Mercedes-Benz ML320. Manual — part 571

Fig. 380: Identifying Crimp Connections - Correct And Incorrect (1 Of 2)

14. Check crimped connection for correct length and distance of strands and insulation, as well as position

and condition of seal.

Correct crimped connection (A):

Insulation and wires are of the correct length in the shackles. Correct distance between the single-strand
insulation and the end of the insulation.

Incorrect crimped connections (B, C):

The single-strand insulation is damaged because the distance between seal and end of insulation is too
small.

Stripped strands are too long, single-strand insulation is therefore not crimped.

2004 Mercedes-Benz ML350

1998-2005 GENINFO Overall vehicle - 163 Chassis

me

Fig. 381: Identifying Crimp Connections - Correct And Incorrect (2 Of 2)

REPAIRING CABLE HARNESS BY SOLDERING - AR00.19-P-0100-05A

Fig. 382: Identifying New Passenger Vehicle Wiring Harness Repair Kit (220 589 04 99 00)

Fig. 383: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)

2004 Mercedes-Benz ML350

1998-2005 GENINFO Overall vehicle - 163 Chassis

me

Fig. 384: Identifying Wiring Harness Repair Kit (220 589 02 99 00)

Fig. 385: Identifying Wire Stripper (220 589 01 99 40)

Fig. 386: Identifying Welding Bead Catcher (129 589 01 98 00)

1. Strip line (2)using wire stripper

.

Do not damage the wire strands.

Do not bend or twist the wire strands.

2. Fill solder connection (1) in soldering area with soldering paste.

2004 Mercedes-Benz ML350

1998-2005 GENINFO Overall vehicle - 163 Chassis

me

Fig. 387: Repairing Cable Harness By Soldering (1 Of 2)

3. Insert cable (1) into solder connection (2).

4. Introduce solder (3) into solder connector (2) and make solder connection as per the drawings opposite.

5. Clean residues from soldering join and contact.

Fig. 388: Repairing Cable Harness By Soldering (2 Of 2)

REPAIR WIRING HARNESSES USING RAPID CONNECTION TECHNOLOGY - AR00.19-P-0100-06A

The cable connectors must only be used inside the vehicle. Cable connectors must only be used once.

Use only 2-, 4-, 6- and 10-terminal cable connectors released by DaimlerChrysler.

The approved cable connectors must only be used for a cable cross section of 0.35 to 0.75 mm

2

.

They are not approved for CAN lines.

1. Select cable connectors according to the cable cross-sections and the number of cables.

2. Insert the cables individually into the notches one by one (arrows).

2004 Mercedes-Benz ML350

1998-2005 GENINFO Overall vehicle - 163 Chassis

me