MERCEDES-BENZ ML430 1997 Complete Repair Manual

2. Now gently pull the female contact, together with the blade holder, with clamping pliers and blade for
RK 2.5 solder contact to remove them from the back of the coupling.
Fig. 587: Contact From Coupling (RK 2, 5 Solder Contact)

REMOVE CONTACTS FROM 2.5 SOLDER CONTACT PLUG ROUND PLUG CONTACT - AR00.19-P-0120-18A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:51 PMPage 366 © 2006 Mitchell Repair Information Company, LLC.

Fig. 588: Identifying Wiring Ha rness Repair Kit, Supplement Fo r Passenger Cars (220 589 04 99 00)
Fig. 589: 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 367 © 2006 Mitchell Repair Information Company, LLC.

Fig. 590: Identifying Wiring Ha rness Repair Kit (220 589 02 99 00)
Fig. 591: Identifying Blad e Holder With Clamping Pliers (220 589 01 99 50)

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:51 PMPage 368 © 2006 Mitchell Repair Information Company, LLC.

Fig. 592: 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)
1. Insert a suitable tool under the slide valve cap (1) and press the slide valve out of the last detent in
direction shown by arrow.
Shown on a 4-pin RK 2.5 solder contact plug
Fig. 593: Pressing Slide Valve Out Of Last Detent
- Shown On A 4-Pin RK 2.5 Solder Contact Plug
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 clamp (1).
Shown on a 2-pin RK 2.5 solder contact plug

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:51 PMPage 369 © 2006 Mitchell Repair Information Company, LLC.

Fig. 594: Opening Retaining Clamp - Shown On A 2-Pin RK 2.5 Solder Contact Plug
Unpin contact from the plug (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 plug.
Align the sleeve of the blade for RK 2.5 solder contact with the spring shackle (1) in the plug
housing.
This step presses on the spring shackle (1) of the plug.
2. Now gently pull the contact pin, together with the blade holder, with clamping pliers and blade for RK
2.5 solder contact to remove it from the back of the plug.
Fig. 595: Contact From Plug (RK 2, 5 Solder Contact)

REMOVE CONTACTS FROM SPADE-TYPE CONTACT SYSTEM COUPLING - AR00.19-P-0120-19A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:51 PMPage 370 © 2006 Mitchell Repair Information Company, LLC.

Fig. 596: Identifying New Passe nger Vehicle Wiring Harness Repair Kit (220 589 04 99 00)
Fig. 597: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)

Fig. 598: 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 371 © 2006 Mitchell Repair Information Company, LLC.

Fig. 599: Identifying Unlocking Device With RK 1.5 Ejector (220 589 01 99 20)
Unpin female contacts from coupling (LKS 1.5)
1. Insert release tool with RK 1.5 ejector i033 into the contact cavity of the connector (1) from the front
end.
In this step, the sleeve (3) of the release tool with RK 1.5 ejector compresses the spring shackles on
the female contact (2).
2. Press the female contact (2) from its seat in the housing using the plunger on the release tool with RK 1.5
e
jector against the spring force of the tool.

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:51 PMPage 372 © 2006 Mitchell Repair Information Company, LLC.

Fig. 600: Unpinning Female Contacts From Coupling (LKS 1.5)
When pressing out the female contact (2), make sure that the tab (4) does not break off.
REMOVE CONTACTS FROM SPADE-TYPE CONTACT SYSTEM PLUG - AR00.19-P-0120-20A
Fig. 601: 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 373 © 2006 Mitchell Repair Information Company, LLC.

Fig. 602: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)
Fig. 603: Identifying Wiring Ha rness Repair Kit (220 589 02 99 00)

Fig. 604: Identifying Unlocking Device With RK 1.5 Ejector (220 589 01 99 20)


2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:51 PMPage 374 © 2006 Mitchell Repair Information Company, LLC.

Unpin contact pins from the plug (LKS 1.5)
1. Insert release tool, with RK 1.5 ejector, into the contact cavity of the plug (1) from the front end.
Applying high pressure could break the webs of the contact cavities.
In this step, the sleeve (3) of the release tool with RK 1.5 ejector compresses the spring tabs on the
contact pin (2).
Fig. 605: Contact Pins From Plug (LKS 1.5)

2. Press the contact-pin (2) from its seat in the housing using the plunger (4) on the release tool with RK 1.5
ejector against the spring force of the tool.
3. Gently pull the respective line to remove the contact pin (2) from the plug (1).
REMOVE CONTACTS FROM SIEMENS ELO COUPLING - AR00.19-P-0120-23A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:51 PMPage 375 © 2006 Mitchell Repair Information Company, LLC.