Mercedes-Benz ML320. Manual — part 573

Fig. 401: Identifying Welding Bead Catcher (129 589 01 98 00)

Workshop equipment/MB testers

1. Expose damaged cable or plug/coupling in easily accessible position and cut off.

Separate cores in wiring harness offset by approx. 45 mm (B).

Fig. 402: Identifying Wiring Harness Offset Distance

2. Cut new section of cable to match old cable.

When cutting the line, add an allowance of approx. 50 mm (C) for loop formation (strain-relief).

3. Remove approx. 15 mm (D) of insulation at line ends.

4. Select solder cup as shown in table below.

Fig. 403: Identifying Dimensions For Cutting Line

WE58.40-Z-1007-03A

Hot-air gun

2004 Mercedes-Benz ML350

1998-2005 GENINFO Overall vehicle - 163 Chassis

me

A maximum of seven individual cables maybe inserted into each solder connection.

5. Insert the cables into the corresponding solder connections (Z) according to the total cable cross-section.

6. Ensure that solder connection (Z) is fully rotated onto cables.

Approx. 5 mm (A) of the stripped line ends should be visible.

Fig. 404: Rotating Solder Connection Onto Cables

7. Heat solder connector using a heat gun (approx. 400°C).

Start at tapered end until soldering ring has dissolved and sleeve has correctly wrapped itself around

the line.

Fig. 405: Heating Solder Connector Using Heat Gun

Selection table for solder connector

Total copper cross-
section A

tot.

Overall diameter with
insulation

Length stripped of
insulation

Color code

0.7 to 2.4 mm

2

3.3 mm

15 mm

green

2.0 to 4.0 mm

2

4.5 mm

15 mm

red

3.5 to 8.0 mm

2

7.0 mm

15 mm

blue

7.5 to 12 mm

2

9.0 mm

15 mm

Yellow

2004 Mercedes-Benz ML350

1998-2005 GENINFO Overall vehicle - 163 Chassis

me

8. Check soldered point.

The soldering ring (1) of the solder connection (Z)must no longer be visible. The covering (2) must be

resting smoothly against the cables.

Fig. 406: Identifying Solder Connection - Correct/Incorrect

9. Fit solder connection onto cable and wrap fabric tape around repaired area.

Solder connections must not be positioned directly one above the other.

Fig. 407: Identifying Solder Connection

GENERAL REPAIR METHODS FOR WIRING HARNESS. - AR00.19-P-0100A

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

Figure/item, etc.

Work instructions

Risk of injury to skin and
eyes caused by handling
hot or glowing objects.

Wear safety gloves,
protective clothing and
safety glasses, if
necessary.

AS00.00-Z-0002-01A

Risk of injury caused by
burns to skin and eyes.

Work in well ventilated
rooms only. Wear safety

AS00.19-Z-0001-01A

2004 Mercedes-Benz ML350

1998-2005 GENINFO Overall vehicle - 163 Chassis

me

Risk of poisoning caused
by inhaling fumes when
working with heat-
shrinkable tubing.

glasses with side
protection and protective
gloves.

Risk of injury caused by
burns to skin and eyes,
risk of poisoning caused
by inhaling fumes during
soldering.

Wear protective gloves,
protective clothing and
safety glasses. Ensure
that the work area is
adequately ventilated.
Secure power supply
cables. Avoid sources of
fire in working area.

AS00.19-Z-0002-01A

Notes on replacement of
safety-relevant and special
components

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

AH00.19-P-1000-08A

Assessment of damage in
wiring harnesses

AH00.19-P-1000-05A

Notes on crimping

AH00.19-P-1000-09A

Notes on soldering

AH00.19-P-1000-10A

Notes regarding plug
connections

AH00.19-P-1000-06A

Advantages of repairing
wiring harnesses

AH00.19-P-1000-03A

Repair methods for wiring
harnesses

AH00.19-P-1000-04A

Notes on soft soldering

AH00.19-P-1000-07A

Notes on cable protection

AH00.19-P-1000-11A

Removing contacts from
plugs and connectors

AR00.19-P-0120A

Repairing wiring harness
using solder connectors

AR00.19-P-0100-09A

Repair wiring harness by
crimping

AR00.19-P-0100-03A

Repair flat conductor
wiring harness by
crimping

Model 164, 211, 216,
219, 221, 251

AR00.19-P-0100-10A

Repair wiring harness by
crimping (with watertight
connections)

AR00.19-P-0100-04A

Repairing cable harness

AR00.19-P-0100-05A

2004 Mercedes-Benz ML350

1998-2005 GENINFO Overall vehicle - 163 Chassis

me