open gas tank MERCEDES-BENZ ML320 1997 Complete Repair Manual

212 What you should know at the gas station
Te ch n ica l
data Instruments
and controlsOperationDrivingInstrument
cluster displayPractical hints Car care Index
What you should know at the gas station
Fuel supplyOpen f l ap by pu ll ing at rear (arrow). Turn f uel c ap to t he
left and hold on to it until possible pressure in tank has
been released, then remove cap. Failure to remove
slowly could result in personal injury.
The fuel filler cap is tethered to the fuel filler neck. Do
not drop the cap. It could damage the vehicle paint
finish.
Manual release of fuel filler flap, see page 274.
Important!
When refueling vehicle make certain that no gasoline
comes into contact with plastic taillamp, to prevent
damaging the lens.
Fuel
To prevent fuel vapors from escaping into open air, fully
insert filler nozzle unit.
Only fill fuel tank until the filler nozzle unit cuts out –
do not top up or overfill.
Wa r n i n g !
Gasoline is highly flammable and poisonous. It
burns violently and can cause serious injury.
Whenever you are around gasoline, avoid inhaling
fumes and skin contact, extinguish all smoking
materials. Never allow sparks, flame or smoking
materials near gasoline!

213 What you should know at the gas station
Te ch n ica l
data Instruments
and controlsOperationDrivingInstrument
cluster displayPractical hints Car care Index Leaving the engine running and the fuel cap open can
cause the “CHECK ENGINE” lamp to illuminate.
Fuel tank capacity approximately 19.0 US gal (72.0 l).
This includes approximately 3.2 US gal (12.0 l) reserve.
Use premium unleaded gasoline: Posted Octane
Index 91 (Average of 96 RON / 86 MON).
•Engine oil
Engine oil level check, see page 89 and page 233.
Fill quantity between upper and lower dipstick
marking level: 2.1 US qt (2.0 l).
Recommended engine oils, see Approved Service
Products sheet.• Coolant
For normal replenishing, use water (potable water
quality).
For further information (e.g. anticorrosion/
antifreeze), see page 292.
• Spark plugs
Approved spark plugs, see page 290.
• Tire pressure
For tire pressure, refer to tire pressure label inside
the fuel filler flap. See page 250 for further details.
• Air conditioner
R-134a refrigerant and special PAG lubricant, see
page 294.
Wa r n i n g !
Overfilling of fuel tank may result in creating
pressure in the system which could cause a gas
discharge such as the gas spraying back out upon
removing the filler nozzle which could cause
personal injury.

212
What you should know at the gas station
Te ch n ica l
data
Instruments
and controls Operation
Driving Instrument
cluster display Practical hints Car care Index
What you should know at the gas station
Fuel supply Open f l ap by pu ll ing at rear (arrow). Turn f uel c ap to t he
left and hold on to it until possible pressure in tank has
been released, then remove cap. Failure to remove
slowly could result in personal injury.
The fuel filler cap is tethered to the fuel filler neck. Do
not drop the cap. It could damage the vehicle paint
finish.
Manual release of fuel filler flap, see page 274.
Important!
When refueling vehicle make certain that no gasoline
comes into contact with plastic taillamp, to prevent
damaging the lens.
Fuel
To prevent fuel vapors from escaping into open air, fully
insert filler nozzle unit.
Only fill fuel tank until the filler nozzle unit cuts out –
do not top up or overfill.
Wa r n i n g !
Gasoline is highly flammable and poisonous. It
burns violently and can cause serious injury.
Whenever you are around gasoline, avoid inhaling
fumes and skin contact, extinguish all smoking
materials. Never allow sparks, flame or smoking
materials near gasoline!

213
What you should know at the gas station
Te ch n ica l
data
Instruments
and controls Operation
Driving Instrument
cluster display Practical hints Car care Index
Leaving the engine running and the fuel cap open can
cause the “CHECK ENGINE” lamp to illuminate.
Fuel tank capacity approximately 19.0 US gal (72.0 l).
This includes approximately 3.2 US gal (12.0 l) reserve.
Use premium unleaded gasoline: Posted Octane
Index 91 (Average of 96 RON / 86 MON).
•Engine oil Engine oil level check, see page 89 and page 233.
Fill quantity between upper and lower dipstick
marking level: 2.1 US qt (2.0 l).
Recommended engine oils, see Approved Service
Products sheet. • Coolant
For normal replenishing, use water (potable water
quality).
For further information (e.g. anticorrosion/
antifreeze), see page 292.
• Spark plugs Approved spark plugs, see page 290.
• Tire pressure For tire pressure, refer to tire pressure label inside
the fuel filler flap. See page 250 for further details.
• Air conditioner R-134a refrigerant and special PAG lubricant, see
page 294.
Wa r n i n g !
Overfilling of fuel tank may result in creating
pressure in the system which could cause a gas
discharge such as the gas spraying back out upon
removing the filler nozzle which could cause
personal injury.

214 OperationAt the gas station
At the gas stationRefueling
The fuel filler flap is located on the
left-hand side of the vehicle towards the
rear. Locking / unlocking the vehicle with
the remote control automatically
locks / unlocks the fuel filler flap.1Fuel filler flap
2Fuel cap

Remove the key from the steering lock.

Open the fuel filler flap1 by pulling in
direction of the arrow.

Turn the fuel cap2 to the left and hold
on to it until possible pressure is re-
leased.

Take off the cap.

Only fill your tank until the filler nozzle
unit cuts out – do not top up or overfill.
Warning!
G
Gasoline is highly flammable and poisonous.
It burns violently and can cause serious inju-
ry. Whenever you are around gasoline, avoid
inhaling fumes and skin contact, extinguish
all smoking materials. Never allow sparks,
flame or smoking materials near gasoline!
!The fuel filler cap is tethered to the fuel
filler neck. Do not drop the cap. It could
damage the vehicle paint finish.!To prevent damaging the lens of the
plastic tail lamp, make certain that no
gasoline comes into contact with it.Warning!
G
Overfilling of the fuel tank may create pres-
sure in the system which could cause a gas
discharge. This could cause the gas to spray
back out when removing the fuel pump noz-
zle, which could cause personal injury.

215 Operation
At the gas station

Replace the fuel cap by turning it to the
right.
You will hear when the fuel cap is tight-
ened.

Close the fuel filler flap.
Check regularly and before a long trip
Open the hood (
page 217)
1Engine oil level
2Coolant level
For normal replenishing, use water (po-
table water quality). More information
on the coolant level can be found in the
“Operation” section (
page 222).
3Brake fluid
4Windshield washer system and
headlamp cleaning system*
More information on filling the reser-
voir can be found in the “Operation”
section (
page 224).
iUse only premium unleaded gasoline
with a minimum Posted Octane Rating
of 91 (average of 96 RON / 86 MON).
Information on gasoline quality can
normally be found on the fuel pump.
More information on gasoline can be
found in the Factory Approved Service
Products pamphlet.
iLeaving the engine running and the fuel
cap open can cause the yellow fuel
tank reserve warning lamp to flash and
the? lamp to illuminate.
See also “Practical hints” section
(page 248).

325 Index
F
Fastening the seat belts 42
Fine adjustment
Cruise control 152
First aid kit 257
Flat tire 274
Lowering the vehicle 276
Mounting the spare wheel 274
Preparing the vehicle 274
Spare wheel 259
Flexible Service System (FSS) 232, 312
Fluid level
Automatic transmission 222
Fog lamp, rear 267
Fog lamps 111
Replacing bulbs 266
Fog lamps, front
Replacing bulbs 267
Switching on 111
Folding
Exterior mirrors 128
Folding electrically
Exterior rear view mirrors
1284-ETS 25, 79
Indicator lamp 252
LOW RANGE mode 80
Malfunction indicator lamp 252
Warning lamp 251
Front airbags 63
Front fog lamps
Indicator lamp 253
Front lamps
Replacing bulbs 266, 268
Front towing eyes 285
FSS (Flexible Service System) 232, 312
Fuel 215
Additives 303
Fuel reserve warning lamp 252
Gasoline additives 303
Premium unleaded gasoline 215,
303
Requirements 303
Reserve warning 25
Fuel additives 303
Fuel filler flap 214
Locking 214
Opening 263
Unlocking 214
Fuel requirements 303Fuel tank
Filler flap 214
Fuels, coolants, lubricants etc. 300
Functions
Trip computer* 186
Fuse box 287, 288
Fuse chart 287
Fuses 287
F us e box i n engi ne com p art me nt 2 87
Fuse box in passenger footwell 288
Fuse chart 287
Fuse extractor 287
Spare fuses 287
G
Garage door opener 29, 180
Erasing in remote control 185
Gasoline see Fuel 215
Gasoline additives 303
Gauge for
Coolant temperature 25
Fuel 25
Outside temperature 25

clothing, safety gloves and eye protection
Potential risks
Risk of death
Risk of explosion caused by liquefied petroleum gas leaking out of the system in closed rooms or when gas the
tank is overheated due to work being done.
Risk of burn injuries caused by explosions.
Risk of frostbite to skin and body parts caused by liquefied petroleum gas spraying out and by coming into
contact with components that are near the valve when the tank is being emptied. Risk of poisoning or risk of
suffocation caused by inhaling liquefied petroleum gas.
Safety instructions/precautions
Wear protective clothing, safety gloves and eye protection
Keep suitable fire extinguishing equipment at hand
Keep any flammable materials and objects away from the equipment
Avoid making any sparks
Perform a fire check of the surroundings after work has carried out
Never perform work in closed rooms
Before commencing any work, ensure that all sources of ignition have been eliminated. Ensure adequate
ventilation of the immediate area around the vehicle.
Adequate ventilation means an exchange of air at least 3 times an hour at a distance of 3 meters from the gas
shutoff valve.
Close the gas shutoff valves at the compressed-gas tanks before commencing repair work.
Close off gas tank valve if vehicle is to remain in closed rooms, e.g. in halls or garages, for longer periods of
time.
Maintenance and repair work may only be carried out by specially trained personnel.
Due to the fact that explosions can occur when the gas system has leaks, a leak test must be performed before
restarting the system after repairs have been done in which the pipes and lines of the gas system have been
opened.
In the Federal Republic of Germany, this leak test can only be performed by specially trained DVFG personnel
as per the DVGW Work Sheet G 607.
(DVFG - German Liquefied Petroleum Gas Association)

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 230 © 2006 Mitchell Repair Information Company, LLC.

(DVGW - German Technical and Scientific Association for Gas and Water)
Observe country-specific regulations.
First aid measures:
Move the victim out of the risk area.
If eyes are affected immediately and thoroughly wash out eyes (making sure that eye lids are open) with plenty
of clean water.
If skin is affected drench with water. The victim must be kept warm and calm.
If inhaled , and if drowsiness, headaches, visual problems or irritation of the eyes, nose and throat occur,
remove victim to fresh air. Place unconscious victims in the recovery position and check for breathing and
pulse. If there is no breathing or insufficient breathing, the preferable action is to perform mouth-to-mouth
resuscitation. If necessary, carry out CPR.
For any of these symptoms immediately call a doctor.
SAFETY INFORMATION: OVERALL VEHICLE - AS00.00-Z-9999ZZ
MODEL all
Risk of injury caused by
pinching or jamming when
working on loaded springs
or spring bodiesMODEL allAS00.00-Z-0001-01A
Risk of injury caused by
scraping or cutting body
parts on sharp vehicle partsMODEL 903 ...AS00.00-Z-0017-01B
Risk of explosion caused by
escaping natural gas or an
overheated compressed-gas
tank when working on
natural gas powered
vehicles. Risk of frostbite to
body parts caused by
escaping natural gas or
contact with components
near the valves when
draining compressed-gas
tanks. Risk of poisoning or
suffocation caused by
inhaling natural gas.MODEL 211 with
CODE (924) Bivalent
natural gas driveAS00.00-Z-0018-01B
Risk of death caused by MODEL allAS00.00-Z-0021-01A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 231 © 2006 Mitchell Repair Information Company, LLC.

SI47.10-P-0004A
Service Information: Procedure when tank is filled with incorrect fuel
19.12.00

MODEL
202 with ENGINE 611

MODEL
203 with ENGINE 611, 612, 646

MODEL
210 with ENGINE 611, 612, 613

MODEL
220 with ENGINE 613, 628, 648

MODEL
163 with ENGINE 612, 628

MODEL
168 with ENGINE 668

MODEL
209 with ENGINE 612

MODEL
211 with ENGINE 628, 646, 647, 648

MODEL
463 with ENGINE 612, 628

Modification notes

26.7.04

Engines have been added and procedure has been updated

Incorrect refueling of diesel-power vehicles with a common rail
injection system. Please be aware that if the customer fills the fuel
tank with the wrong type of fuel, this is the customer's fault and

cannot be submitted as a warranty claim.

If the diesel-powered vehicle with a common rail injection system has

been refueled with gasoline, follow the steps below:

1.
If the engine was not started after fuel tank is filled with the wrong

type of fuel, then emptying the fuel tank and cleaning the fuel low-

pressure lines should be enough to solve the problem.
2.

If the engine was started after fuel tank was filled with wrong type

of fuel:

On engines 611, 612, 613, 668:
-
On the rail, open the low pressure connection of the high
pressure pump return (plastic connection in area of pressure

regulator valve) and check connecting point in rail for chips.

On engine 646, 647, 648, 628:
-
Disconnect Y-distributor unit (return line HDP/Rail) at the output

and, with ignition ON, collect the fuel in a clean container. Check

fuel for metal shavings.

If the high pressure pump is not damaged and there are no metal

shavings in the injection system:

-
As in step 1, empty fuel as per the guidelines and clean the fuel

low-pressure lines. In addition to this, remove/install/replace the

high-pressure pump and fuel filter.

If metal shavings are found in the fuel

system or the high pressure pump drive is

damaged:

#
b

Engine runs rough, surges or does not start
ENGINE 611 in MODEL 203, 202, 210
ENGINE 612 in MODEL 163, 203, 210, 209

ENGINE 613 in MODEL 210, 220

ENGINE 628 in MODEL 163, 220, 211

ENGINE 646 in MODEL 203, 211

ENGINE 647 in MODEL 211

ENGINE 648 in MODEL 220, 211

ENGINE 668 in MODEL 168

ENGINE 612, 628 in MODEL 463

AF07.00-P-9000B

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
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