Mercedes-Benz ML320. Service manual - part 509

 

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Mercedes-Benz ML320. Service manual - part 509

 

 

Overview of authorized reworking on wiring harnesses 

into the body  

Lines get pinched in clamps 
or trim parts  

Fatigue 

Lines routed or secured 
incorrectly  

Excessive stress  

Open circuit in wiring  

Corrosion 

Due to contact with acids or 
aggressive fluids (e.g. brake 
fluid, antiseize, coolant 
additives, fuels, lubricants), 
water penetration due to 
defective seals, use of high 
pressure cleaner  

Wiring harness covered in 
paint after paint repair  

Hardening of insulation due 
to contact with an 
incompatible agent (e.g. 
solvent)  

Line open circuit, contact 
pairing not longer conductive 
(transition resistances)  

Insulation and wires 
damaged  

Lines or connections to 
contacts  

High line resistance  

Components with sharp 
edges  

Corrosion  

Assembly fault 

Use of incorrect tools, e.g. 
wrong crimper or wrong 
release tool  

Damaged contacts or lines 
through use of unsuitable test 
tools (e.g. probes)  

Lines pinched or screwed in  

Loose contacts in plug 
connections  

Wrong contacts crimped  

Undesirable transition 
resistances  

Open circuit in wiring, short-
circuit  

Insulation damaged  

Type of fault

Remedial action

Faulty contact part 

 

Contact part 

missing  

wrong part  

deformed  

Install new contact part  

Contact part not engaged properly

Latch contact part, then check, and replace if 
necessary  

Not all individual wires are crimped

Cut off contact part and install new part  

Insulation also crimped

Cut off contact part and install new part  

Conductor not far enough in contact part

Cut off contact part and install new part  

 

2004 Mercedes-Benz ML350 

1998-2005 GENINFO Overall vehicle - 163 Chassis

  

me 

 

NOTES REGARDING PLUG CONNECTIONS - AH00.19-P-1000-06A

Contact part not tin-plated

Cut off contact part and install new part  

Sleeve 

oxidized  

wrong part  

Cut off contact part and install new part  

Not soldered properly/dry solder joint

Resolder contact part and replace if necessary 

Plug-in area full of solder

Cut off contact part and install new part  

Fault with housing 

 

Screw connections loose

Tighten screw connections using an adjusted 
torque wrench, replace if necessary  

Screw connections 

wrong part  

damaged  

Install new screw connections (cable 
connectors)  

Coupling housing or plug housing damaged

Install new coupling or housing  

Check contact and replace if necessary  

Coupling housing or connector housing not closed 
properly

Close coupling or housing properly  

Cap screw in handle recess 

missing  

loose  

Tighten cap screw, replace if necessary  

Cable fault 

 

Insulating tubing damaged

Rewrap with PVC tape  

Insulation damaged

Cut through affected line at damaged area and 
repair using Raychem repair method  

Insulation pulled up

Cut through affected line at damaged area and 
repair using Raychem repair method  

Wrapping defective

Rewrap  

Splashes of solder on cable

Carefully remove splashes of solder using a 
suitable tool without sharp edges.  

Grommet 

missing  

wrong part  

installed incorrectly  

damaged  

Pull on new grommet, or install correctly  

 

2004 Mercedes-Benz ML350 

1998-2005 GENINFO Overall vehicle - 163 Chassis

  

me 

 

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
  

Terminology of plug connections:  

The coupling and the plug form a plug connection. The female contact and the contact pin form the contact pair.

Illustrated: SLK family, coding A (with circular conductor)  

Fig. 11: Identifying Plug Connections - SLK Family, Coding A (With Circular Conductor) 

Plugs and couplings  

The plugs and couplings are grouped into families in the same way as the contact groups (e.g. SLK, JPT). The 
type and shape of the receptacle chambers in the housing is the major differentiating characteristic. Different 
contact families may be installed in the same housing. In addition, different codings (e.g. A, B, C) may exist 
within the same plug/coupling family. 

Codings are special profiles or teeth on the housings of the coupling and the plug, which may be marked in 
different colors (e.g. black, white, violet). 

These ensure that connector pairings can only be made with the same codings. 

Safety and restraint systems (airbag, emergency tensioning retractor, roll bar) have yellow, orange, or red 
plug connections for easy identification.  

Part number assignments  

The housings are assigned according to the part numbers on the housings. On housings made up of several 
components, the number on the external housing is critical. (When ordering, all the individual part numbers 
must be ascertained.) 

This method of identification by means of part numbers can be used when referring to the literature. 

Contacts  

 

2004 Mercedes-Benz ML350 

1998-2005 GENINFO Overall vehicle - 163 Chassis

  

me 

 

A distinction is made between the contact pin and the female contact. Each contact pin and each female contact 
can be clearly assigned to one group or "family" (e.g. SLK, JPT). Within these families distinctions are made 
according to the cable cross section and whether there is single-strand insulation for watertight connections. The 
contacts are also distinguished by their coating (tin, gold or silver). 

The contacts are fastened to the cables by means of crimping. ? 

Crimp connections  

These are used to attach the female contacts or contact pins to the cable. Each contact type must be crimped 
with the aid of specifically assigned die sets using a pair of pliers. Determining factors: contact family, size of 
cable cross section, with or without single-strand insulation. 

 Only lines up to 4 mm shall be crimped. 

Unpinning  

This requires a release tool appropriate to the contact family in order to remove female contacts and contact pins 
from plugs and couplings. 

On some plugs and couplings the housings must first be disassembled and unlocked (secondary release) 
according to the instructions before the actual unpinning. 

Contact materials  

The contacts used in the interior of the vehicle are primarily tin/tin combinations. Those used on the exterior 
and in the splash zone are generally silver/silver. Safety systems (particularly the airbag) are equipped with 
gold/gold contacts. 

 Only "identical" contact pairings are permitted for repair work. 

NOTES ON SOFT SOLDERING - AH00.19-P-1000-07A 

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 information  

Soft-soldering is a process for creating an inseparable join between two or more metal parts using additional 
metals (e.g. soldering tin). The solder melting temperature lies below the melting temperature of the metals to 
be joined and is lower than 450°C. 

The connection is created by wetting the joint locations with hot liquid solder, without melting the parts to be 
joined. 

The joining procedure is assisted by using a flux, which releases surface oxides on the parts to be joined, 
eliminating and preventing surface films (e.g. greases).

 

2004 Mercedes-Benz ML350 

1998-2005 GENINFO Overall vehicle - 163 Chassis

  

me 

 

 

 

 

 

 

 

 

Content   ..  507  508  509  510   ..