Mercedes-Benz ML320. Manual — part 508

Cable tails are prefabricated partial wiring harness kits available as Mercedes-Benz replacement parts. They
have the appropriate cable cross-sections and crimped contacts. The Raychem repair method is used to integrate
the cable tails into the wiring harnesses.

Only use cable tails for lines between 4 and 10 mm

2

. Starting at 10 mm

2

the wiring harnesses must be

replaced.

Fig. 7: Identifying Raychem Repair Method

Soldering repair method

The strands of the cable (2) are soldered in the solder contact (axial or radial version) (1) using a soldering iron.
Commercially available solder is used for the soldered connection. This method is only used for repairing plug
connections.

Fig. 8: Identifying Soldering Repair Method

Repair method using rapid connection technology

This method uses special rapid-connection wire connector blocks. Mercedes-Benz permits the 2-, 4-, and 6-pin
versions. They contain tin-plated rapid connection contacts, which are pressed together to touch the wires of the
cables using pliers. The lines do not have to be separated or stripped.

This method can be used for connection to cables with a cross section of 0.35 to 0.75 mm

2

and for wire end

connections.

2004 Mercedes-Benz ML350

1998-2005 GENINFO Overall vehicle - 163 Chassis

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The rapid connection method must only be used inside the vehicle or in the trunk because the connection is

not watertight. They are not permissible for CAN lines.

Fig. 9: Identifying Repair Method Using Rapid Connection Technology

Flat conductor cable repair method

Select crimp contacts in the wiring harness repair kit and insert into the tool head of the open manual crimp
pliers (2). The flat conductor cable (7) must make contact with the tool head, and the correct edge of the flat
conductor cable (7) must make contact with the adjusting stop (3). The optical adjusting device (4) in the
manual crimp pliers (2) must be fully visible between 2 conductor tracks. Press the manual crimp pliers (2)
together all the way. After it has been pressed down all the way, it can be opened again. Remove the finished
crimp connection.

Fig. 10: Identifying Flat Conductor Cable Repair Method

Comparison of circular conductor repair methods

Crimping

Raychem/cable tail
repair method

Soldering

Rapid connection
technology

Applications

Repair cables
Replace damaged
contacts
Repair connectors
Additional line
connection

Repair cables
Cable extension
Integrate repaired
cables (cable tails,
replacement wires) in
the wiring harness

Replace soldered
contacts (special
applications)

Repair cables
Additional line
connection
Wire end
connection

2004 Mercedes-Benz ML350

1998-2005 GENINFO Overall vehicle - 163 Chassis

me

ASSESSMENT OF DAMAGE IN WIRING HARNESSES - AH00.19-P-1000-05A

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

Always assess the damage thoroughly before repairing the wiring harnesses.

The following criteria must be observed:

Type of damage:



Damage caused by scorching/overheating, chafing, clamping, crushing, severing, fatigue, corrosion, cable
chewed by an animal, assembly fault.

Cause of damage:

Equipment and
tools required

Side cutting pliers
Wire stripper
Crimper with
special die sets

Side cutting pliers
Wire stripper
Hot air blower with
special reflector
Raychem connection
Cable tails
Heat shield mat

Side cutting pliers
Wire stripper
Soldering iron with
accessories
Heat shield mat as
drip protection

Side cutting pliers
Water-pump pliers

Type of contact

clamped

soldered

soldered

clamped

Heat source

None

Hot air gun with
special reflector
(400°C)

Soldering iron
(400°C)

None

Advantages

Quick repair, no
mains power
connection required
Strain relieved by
clamping the
insulation
Simple visual
inspection of
connection

Insulation occurs
automatically
Sealing occurs
automatically
Avoids taut wires by
introducing additional
wires

Replace soldered
contacts (special
applications)

No wire stripping
or cutting required
Relatively short
set-up time
No special tool
required

Disadvantages

Special crimping
components
required

Mains power
connection required
Accessibility for hot
air gun must be
ensured
Measures for heat
protection required

Extensive
preparation and
post-working
required

No watertight
versions, therefore
only suitable for
use inside the
vehicle or in the
trunk area
Use limited to
certain cable cross-
sections
Not permissible for
CAN lines

2004 Mercedes-Benz ML350

1998-2005 GENINFO Overall vehicle - 163 Chassis

me



The cause for the damage must be determined to ensure that the damage does not reoccur after the wiring
harness has been repaired.

Scope of the damage:



Which components are damaged, can the damage be identified exactly?



Can you be sure that no other components are damaged?

Repair options:



What are the options for repair?



Which replacement parts are available?

Overview of causes for damage to wiring harnesses

Type of damage:

Possible causes for damage

Possible scope of damage

Scorching/ overheating



Through external
overheating:

Through contact with hot
components (e.g. exhaust
system), during welding and
soldering, painting and
drying work



Fire



Internal overheating because
electric currents are too high:
Short circuits at defective
components or lines, cable
cross-section too small,
incorrect fusing (parts not
installed correctly or repairs
not carried out correctly),
short circuits due to bridging
(e.g. at wire ends that are not
insulated, if insulation is
damaged)



Insulation and wires
damaged



Connector housing deformed



Open circuit in wiring



Insulated hard and cracked

Chafing, clamping, crushing,
severing



Lines routed or secured
incorrectly



Damage as a result of an
accident



Damage to cable when
boring holes or when
screwing sheet metal screws



Insulation and wires
damaged



Lines or connections to
contacts



High line resistance



Short circuit to ground and
power

2004 Mercedes-Benz ML350

1998-2005 GENINFO Overall vehicle - 163 Chassis

me