulation are correct length).
Correct crimped connection (A):
Correct length of insulation is enclosed by the shackle (1).
Wires (3) are the correct length in the tab (2).
Incorrect crimped connection (B):
Insulation is too short and is not correctly enclosed by the tab (1).
Therefore insulation cannot withstand the required tensile load.
Incorrect crimped connection (C, D):
Wire strands (3) are too long.
Leads (3) are too short.
Shown with circular conductor

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 30 © 2006 Mitchell Repair Information Company, LLC.

Fig. 14: Identifying Crimped Connection - Correct And Incorrect (2 Of 2)
NOTES ON SOLDERING - AH00.19-P-1000-10A
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
Evenly heat parts to be joined and solder. Avoid heat-dissipating mounts and brackets. The soldering process
lasts between 2 and 4 seconds for the joining of wires and component connections, depending on the cross-
section.
The same time must be fixed up to hardening.
Unnecessarily high heating and associated damage to components must be avoided.
During pauses in soldering, it must be ensured that the soldering tip remains adequately tin-plated.
Surface of the soldering join
Correct soldering join (A):
The solder surface (4) is smooth, shiny, no sharp edges, no interruptions, fluid and free of residues and
oxidation.
Incorrect soldering join (B):
The surface of the solder (4) is matt and uneven, it has sharp-edged ends, interruptions, has not flown, covered
with residue.

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Saturday, October 02, 2010 3:47:44 PMPage 31 © 2006 Mitchell Repair Information Company, LLC.

Fig. 15: Identifying Surface Of Soldering Join - Correct And Incorrect
Wire position and contour of soldering join
Correct soldering join (A):
The distance (a) between the solder connector (2) and the line insulation is about 1 mm. The soldered area does
not extend beyond the collar of the solder connector (2). Solder flows in a radius in the direction of the line
insulation and surrounds at least 2/3 of the lead outside the solder connector (2). There are no bare copper wires
visible in the soldering area.
Incorrect soldering joint (B):
If the distance (a) between the solder connector (2) and the line insulation (a) is greater than 2 mm, the line is
incorrectly inserted. The solder protrudes beyond the extension line from the collar of the solder connector (b).
The solder flows in the wrong direction, the transition from solder to lead is jagged, the solder surface (3) has
not flown and is thus a dr
y solder joint.

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Saturday, October 02, 2010 3:47:44 PMPage 32 © 2006 Mitchell Repair Information Company, LLC.

Fig. 16: Identifying Wire Position And Contour Of Soldering Join - Correct And Incorrect
Solder covering and solder quantity for the soldering join
Correct soldering join (A):
The quantity of solder (4) is adequate. Lead of wire (1) is completely surrounded. Solder connector (2) is not
covered with solder (4) around the collar.
Incorrect soldering join (B):
The quantity of solder (4) is inadequate. Lead of wi re (1) is not completely surrounded. Single wires are not
incorporated by the solder (4).
Fig. 17: Identifying Solder Covering A nd Solder Quantity For Soldering Join
- Correct And Incorrect
NOTES ON CABLE PROTECTION - AH00.19-P-1000-11A
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
General
An attempt should be made to restor e the cable protection to its original condition after all repairs to wiring
harnesses.

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Saturday, October 02, 2010 3:47:44 PMPage 33 © 2006 Mitchell Repair Information Company, LLC.

In areas exposed to particularly high stresses (dampness, scouring), additional safety precautions may however
be required.
The following measures are recommended depending on the application.
Protect repair area using:
Heat-shrinkable tube
Corrugated tube
Wrapping with fabric tape
Spaghetti insulation
BASIC KNOWLEDGE
MODEL SURVEY - GF00.10-P-0025-01I
MAJOR ASSEMBLY OVERVIEW - GF00.10-P-0025-02I
COMPLETE VEHICLE, MODEL/COMPONENT INSTALLATION SURVEY, BUILD CONDITION - GF00.10-P-0801I
MODEL 163
163.1163.11163.113ML 270 CDI
163.12163.128ML 400 CDI
163.13163.136ML 230
163.15163.154ML 320
163.157ML 350
163.17163.172ML 430
163.174ML 55 AMG
163.175ML 500
Sales
designationModelEngineManual
transmissionAutomatic
transmissionSteering gear
ML 270 CDI163.113612.963716.644722.661-
ML400CDI163.128628.963-722.666
722.673-
ML 230163.136111.977717.461722.660-
ML 320163.154112.942-722.662-
ML 350163.157112.970-722.674-
ML 430163.172113.942-722.663-
ML 55 AMG163.174113.981-722.666-
ML 500163.175113.965-722.666-

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 34 © 2006 Mitchell Repair Information Company, LLC.

Fig. 18: Identifying Complete Vehicle
FEMALE CONTACTS AND CONTACT PINS, INSTALLATION SURVEY, AS-BUILT CONFIGURATION - GF00.19-P-7000A
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
Fig. 19: Identifying Junior Power Timer (JPT) Pin
Component surveyModel 163GF00.10-P-0025-02I
Model surveyModel 163GF00.10-P-0025-01I

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 35 © 2006 Mitchell Repair Information Company, LLC.