Page 2921 of 4133
Fig. 394: Wrapping Insulating Tape Around Corrugated Hose At Both Ends 
PROTECT REPAIR AREA  AFTER CABLE REPAIRS - AR00.19-P-0100-08C 
Protect repair area by wrapping fabric tape around it.    
1. Wrap fabric tape around repair area as per original condition.  
 Fabric tape restores the appearan  ce of the repair area and provides pr otection from chafing. In parts of  
vehicle subject to high levels of st  ress (e.g. engine compartment) fabric  tape should only be used together  
with other (watertight) protective measures. 
REPAIRING WIRING HARN  ESS USING SOLDER CONNECTORS - AR00.19-P-0100-09A 
Fig. 395: Identifying New Passe nger Vehicle Wiring Harness Repair Kit (220 589 04 99 00)  
Fig. 396: Identifying Wiring Harness   Repair Kit, Basic (000 589 13 99 00)
 
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Fig. 397: Identifying Wiring Ha rness Repair Kit (220 589 02 99 00)  
Fig. 398: Identifying Wi  re Stripper (220 589 01 99 40)
  
Fig. 399: Identifying Reflector (220 589 01 99 41)
  
Fig. 400: Identifying Adapter (220 589 01 99 42)
 
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        Page 2923 of 4133
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-1007-03AHot-air gun
 
2004 Mercedes-Benz ML350 
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        Page 2924 of 4133

 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 
insulationLength stripped of 
insulationColor code
0.7 to 2.4 mm2 3.3 mm15 mmgreen
2.0 to 4.0 mm2 4.5 mm15 mmred
3.5 to 8.0 mm2 7.0 mm15 mmblue
7.5 to 12 mm 2 9.0 mm15 mmYellow
 
2004 Mercedes-Benz ML350 
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        Page 2925 of 4133

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
 
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        Page 2926 of 4133

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 
componentsModel 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, 463AH00.19-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 
crimpingModel 164, 211, 216, 
219, 221, 251AR00.19-P-0100-10A
 Repair wiring harness by 
crimping (with watertight 
connections) AR00.19-P-0100-04A
 Repairing cable harness  AR00.19-P-0100-05A
 
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        Page 2927 of 4133
REMOVE CONTACTS FROM SENSOR SPADE- TYPE CONTACT PLUG - AR00.19-P-0120-01A 
Fig. 408: Identifying Wiring Harness Repair Kit, Supplement Fo r Passenger Cars (220 589 04 99 00)  
Fig. 409: Identifying Wiring Harness   Repair Kit, Basic (000 589 13 99 00)
by soldering
 Repair cable harness using  
rapid connection  
technology AR00.19-P-0100-06A
 Protect repair area after  
cable repairsHeat-shrinkable tubeAR00.19-P-0100-08A
 Protect repair area after  
cable repairsCorrugated tubeAR00.19-P-0100-08B
 Protect repair area after 
cable repairsFabric tapeAR00.19-P-0100-08C
 Checking wiring harness AR54.18-P-0600-01A 
 Plugs and couplings as-
built configuration GF00.19-P-8000A
 Female contacts and  
contact pins, installation  
survey, as-built  
configuration GF00.19-P-7000A
 
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        Page 2928 of 4133
Fig. 410: Identifying Wiring Ha rness Repair Kit (220 589 02 99 00)  
Fig. 411: Identifying Blad  e Holder With Clamping Pliers (220 589 01 99 50)
  
Fig. 412: Identifying SLK 2.8 
- 97 Blade (220 589 01 99 63)  
Unpin contact pins from   the plug (SLK design 97)   
1. Insert blade holder with clamping   pliers   and SLK 2.8 - 97 blade   fro m front side into contact cavity  
of connector housing (4).  
 Both spring shackles on the contact pin (7) are pre  ssed together and, simultaneously, the locking tab  
(5) of the connector housing (4) is lifted.  
2. Remove contact pin (7) from connector housin
g (4) by gently pulling the corresponding line. 
 
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1998-2005 GENINFO Overall vehicle - 163 Chassis  
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