1997 MERCEDES-BENZ ML320 Complete Repair Manual

cooling brake sensor air filter horn brake fluid brake pads

Page 2665 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual 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,

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 setsSide cutting pliers
Wire stripper
Hot air blower with
special reflector
Raychem connection
Cable tails
Heat shield matSide cutting pliers
Wire stripper
Soldering iron with
accessories
Heat shield mat as
drip protectionSide cutting pliers
Water-pump pliers
Type of contact clampedsolderedsolderedclamped
Heat source NoneHot 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
connectionInsulation occurs
automatically
Sealing occurs
automatically
Avoids taut wires by
introducing additional
wiresReplace soldered
contacts (special
applications)No wire stripping
or cutting required
Relatively short
set-up time
No special tool
required
Disadvantages Special crimping
components
requiredMains power
connection required
Accessibility for hot
air gun must be
ensured
Measures for heat
protection requiredExtensive
preparation and
post-working
requiredNo 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
Saturday, October 02, 2010 3:47:44 PMPage 20 © 2006 Mitchell Repair Information Company, LLC.

Page 2666 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual 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

Page 2667 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual 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 ci

Page 2668 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual 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 instal

Page 2669 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual 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

Page 2670 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual 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

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,
eliminatin
g and preventing surface films (e.g. greases).

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 25 © 2006 Mitchell Repair Information Company, LLC.

Page 2671 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual Soft soldering materials
The alloy (mainly lead and tin) of the solder determines its melting point and thus the working temperature for
the soft soldering process. Additives modify the properties.

Page 2672 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual Plugs and couplings. with yellow, orange or red housing colors are reserved for safety and restraint systems
(SRS) and roll bars.
Observe the following when repairing couplings for squibs (SRS sys

Plugs and couplings. with yellow, orange or red housing colors are reserved for safety and restraint systems
(SRS) and roll bars.
Observe the following when repairing couplings for squibs (SRS systems):
The repair area must be between 100 mm and 1000 mm behind the squib. Cables which have already been
repaired are provided with a yellow marking. This is to be applied retroactively to repair lines without color
marking.
Carry out the first repair as close to the plug as possible. In the case of subsequent repairs the old soldered
connectors should be removed and the new ones should be attached behind them, the wiring harness should be
replaced if necessary.
Before cutting through the lines it is absolutely essential to assign the lines to the corresponding pins in
accordance with the wiring diagram. Do not mix up the pin assignment.
The line colors of the repair kit may deviate from the original fitting
Screened lines and light plastic-sheathed cable must never be repaired
In general the following applies to cable repair:
If more than ten lines per branch-off line are damaged, the wiring harness module must be replaced.
Overview (lines/contacts)
Overview (lines/contacts to components)
Lines/contacts (Function)Scope affected
CableContact
Radio antenna linesExchange wiring harness/lineExchange wiring harness/line
Navigation antenna linesExchange wiring harness/lineExchange wiring harness/line
Emergency call system antenna
linesExchange wiring harness/lineExchange wiring harness/line
Telephone antenna linesExchange wiring harness/lineExchange wiring harness/line
Radio antenna linesExchange wiring harness/lineExchange wiring harness/line
TV-antenna linesExchange wiring harness/lineExchange wiring harness/line
D2B (fiber optic cable)Exchange wiring harness/lineExchange wiring harness/line
MOST (fiber optic cable)Exchange wiring harness/lineExchange wiring harness/line
Telephone handset linesExchange wiring harness/lineExchange wiring harness/line
ESP/SBC cablesExchange wiring harness/lineExchange wiring harness/line
Lines/contacts for the following
componentsScope affected
CableContact
Airbag control unit couplingExchange wiring harnessExchange wiring harness
Squibs coupling (SRS systems)Install repair wiring harnessInstall repair wiring harness

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 27 © 2006 Mitchell Repair Information Company, LLC.

Load next 8 pages

Page: < prev 1-10 ... 2633-2640 2641-2648 2649-2656 2657-2664 2665-2672 2673-2680 2681-2688 2689-2696 2697-2704 ... 4136 next >

transmission tire size glove box fuse radio controls compression ratio