Mercedes-Benz ML320. Service manual - part 573

 

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Mercedes-Benz ML320. Service 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 

 

 

 

 

 

 

 

 

Content   ..  571  572  573  574   ..