Mercedes-Benz ML320. Service manual - part 508

 

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Mercedes-Benz ML320. Service 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

  

me 

 

 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 

 

 

 

 

 

 

 

 

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