Page 2673 of 4133

NOTES ON CRIMPING - AH00.19-P-1000-09A 
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  
1. Check crimped connection for deformation and ensure that the wires fill the crimp tab correctly (cross-
section of enclosed wires). 
 Correct crimped connection (A):  
The strands of the cable are evenly enclosed. 
The crimp tab is evenly shaped. 
 Incorrect crimped connection (B):  
The crimp tab has an incorrect cross-section and is not full enough. 
 Incorrect crimped connection (C):  
Individual wire strands are outside the crimp shackle. 
The crimp tab is too full. 
 Incorrect crimped connection (D):  
The crimp claws touch the bottom of the crimped fitting. 
The crimp tab is too full. 
The crimp tab is deformed and therefore damaged. 
Shown with circular conductor  
 
2004 Mercedes-Benz ML350 
1998-2005 GENINFO Overall vehicle - 163 Chassis  
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Fig. 12: Cross-Section Of Enclosed Wires - Correct And Incorrect 
2. Check crimped connection (ensure all wires are enclosed correctly). 
 Correct crimped connection (A):  
Leads (3) enclosed correctly by the tab (2). 
Insulation is enclosed correctly by the tab (1). 
 Incorrect crimped connection (B, C):  
Leads (3) are damaged due to deformed tab (2). 
Insulation is pinched by deformed tab (1) and damaged. 
Shown with circular conductor  
 
2004 Mercedes-Benz ML350 
1998-2005 GENINFO Overall vehicle - 163 Chassis  
me  
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Fig. 13: Identifying Crimped Connection - Correct And Incorrect (1 Of 2) 
3. Check crimped connection (ensure that wires and insulation are correct length). 
 Correct crimped connection (A):  
Correct length of insulation is enclosed by the shackle (1). 
Wires (3) are the correct length in the tab (2). 
 Incorrect crimped connection (B):  
Insulation is too short and is not correctly enclosed by the tab (1). 
Therefore insulation cannot withstand the required tensile load. 
 Incorrect crimped connection (C, D):  
Wire strands (3) are too long. 
Leads (3) are too short. 
Shown with circular conductor  
 
2004 Mercedes-Benz ML350 
1998-2005 GENINFO Overall vehicle - 163 Chassis  
me  
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Fig. 14: Identifying Crimped Connection - Correct And Incorrect (2 Of 2) 
NOTES ON SOLDERING - AH00.19-P-1000-10A 
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  
 Evenly heat parts to be joined and solder. Avoid heat-dissipating mounts and brackets. The soldering process 
lasts between 2 and 4 seconds for the joining of wires and component connections, depending on the cross-
section. 
The same time must be fixed up to hardening. 
Unnecessarily high heating and associated damage to components must be avoided. 
During pauses in soldering, it must be ensured that the soldering tip remains adequately tin-plated. 
Surface of the soldering join  
 Correct soldering join (A):  
The solder surface (4) is smooth, shiny, no sharp edges, no interruptions, fluid and free of residues and 
oxidation. 
 Incorrect soldering join (B):  
The surface of the solder (4) is matt and uneven, it has sharp-edged ends, interruptions, has not flown, covered 
with residue. 
 
2004 Mercedes-Benz ML350 
1998-2005 GENINFO Overall vehicle - 163 Chassis  
me  
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Fig. 15: Identifying Surface Of Soldering Join - Correct And Incorrect 
Wire position and contour of soldering join  
 Correct soldering join (A):  
The distance (a) between the solder connector (2) and the line insulation is about 1 mm. The soldered area does 
not extend beyond the collar of the solder connector (2). Solder flows in a radius in the direction of the line 
insulation and surrounds at least 2/3 of the lead outside the solder connector (2). There are no bare copper wires 
visible in the soldering area. 
 Incorrect soldering joint (B):  
If the distance (a) between the solder connector (2) and the line insulation (a) is greater than 2 mm, the line is 
incorrectly inserted. The solder protrudes beyond the extension line from the collar of the solder connector (b). 
The solder flows in the wrong direction, the transition from solder to lead is jagged, the solder surface (3) has 
not flown and is thus a dr
y solder joint. 
 
2004 Mercedes-Benz ML350 
1998-2005 GENINFO Overall vehicle - 163 Chassis  
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Fig. 16: Identifying Wire Position  And Contour Of Soldering Join - Correct And Incorrect  
Solder covering and solder quantity for the soldering join     
Correct soldering join (A):     
The quantity of solder (4) is adequate. Lead of wire   (1) is completely surrounded. Solder connector (2) is not  
covered with solder (4) around the collar.  
Incorrect soldering join (B):     
The quantity of solder (4) is inadequate. Lead of wi  re (1) is not completely surrounded. Single wires are not  
incorporated by the solder (4).  
Fig. 17: Identifying Solder Covering A  nd Solder Quantity For Soldering Join 
- Correct And Incorrect 
NOTES ON CABLE PROTECTION - AH00.19-P-1000-11A 
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     
An attempt should be made to restor  e the cable protection to its original condition after all repairs to wiring  
harnesses. 
 
2004 Mercedes-Benz ML350 
1998-2005 GENINFO Overall vehicle - 163 Chassis  
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In areas exposed to particularly high stresses (dampness, scouring), additional safety precautions may however 
be required. 
The following measures are recommended depending on the application. 
Protect repair area using: 
Heat-shrinkable tube  
Corrugated tube  
Wrapping with fabric tape  
Spaghetti insulation  
BASIC KNOWLEDGE 
MODEL SURVEY - GF00.10-P-0025-01I 
MAJOR ASSEMBLY OVERVIEW - GF00.10-P-0025-02I 
COMPLETE VEHICLE, MODEL/COMPONENT INSTALLATION SURVEY, BUILD CONDITION - GF00.10-P-0801I 
MODEL 163  
163.1163.11163.113ML 270 CDI
163.12163.128ML 400 CDI
163.13163.136ML 230
163.15163.154ML 320
163.157ML 350
163.17163.172ML 430
163.174ML 55 AMG
163.175ML 500
Sales 
designationModelEngineManual 
transmissionAutomatic 
transmissionSteering gear
ML 270 CDI163.113612.963716.644722.661-
ML400CDI163.128628.963-722.666 
722.673-
ML 230163.136111.977717.461722.660-
ML 320163.154112.942-722.662-
ML 350163.157112.970-722.674-
ML 430163.172113.942-722.663-
ML 55 AMG163.174113.981-722.666-
ML 500163.175113.965-722.666-
 
2004 Mercedes-Benz ML350 
1998-2005 GENINFO Overall vehicle - 163 Chassis  
me  
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Fig. 18: Identifying Complete Vehicle 
FEMALE CONTACTS AND CONTACT PINS, INSTALLATION SURVEY, AS-BUILT CONFIGURATION - GF00.19-P-7000A 
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  
Fig. 19: Identifying Junior Power Timer (JPT) Pin
 Component surveyModel 163GF00.10-P-0025-02I
 Model surveyModel 163GF00.10-P-0025-01I
 
2004 Mercedes-Benz ML350 
1998-2005 GENINFO Overall vehicle - 163 Chassis  
me  
Saturday, October 02, 2010 3:47:44 PMPage 35 © 2006 Mitchell Repair Information Company, LLC.