Mercedes-Benz ML320. Manual — part 511

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

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

me

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 dry solder joint.

2004 Mercedes-Benz ML350

1998-2005 GENINFO Overall vehicle - 163 Chassis

me

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 wire (1) is not completely surrounded. Single wires are not
incorporated by the solder (4).

Fig. 17: Identifying Solder Covering And 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 restore the cable protection to its original condition after all repairs to wiring
harnesses.

2004 Mercedes-Benz ML350

1998-2005 GENINFO Overall vehicle - 163 Chassis

me