Mercedes-Benz ML320. Manual — part 510

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

me

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

Cable

Contact

Radio antenna lines

Exchange wiring harness/line

Exchange wiring harness/line

Navigation antenna lines

Exchange wiring harness/line

Exchange wiring harness/line

Emergency call system antenna
lines

Exchange wiring harness/line

Exchange wiring harness/line

Telephone antenna lines

Exchange wiring harness/line

Exchange wiring harness/line

Radio antenna lines

Exchange wiring harness/line

Exchange wiring harness/line

TV-antenna lines

Exchange wiring harness/line

Exchange wiring harness/line

D2B (fiber optic cable)

Exchange wiring harness/line

Exchange wiring harness/line

MOST (fiber optic cable)

Exchange wiring harness/line

Exchange wiring harness/line

Telephone handset lines

Exchange wiring harness/line

Exchange wiring harness/line

ESP/SBC cables

Exchange wiring harness/line

Exchange wiring harness/line

Lines/contacts for the following

components

Scope affected

Cable

Contact

Airbag control unit coupling

Exchange wiring harness

Exchange wiring harness

Squibs coupling (SRS systems)

Install repair wiring harness

Install repair wiring harness

2004 Mercedes-Benz ML350

1998-2005 GENINFO Overall vehicle - 163 Chassis

me

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

me

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

me