service reset MERCEDES-BENZ ML320 1997 Complete Owner's Manual

AF54.30-P-2064A
Fuel gauge not registering correctly after refueling vehicle
4.2.03

MODEL
163.### #A as of 221506 up to 364039,

163.### #X as of 734088 up to 777100

Operation no. of operation texts or standard texts and flat rates

Sector

Op. no.
Operation text

Time
Acc. no.
Code

P
023803
RECODE INSTRUMENT CLUSTER
003 WU/0.3 h
54 208 50
---

Damage Code
Cause
Remedy

Refuel recognition software may not

recognize incremental refueling (< 7 L).

In case of complaint
#

The fuel gauge operation defaults to back-

up mode, and continuously decreases last

stored sensor value based on consumption

data supplied via engine management. This

continues until either refuel recognition or

instrument cluster (A1) reset occurs (via

STAR Diagnosis or power disconnect).
Vehicles with 83 L fuel tank (as of MY2002)
are more susceptible to this condition.

This applies only to instrument clusters

(A1) with diagnostic version 3/05, 3/06,

and 3/07.
1
Connect STAR Diagnosis.

2
Under "Control module adaptations" in

"ICM" menu, set "Fuel tank characteristic

curve" from "Normal" to "Direct sensor

value".

DO NOT replace the instrument cluster

(A1) or fuel pump assembly (M3) for this

condition.

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Fig. 316: Identifying 14-Pin MLK Plug
ACTIVE SERVICE SYSTEM (ASSYST) OPERATING NOTES - GF00.20-P-0003-01A
Displaying remaining distance, remaining time or service exceeded when vehicle stationary or when
driving on driver request:
Wake-up instrument cluster.
Start switch in position "2" or driving.
Operate reset button for trip counter twice within 1 s: the current remaining distance, the current
remaining time or the current service exceeded appears.
Displaying oil level at driver request:
After start switch in position "2", wait 10 s until "DISPLAY OIL LEVEL" text and oil can symbol (or oil
can and clock symbol) appears.
Press reset button for trip counter twice within 1 s: the message "OIL LEVEL OKAY" (or "O.K.") or the
current missing oil quantity appears. If correct oil level measurement is not possible, the text "OBSERVE
WAITING TIME" appears (or the clock s
ymbol and the oil can symbol; the clock symbol flashes).
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
Notes regarding plug
connections AH00.19-P-1000-06A
Remove contacts from
mini laminated contact
coupling AR00.19-P-0120-26A
Remove contacts from
mini laminated contact
plug AR00.19-P-0120-27A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:47 PMPage 195 © 2006 Mitchell Repair Information Company, LLC.

(The texts in parentheses relate to vehicles without multifunction display.)
Resetting ASSYST after oil change (oil change reset) at instrument cluster:
Move start switch into position "2".
Within the first 4 s after moving start switch into position "2": press reset button for trip counter twice
within one second. The display for the servi ce request is thus activated for 10 s.
Within these 10 s move start switch into position "0". The service request continues to be displayed.
Press reset button for trip counter and hold pressed .
Move start switch into position "2".
Continue to hold reset button for trip counter pressed (about 10 s) until the signal sounds and the new
start distance appears in the display.
BLOCK DIAGRAM OF ACTI VE SERVICE SYSTEM (ASSYST) - GF00.20-P-0003-03A
Fig. 317: Block Diagram Of Acti ve Service System (ASSYST)
ACTIVE SERVICE SYSTEM (ASSYST) DISPLAY FACILITIES - GF00.20-P-0003-04A
The table shows a number of pos sible types of displays of the active se rvice system for different vehicles and
different instru ment clusters.
(The display appears in the language set with the HHT under national code.)

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
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The figure may differ from this, however, depending on quality factors.
The start distance is automatically reset to its initial value by the oil change reset each time the oil is changed.
The start distance is an internal computed quantity and cannot be displayed in the instrument cluster. It is
possible to display the start distance with the HHT.
What is normally displayed in the instrument cluster is the remaining distance .
The remaining distance is the same as the start distance immediately after the oil change. On engines with oil
sensor (e.g. 112, 113, 166, 611, 668) this applies only, however, if the specified quantity of oil has been added
during the oil change.
The remaining distance is the distance which remains from the current kilometer reading until the next
service. The possible length of the interval is at least as great as the remaining distance displayed
immediately after an oil change, and is at the most twice the start distance.
The remaining distance is dependent on
the start distance
the driving conditions (a weighting of the distance driven takes place)
any oil replenishments in the case of engines with oil sensor (e.g. 112, 113, 166, 611, 668)
Consequently, ASSYST also takes into account the driving conditions: In the case of a favorable weighting
(e.g. small number of cold starts, no high engine revs, small number of short-distance trips, minimum extent of
towing a trailer etc.) and oil replenishments, the driver is provided with a bonus which extends the remaining
distance and thus the service interval. Account is also taken of whether the vehicle is actually driven or whether
the engine runs at idle speed. ASSYST is constantly supplied with the data regarding the current operating
conditions of the vehicle for this purpose.
In the case of the best weighting , only 0.6 km are added for each kilometer driven.
In the case of the most unfavorable weighting of the distance (e.g. frequent short-distance trips, large number
of cold starts), the remaining distance and thus the service interval is smaller than in the case of the most
favorable weighting (assuming identical quality factors).
In the case of the most unfavorable weighting, up to 3 km are added for each kilometer driven.
The start distance and the remaining distance are once again presented in the form of a graph in the diagram
opposite, taking the example of gasoline engines
Each time the oil is changed, the start and remaining distances are set to the initial value. In this case, the
normal value of 15 000 km is entered as the start distance (top bar) (shaded + dark section). The start distance
may differ from 15 000 km (e.g. 14 000 km; shaded section) if the quality factors do not correspond to the basic
setting. In the case of engines fitted with oil sensor (e.g. 112, 113, 166) the start distance may also be less than
15 000 km if the specified oil quantity was not added during the oil change. The remaining distance (bottom
bar) is always 15 000 km, however, immediately after an oil change. In addition, the service interval is
always at least 15 000 km .

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:47 PMPage 204 © 2006 Mitchell Repair Information Company, LLC.

MODEL 129 as of 1.6.97
MODEL 140 as of 1.6.97
MODEL 163
MODEL 168
MODEL 170 as of 1.6.97
MODEL 202 as of 1.6.97
MODEL 208 up to 31.7.99
MODEL 210 as of 1.3.97 up to 30.6.99
Start time and remaining time
Start time refers to the service interval in days immediately after the oil change
The start time is not dependent on the driving conditions and any oil replenishments .
The start time is 730 days ( 365 days).
The start time is automatically reset to its initial value by the oil change reset after each oil change. The start
time is an internal computed variable and cannotbe displayed in the instrument cluster. It is possible to display
the start time with the HHT.
The remaining time is displayed in the instrument cluster under certain conditions as stated below.
The remaining time is the time which remains until the next service.
The remaining time is only of importance for "low-mileage drivers". (It is therefore the remaining distance
which is displayed as a general rule.)
The remaining time depends on:
the start time
the driving conditions (the distance driven is weighted in this case.)
Replenishing oil, however, does not have any influence on the remaining time.
As a result of these dependent factors, ASSYST proves to be a demand-oriented system even for "low-mileage
drivers". Depending on the weighting of the factors, the service interval for "low-mileage drivers" is between 1
and 2
years.

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:47 PMPage 207 © 2006 Mitchell Repair Information Company, LLC.

Fig. 325: Engine Oil Monitor Function - (4 Of 4)
DISPLAYING SERVICE, FUNCTION - GF00.20-P-2010B
MODEL 129 as of 1.8.99
MODEL 163 as of 1.1.00
MODEL 168 as of 1.9.99
MODEL 170 as of 1.12.99
Active service system survey
of display facilities GF00.20-P-0003-04A
Active service system
technology/ influencing
variables GF00.20-P-0003-05A
Active service system survey
model/engine/
sensor/instrument cluster GF00.20-P-0003-06A
Active service system
(ASSYST) operating
instructions, resetting GF00.20-P-0003-01A
Oil sensor
position/task/functionOil sensor position, task,
functionGF18.40-P-4111A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:47 PMPage 215 © 2006 Mitchell Repair Information Company, LLC.

AD54.30-P-2000-02GC
Notes on HHT previous knowledge diagnosis
IC


HHT :

The instrument cluster and active service system (ASSYST) sub-

function are checked with HHT, there being the choice of the

following functions for this:
1. Control module version

2. Fault memory

3. Actual values

4. Actuations

5. Control module adaptation

Additional information on test items 2, 3 and 5 can be called up using

the INPUT key


Control module adaptation

The following alternatives are available in the HHT under control

module adaptation:

1.)
Read out coding and transfer to new instrument cluster. IC and

ASSYST.

2.)
Read out/change codings e.g.:

Engine and national variants,

version of fuel tank,

special equipment etc.
3.)

Settings:

1
Clock

2
Put forward kilometer reading

3
Put back kilometer reading

4
Oil change

5
Reset oil change initiated inadvertently

6
Active Service System

7
Enter times with battery disconnected

8
Set minimum oil warning


Before replacing a defective instrument cluster, readout the existing

variant codings (driving data and instrument cluster data) and store in
the HHT on an interim basis. Read in the values stored on an interim

basis again after installing the new instrument cluster.

If it is not possible to read out the stored variant coding, all variant

codings must be input manually (menu-assistance in HHT).

When installing an instrument cluster on an experimental basis, do

not put forward the kilometer reading as it cannot be put back later.

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AF54.30-P-8400A
Instrument cluster indicates: Oil sensor defective, oil level below min. or oil level

above max. with engine running and at operating temperature. No DTC stored.
19.5.98

MODEL
129.0, 163.1, 202.0, 208.3 /4, 210.0 /2 /6, 220.0 /1 with ENGINE 112

MODEL
129.0, 163.1, 202.0, 208.3 /4, 210.0 /2, 220.0 /1 with ENGINE 113

Damage code
Cause
Remedy

54 201 90
Oil low, connector defective or coding error
1
Shut off engine and wait 2 min. (key

position 0)

Instrument cluster indicates oil sensor

defective, oil level below min. or oil level

above max. with engine warm and running.

No DTC stored in DTC memory!

2
Check oil level with oil dipstick

3
Check oil level on instrument cluster:

- Key in steering wheel lock position 2,

engine not running

- Wait until - - - - - - appears on

instrument cluster

- When this is displayed press the reset

button for the tripodometer twice within

1 sec. (display appears only after

expiration of a waiting time (max. 30

min.) depending on engine oil

temperature)

Oil level is at bottom mark on oil dipstick

and instrument cluster indicates:
-1L
, -
1,5L
or -2L
#
4
Add quantity of oil indicated on

instrument cluster display and repeat

test.

Oil level at upper mark on dipstick and

instrument cluster indicates either oil level

okay or -1L
, -
1,5L
, -2L

#
5
Recode instrument cluster

AF54.30-P-8600A

Problem still present
#
6
Check cable to oil sensor, oil sensor
connectors, control module and fuse

box (see wiring diagram) for good contact

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9
Install inner cover (E) at 60 % bench

Insert cover past the springs from the rear

and rotate into position in a clockwise

direction. Insert locating tabs (19). Press the

front cover down and reset so that locating

tabs (20) engage. Press rear cover down until

locating tabs (18) engage.

10
Install outer cover (D) at 60 % bench

Guide the cover past the lateral curtain.

Insert locating tab (17), push front cover down

and reset so that locating tabs (16) engage.

Press the outer edge of the cover down and

insert lateral locating tabs (15). Raise rear
cover on the inside, press down until locating

tab (14) and rear locating tab (13) engage.

11
Install curtain at front 60 % bench

12
Install inner cover (C) at 40 % bench

Insert cover from the front and insert

locating tabs (11). Press the front cover down

and reset so that locating tabs (12) engage.

13
Install outer cover (B) at 40 % bench
Guide the cover past the lateral curtain.

Insert locating tab (10), push front cover down

and reset so that locating tab (9) engages.

Press the outer edge of the cover down and

insert lateral locating tabs (8). Insert locating

tab (7), push cover down at locating tab (6)

and engage.

14
Install curtain at front 40 % bench

15
Install rear cover (A)

Insert cover from the rear and press down

and forwards so that locating tabs (5) engage.

Press front ends of the cover down, so that

locating tabs (2, 3, 4) engage. Insert locating

tabs (1) into covers (C, E).

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5
Remove key and engage steering lock

6
Unscrew bolt (32c)

Hold the steering wheel (32).


Installation:
Replace bolt (32c).


*BA46.10-P-1001-02A

7
Pull off steering wheel (32)

Pass cables carefully through the openings.


Installation:
Align recesses of the splines

in the steering wheel with the markings on the

steering shaft (arrows).

8
Check fanfare horns and airbag clock spring

contact (A45) for damage

The clock spring contact must not be

turned while the steering wheel is removed

otherwise it will be damaged.

Visual inspection, replace clock spring

contact if necessary:

#

Removing and installing clock spring contact

AR46.10-P-0200GH

9
Install in the reverse order

10
Carry out road test

Tests during the road test:

Turn signal canceling:

When the steering wheel is offset by

more than 1 tooth, satisfactory resetting of the

turn signal is no longer guaranteed.

Airbag indicator lamp:

The SRS indicator lamp must not light up

on full steering lock in both directions.

Steering wheel position:

If the steering wheel is crooked, adjust it

by max. 1 tooth. If the difference is greater:

#

Check toe on front axle and adjust if

necessary, see:

#

Performing chassis alignment check

AR40.20-P-0200A

Steering wheel

Number

Designation
Model 163

BA46.10-P-1001-02A
Bolt, steering wheel to steering shaft
Nm
80

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