MERCEDES-BENZ ML430 1997 Complete Repair Manual

Fig. 567: Pushing Slide Valv e Out Of Last Detent - Shown On A 1-Pin RK 2.5 Coupling
Secondary release on version with lock tab (RK 2.5)
1. Using a suitable tool (1), open the lock tab (2) in direction shown by arrow.
Shown on a 2-pin RK 2.5 coupling
Fig. 568: Opening Lock Tab
- Shown On A 2-Pin RK 2.5 Coupling
Secondary release on version with secondary contact retainer (RK 2.5)
1. Move contact fuse (1) into pre-locking position using a suitable tool.
Shown on a 12-pin RK 2.5 coupling

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:51 PMPage 356 © 2006 Mitchell Repair Information Company, LLC.

Fig. 569: Moving Contact Fuse - Shown On A 12-Pin RK 2.5 Coupling
Unpin female contacts from coupling (RK 2.5)
1. Insert release tool with RK 2.5 ejector into the contact cavity of the coupling (1) from the front end.
In this step, the sleeve (4) of the tool compresses the spring shackles on the female contact (2).
2. By means of the plunger (3) of the release tool with RK 2.5 ejector , press the contact pin (2) against
the spring force of the tool out of the housing seat.
Fig. 570: Female Contacts From Coupling (RK 2.5)

3. Gently pull the respective line to remove the female contact (2) from the coupling (1).

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:51 PMPage 357 © 2006 Mitchell Repair Information Company, LLC.

REMOVE CONTACTS FROM 2.5 ROUND PLUG CONTACT PLUG - AR00.19-P-0120-16A
Fig. 571: Identifying Wiring Harness Repair Kit, Supplement Fo r Passenger Cars (220 589 04 99 00)
Fig. 572: 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 3:47:51 PMPage 358 © 2006 Mitchell Repair Information Company, LLC.

Fig. 573: Identifying Wiring Harness Repair Kit (220 589 01 99 30)
Fig. 574: Identifying Release Tool With RK 2.5 Ejector (220 589 01 99 30)
Secondary release on versio n with slide valve (RK 2.5)
1. Using a suitable tool (1), push the slide valve (2) out of the last detent in direction shown by arrow.
Shown on a 1-pin RK 2.5 plug
Fig. 575: Pushing Slide Valve
- Shown On A 1-Pin RK 2.5 Plug
Secondary release on version with contact retainer (RK 2.5)
1. Using a suitable tool (1), ope n the contact retainer (2).
Shown on a 2-pin RK 2.5 plug

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:51 PMPage 359 © 2006 Mitchell Repair Information Company, LLC.

Fig. 576: Opening Contact Retainer - Shown On A 2-Pin RK 2.5 Plug
Secondary release on version with secondary retainer (RK 2.5)
1. Using a suitable tool, slide the secondary retainer (1) to the pre-locking position.
Shown on a 12-pin RK 2.5 plug

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:51 PMPage 360 © 2006 Mitchell Repair Information Company, LLC.

Fig. 577: Locating Secondary Retainer - Shown On A 12-Pin RK 2.5 Plug
Secondary release on version with lock tab (RK 2.5)
1. Using a suitable tool, slide the lock tab to the pre-locking position. Shown on an 8-pin RK 2.5 plug
Fig. 578: Sliding Lock Tab
- Shown On An 8-Pin RK 2.5 Plug
Unpin contact pins fr om the plug (RK 2.5)
1. Insert release tool with RK 2.5 ejector into th e contact cavity of the plug (1) from the front end.
In this step, the sleeve (4) of the release tool compresses the spring shackles on the contact-pin (2).
2. Press the plunger (3) on the release tool with RK 2.5 ejector to apply spring pressure to force the
contact pin (2) from its seat in the connector housin
g.

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:51 PMPage 361 © 2006 Mitchell Repair Information Company, LLC.

Fig. 579: Contact Pins From Plug (RK 2.5)
3. Gently pull the respective line to remove the contact pin (2) from the plug (1).
REMOVE CONTACTS FROM 2.5 SOLDER CONTACT COUPLING ROUND PLUG CONTACT - AR00.19-P-0120-17A
Fig. 580: Identifying Wiring Harness Repair Kit, Supplement For Passenger Cars (220 589 04 99 00)

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:51 PMPage 362 © 2006 Mitchell Repair Information Company, LLC.

Fig. 581: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)
Fig. 582: Identifying Wiring Ha rness Repair Kit (220 589 02 99 00)

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:51 PMPage 363 © 2006 Mitchell Repair Information Company, LLC.

Fig. 583: Identifying Blad e Holder With Clamping Pliers (220 589 01 99 50)
Fig. 584: Identifying RK 2.5 Blad e Solder Contact (220 589 01 99 53)

Secondary release on version with slide valve (RK 2.5 solder contact)

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:51 PMPage 364 © 2006 Mitchell Repair Information Company, LLC.

1. Insert a suitable tool under the slide valve cap (1).
2. Using a suitable tool, press the slide valve out of the last detent in direction shown by arrow.
Shown on a 4-pin RK 2.5 solder contact coupling
Fig. 585: Pressing Slide Valve Out Of Last Detent
- Shown On A 4-Pin RK 2.5 Solder Contact Coupling
Secondary release on version with ret aining clamp (RK 2.5 solder contact)
1. Using a suitable tool, pry up the side clips of the retaining clamp (1).
2. Open the retaining bracket (1) in direction shown by arrow.
Shown on a 2-pin RK 2.5 solder contact coupling
Fig. 586: Opening Retaining Bracket
- Shown On A 2-Pin RK 2.5 Solder Contact Coupling
Unpin contact from couplin g (RK 2, 5 solder contact)
1. Insert blade holder with clamping pliers and blade for RK 2.5 solder contact from the back side into
the cable duct of the coupling.
Align the sleeve of the blade for RK 2.5 solder c ontact with the spring shackle (1) in the coupling.
This step presses the sprin
g shackle (1) in the coupling into position.

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:51 PMPage 365 © 2006 Mitchell Repair Information Company, LLC.