1997 MERCEDES-BENZ ML430 wiring

connections with self
tapping screws01SM
Key to chassis numberMODEL 107 as of 1.8.83, 124, 126
as of 1.8.83, 129, 140, 201, 202, 210AH00.00-P-2000-01A
Chassis number
breakdownMODEL
163.113/128 /136 /154 /172 /174 /175AH00.00-P-2000-
01GH
Chassis number
breakdownMODEL 450AH00.00-P-2000-
01SM
Chassis number
breakdownMODEL 463.249 /246 /271AH00.00-P-2000-01U
Layout of vehicle data
cardMODEL 100, 107, 108, 109, 111,
112, 113, 114, 115, 116, 123 from
01.01.60 until 31.12.77AH00.00-P-3000-01A
Layout of vehicle data
cardMODEL 123, 124, 126, 129, 140,
163, 168, 170, 201, 202, 208, 210,
215, 220 ab 01.01.78AH00.00-P-3000-01B
Key to body plateMODEL 100, 107, 108, 109, 111,
112, 113, 114, 115, 116, 123, 124,
126, 129, 140, 163, 168, 170, 201,
202, 208, 210...AH00.00-P-4000-01A
Conversion measures
resulting in alteration to
vehicle modelMODEL 100, 107, 108, 109, 111,
112, 113, 114, 115, 116, 123, 124,
126, 129, 140, 163, 168, 170, 201,
202, 208, 210...AH00.10-P-1000-01A
Converting vehicles to
operate on liquefied
petroleum gasMODEL 123.220 /280, 124.020 /080,
126.021, 201.023AH00.10-P-1000-02A
Notes on performance
correctionENGINE 104, 111, 112, 113, 119,
120, 137, 166, 601, 602, 603, 604,
605, 606 ...AH00.10-P-2010-01A
Correction tables for
calculating actual
performance valueENGINE 104, 111, 112, 113, 119,
120, 137, 166, 601, 602, 603, 604,
605, 606 ...AH00.10-P-2010-02A
Notes on replacing
safety-relevant
componentsMODEL allAH00.19-P-1000-02A
Advantages of repairing
wiring harnessesMODEL 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...AH00.19-P-1000-03A
Advantages of repairing
wiring harnessesMODEL 452.3 /4AH00.19-P-1000-
03RC
Advantages of repairing
wiring harnessesMODEL 450.3 /4, 454.0AH00.19-P-1000-
03SM

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 7 © 2006 Mitchell Repair Information Company, LLC.

Repair methods for
wiring harnessesMODEL 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 ...AH00.19-P-1000-04A
Methods for repairing
wiring harnessesMODEL 452.3 /4AH00.19-P-1000-
04RC
Repair methods for
wiring harnessesMODEL 450.3 /4, 454.0AH00.19-P-1000-
04SM
Notes regarding plug
connectionsMODEL 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 ...AH00.19-P-1000-06A
Notes on soft solderingMODEL 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 ...AH00.19-P-1000-07A
Notes on crimpingMODEL 452.3 /4 Crimp- and
Stripping PliersAH00.19-P-1000-
09RC
Notes on crimpingMODEL 450.3 /4, 454.0 Crimp- and
Stripping PliersAH00.19-P-1000-
09SM
Notes on solderingMODEL 450.3 /4AH00.19-P-1000-
10SM
Notes on cable
protectionMODEL 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 ...AH00.19-P-1000-11A
Notes on stripping wiresMODEL 452.3 /4 Crimp- and
Stripping PliersAH00.19-P-1000-
12RC
Notes on stripping wiresMODEL 452.3 /4 Stripping PliersAH00.19-P-1000-
12RR
Notes on stripping wiresMODEL 450.3 /4, 454.0 Crimp- and
Stripping PliersAH00.19-P-1000-
12SM
Notes on stripping wiresMODEL 450.3 /4, 454.0 Stripping
PliersAH00.19-P-1000-
12SN
Notes on self-locking
nuts and boltsMODEL allAH00.00-N-0001-
01A
Measures for preventing
damage to vehicles or
components when
performing arc welding
workMODEL 450.3 /4AH00.00-P-0005-
01SM

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 8 © 2006 Mitchell Repair Information Company, LLC.

Information on function
and performance test on
roller dynamometerMODEL 460, 461, 463 ...AH00.10-P-1000-03A
Measures for preventing
damage to vehicles or
components when
performing arc welding
workMODEL allAH00.00-N-0005-
01A
Measures for preventing
damage to vehicles or
components when
performing electric
welding workMODEL 451.3/4, 454.0AH00.00-P-0005-
01FF
Notes on thread repairsMODEL 452.3 /4AH00.00-P-0008-
01RR
Notes on thread repairsMODEL 450.3 /4AH00.00-P-0008-
01SM
Notes on removing glue
residues and foils on
paint and metal surfaces
with eraser discMODEL 169.0 /3, 216.3, 219.3,
221.0/1, 245.2AH00.00-P-0013-
01AK
Assessment of damage
in wiring harnessesMODEL 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...AH00.19-P-1000-05A
Assessment of damage
to cable harnessesMODEL 452.3 /4AH00.19-P-1000-
05RC
Assessment of damage
in wiring harnessesMODEL 450.3 /4, 454.0AH00.19-P-1000-
05SM
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, 463...AH00.19-P-1000-08A
Notes on crimpingMODEL 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...AH00.19-P-1000-09A
Notes on solderingMODEL 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...AH00.19-P-1000-10A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 9 © 2006 Mitchell Repair Information Company, LLC.

NOTES ON REPLACING SAFETY - RELEVANT COMPONENTS - AH00.19-P-1000-02A
General
With the approval of repair solutions for wiring harnesses (in particular airbag, side airbag, window airbag,
emergency tensioning retractor wiring harness), it is necessary to introduce a modified ordering routine for
procuring safety-relevant components. The order formalities are by and large the same as those which are
already familiar from theft-relevant components.
Procedure
It is only possible to order safety-relevant components by stating the vehicle ident number (refer parts order
note on the parts microfiche).
The repair orders and invoices should be filed in the usual way.
All orders received for safety-relevant components are additionally automatically documented in Fdok.
ADVANTAGES OF REPAIRING WIRING HARNESSES - AH00.19-P-1000-03A
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
Advantages of repairing wiring harnesses
Wiring harnesses are essentially repaired to reduce repair costs.
If repairs are carried out properly, there is no difference in function or quality between the repaired wiring
harness and a brand new wiring harness.
Repairing wiring harnesses helps to save resources.
This also complies with the "Technical Alliance Center" requirements for less dismantling and
installation cost.
REPAIR METHODS FOR WIRING HARNESSES - AH00.19-P-1000-04A
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
Repair method summary
The following methods have been approved by DaimlerChrysler for repairing wiring harnesses in Mercedes-
Benz passenger cars:
Repair methods:
1.20711.21811.22901.23981.25051.302811.27171.229011.29251.30281.3130
7801.21481.22591.23691.24781.25851.23691.21.27981.29041.30081.32141.3214

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 16 © 2006 Mitchell Repair Information Company, LLC.

Crimping
Solder connection (Raychem)
Axial solder connection (Raychem)
Combination of Raychem and cable tail
Soldering
Insulation displacement method
Flat conductor pliers
Application
Individual cases must be analyzed in detail to decide which method can and cannot be used to repair wiring
harnesses (wires, contacts and connectors).
Crimping repair method
In crimping, the insulation is first stripped off an appropriate distance (a) from the end of the wire. Then the
contact pin is placed over the stripped end of the wire and pinched ("crimped") in place by means of a special
pliers-like crimping tool. Crimping is performed quickly and with ease. A special crimper is required.
Only lines up to 4 mm
2 shall be crimped.
Fig. 6: Identifying Crimping Repair Method

Raychem repair method
With this method, special solder connectors are used. The solder connections contain the solder and they also
feature insulation and a seal. A special hot air blower provides the heat required for soldering and shrinking the
insulation. A special reflector is fitted to the hot air blower. The minimum temperature for this repair method is
400°C.
Raychem is the manufacturer of the solder connections that are required for this method. The Raychem
repair method is mainly used for integrating repair wiring harnesses (cable tails): ?
Combination of Raychem repair method and cable tail repair

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 17 © 2006 Mitchell Repair Information Company, LLC.

Cable tails are prefabricated partial wiring harness kits available as Mercedes-Benz replacement parts. They
have the appropriate cable cr oss-sections and crimped contacts. The Rayc hem repair method is used to integrate
the cable tails into the wiring harnesses.
Only use cable tails for lines between 4 and 10 mm
2 . Starting at 10 mm2 the wiring harnesses must be
replaced.
Fig. 7: Identifying Raychem Repair Method

Soldering repair method
The strands of the cable (2) are soldered in the solder c ontact (axial or radial version) (1) using a soldering iron.
Commercially available solder is used for the soldered connection. This method is only used for repairing plug
connections.
Fig. 8: Identifying Soldering Repair Method

Repair method using rapid connection technology
This method uses special rapid-connect ion wire connector blocks. Mercedes-Benz permits the 2-, 4-, and 6-pin
versions. They contain tin-plated rapi d connection contacts, which are pressed together to touch the wires of the
cables using pliers. The lines do not ha ve to be separated or stripped.
This method can be used for connection to ca bles with a cross section of 0.35 to 0.75 mm
2 and for wire end
connections.

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 18 © 2006 Mitchell Repair Information Company, LLC.

The rapid connection method must only be used inside the vehicle or in the trunk because the connection is
not watertight. They are not permissible for CAN lines.
Fig. 9: Identifying Repair Method Using Rapid Connection Technology

Flat conductor cable repair method
Select crimp contacts in the wiring harness repair kit an d insert into the tool head of the open manual crimp
pliers (2). The flat conductor cable (7) must make contact with the tool head, and the correct edge of the flat
conductor cable (7) must make contac t with the adjusting stop (3). The optical adjusting device (4) in the
manual crimp pliers (2) must be fully visible between 2 conductor tracks. Press the manual crimp pliers (2)
together all the way. After it has been pressed down al l the way, it can be opened again. Remove the finished
crimp connection.
Fig. 10: Identifying Flat Conductor Cable Repair Method

Comparison of circular conductor repair methods
CrimpingRaychem/cable tail
repair methodSolderingRapid connection
technology
Applications Repair cables
Replace damaged
contacts
Repair connectors
Additional line
connectionRepair cables
Cable extension
Integrate repaired
cables (cable tails,
replacement wires) in
the wiring harnessReplace soldered
contacts (special
applications)Repair cables
Additional line
connection
Wire end
connection

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 19 © 2006 Mitchell Repair Information Company, LLC.

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.