MERCEDES-BENZ ML350 1997 Complete Repair Manual

AR01.20-P-5014-02B
Remove/install cylinder head cover trim
Crankcase ventilation, cylinder head cover

Number

Designation
Engine

612.961/

962/967
Engine

612.963
Engine

612.965/

966
Engine

612.990

BA01.20-P-1002-01A
Screw of trim panel of cylinder head cover

to cylinder head cover
NM
101010
8

BA01.20-P-1003-01A
Screw attaching cover panel to charge air

distribution pipe
NM
101010
-

P01.20-2018-11

1
Unscrew bolts (3, 4).


Installation:
Pay attention to tightening torques
.
2
Pull out trim panel (2) of charge air distribution pipe to the side.


Installation:
Insert shackles of trim panel (2) into the rubber

mounts (5), so that the trim panel (2) is not damaged.

3
Take off trim panel (1) of cylinder head cover.

Installation:
Ensure the trim panel is correctly installed; ensure
no lines are trapped.

4
Install in reverse sequence.

Illustrated on Engine 612.961

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BT27.60-P-0003-01A
Deletion of lever for shift lock cable ignition

lock at transmission
k

TRANSMISSION
722.700 ## as of 0129631 as of 24.1.01,
722.701 ## as of 0132072 as of 8.2.01

P27.60-0421-01

1
Shift lock lever ignition lock

2
Shift lock lever brake pedal

Because of the deletion of the shift lock cable ignition lock the lever for the shift lock cable ign
ition

lock (1) at the transmission is likewise deleted.

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BT27.60-P-0001-02A
Deletion shift lock cable ignition lock to

transmission
k

TRANSMISSION
722.7 in MODEL WDB168.### ## as of 548031 as of 10.1.01

P27.60-2187-06

1
New ignition lock cable

2
Shift lock cable

For cost-saving reasons the shift lock cable of

the ignition lock to transmission is

discontinued. A cable from the ignition lock to

the brake pedal is used in its place.

Consequently, it is only possible to

withdraw the ignition key when the brake

pedal is depressed
.

The new ignition lock cable (1) does no
longer require to be adjusted.
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OF91.60-P-1000-01A
Disconnecting airbag, certificate


After the front passenger airbag or emergency tensioning retractor

has been deactivated it must be ensured that the declaration is

signed by the customer.

Reconnection should be stamped and signed on the declaration by

the Mercedes-Benz service station performing the work.

a mb

Declaration

after disconnecting front passenger airbag on request by customer

I have explicitly requested the operation of the passenger airbag and

the passenger emergency tensioning retractor with belt force limiter

to be deactivated.

I have been informed that due to this measure the additional passive

safety guaranteed by the front passenger airbag as well as the front

passenger emergency tensioning retractor with belt force limiter is no

longer available and thereby increases the injury hazard for the

passenger.

Particularly body regions such as head, neck and chest can be

affected by reduced restraint. Direct contact with passenger

compartment components can occur more probably.

I hereby forego all claims against DaimlerChrysler AG that arise from

the deactivation of the passenger airbag and the passenger
emergency tensioning retractor with belt force limiter, whatever the

legal reason for the claim.

Moreover, I acknowledge that I am obligated to indicate to

passengers, any subsequent owner of the vehicle or any person

using the vehicle that this protective function has been deactivated

as well as the associated hazards.
A sticker has been attached to the passenger airbag which may be

removed only when the passenger airbag is reactivated by a

Mercedes-Benz service station.

Disconnection is to be noted in the registration papers.

......................................................................

Date/signature of customer

.....................................................................

Date/stamp/signature/Mercedes-Benz service station

Customer address:
...........................................................................
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chassis ident no.:....................................................................

Reactivation of the passenger airbag should be accomplished only by

a Mercedes-Benz service station.

Reactivation:....................................................................

Date/stamp/signature/Mercedes-Benz service station

s

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GF54.30-P-2002A
Display instruments, location / task / function
24.10.96

MODEL
129, 140 as of 1.6.96,

163, 168, 170,

202 as of 1.8.96,

208 up to 31.7.99,

210 as of 1.6.96 up to 30.6.99

Display
Type of data transmission

D
Outside temperature indicator (A1p4)

D
Fuel level gauge (A1p2)

D
Engine oil pressure gauge (A1p3), only

model 129 and model 140

D
Low windshield washer fluid level

indicator lamp (A1e13), model 163 as of

01.09.01

Direct lines

GF54.30-P-3004A

D
Total mileage odometer (A1h4)

D
Electronic speedometer (A1p8)

D
Tachometer (A1p5)

D
Coolant temperature gauge (A1p1)

D
Active service system (ASSYST)

D
Gear indicator (A1p12), only model 168

CAN data lines

GF54.30-P-3005A

D
Electronic clock
Internal

GF54.30-P-3011A

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AD54.30-P-3000-03A
Display instruments/multi-function display

function check IC

Display

instruments

The display instruments must indicate according to operating

conditions.

Phototransistor (models 202, 208, 210)

Point a beam of light at the phototransistor with a pocket lamp, the

display illumination of the LCD displays (outside temperature, trip

odometer, total mileage recorder and electronic clock) must get

brighter.
Instrument cluster with multi-function display

If there are malfunctions (e.g. brake linings worn, coolant level too

low, exterior lamp failure etc.) or system faults (anti-lock brake

system faulty, supplemental restraint system faulty) the warning

display with warning information is inserted in place of outside

temperature, odometer, total mileage recorder and electronic clock.

The warning information is displayed in yellow or red depending on

the fault and a warning tone also sounds.
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GF54.30-P-3028GH
Displaying coolant level, function
28.6.99

MODEL
163 as of 1.3.99

Function prerequisite

Engine: ON

Function

If the coolant level drops below the minimum mark the low ECL

indicator lamp (A1p11) is illuminated.

To record the coolant level the instrument cluster (A1) is connected

direct to the
coolant level indicator electronic switch (S41)
via two

cables. The
coolant level indicator electronic switch (S41)

consists of two electrodes.

D
If the
level is correct
both electrodes are immersed in the

coolant. The coolant serves as a dielectric between the

electrodes.

D
If the coolant level is below the minimum mark the electrodes of

the sensor are no longer immersed in the coolant. There is only

air between the electrodes as a dielectric. Evaluation

The instrument cluster (A1) sends test pulses to the sensor for

a period of one millisecond. These pulses are deformed

differently depending on the dielectric (air or coolant).

The instrument cluster (A1) evaluates the pulse shape and, if

the coolant level is below the minimum (electrodes are

completely in air), actuates the low ECL indicator lamp (A1p11)

after a delay of
approx. 60 seconds
.

The delay serves to prevent the indicator lamp flickering due to

the coolant moving from side to side on corners or off-road.

Diagnosis

Diagnosis is carried out, as described in the Diagnosis Manual, via

the simulation of the
coolant level indicator electronic switch (S41)

by a resistance.

Coolant level switch,

location/task/design/function

GF54.30-P-4103GH

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GF00.20-P-2010B
Displaying service, function
25.3.99

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

MODEL
202 as of 1.8.99

Display of service to be performed

In addition to the various service displays, the service work to be

performed (A or B) also appears.

The service symbol (wrench) appears once or twice in the display for

this purpose.

The service symbol appears
D
once
for service
A

D
twice
for service B
.

A service A is always followed by a service B.

Following a service B, the next service must be calculated

taking into account the kilometer readings. If the distance of the

current service interval is less than 22 000 km, the next service

is service A, otherwise service B.

This calculation is now performed
automatically
in the

instrument cluster (A1).

The path of the service displayed A or B can be processed in

the service sheet without the need for a calculation.
There is no external difference in the instrument clusters with

and without the service display.

If service A (one service symbol) is displayed, it is then

necessary to ensure by means of the
production date
or the

control unit identifier
, that the vehicle in question is in fact a

vehicle
with service display
. If this is not the case, the service

must be determined as specified in the service sheet.

The table below shows from which control unit identifier the

instrument cluster features the service display:

The control unit identifier can be read with the HHT under menu point

"Control unit version".
Model

Control unit identifier

129
2/04

163
3/04

168
3/20

170
2/23

202
0/20

Displaying remaining service function

GF00.20-P-2007A

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AR82.20-P-0110GH
Removing and installing front dome lamp
13.3.97

MODEL
163

P82.20-0400-11

1
Overhead control panel

2
Bulb

3
Socket

4
Dome lamp switch

5
Screws

6
Reflector housing


Removal, installation

1
Remove overhead control panel (1)

AR82.20-P-1100GH

2
Remove bulb (2)

3
Release socket (3) for bulb (2) by pressing in

The bulb socket is clipped to the overhead

control panel.

4
Pull dome lamp switch (4) off of reflector

housing (6)

5
Unscrew screws (5) from reflector housing (6)

on left and right on overhead control panel (1)

6
Pry reflector housing (6) out of overhead

control panel (1)


Avoid damaging reflector housing

7
Reinstall in opposite order

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AR72.10-P-2100GH
Remove/install door catch
11.2.97

MODEL
163.113 /128 /136 /154 /157 /172 /174 /175

P72.10-0483-01

1
Bolt

2
Mount for seal

3
Seal

4
Bracket

5
Door retaining strap

6
Nut

P72.10-0484-01

Removing, installing
1
Remove door lining
Front door

AR72.10-P-1000GH

Rear door

AR72.12-P-1010GH

2
Pull foil off of inner door panel in front area

Installation:
Replace damaged foil.

3
Unscrew screw (1) on door retraining strap


Avoid damaging paint.

Installation:
Apply glue to screw.
*BR00.45-Z-1013-02A


*BA72.10-P-1001-01D


*BA72.12-P-1003-01C

4.1
Pull seal (3) off of door retaining strap (5)
Up to 08/99.

5
Close crank window

6
Unscrew nuts (6) from door retaining strap


Hold door retaining strap to prevent it

from falling into the door


*BA72.10-P-1002-01D

7
Remove door retaining strap through

installation opening in inner door panel

Pull rubber out of retaining clip at bottom

of window guide rail and move along door

catch.

Installation:
Install window guide rail

correctly.

8
Install in the reverse order


Front door

Number

Designation
MODEL

Series 163

BA72.10-P-1001-01DBolt, door catch at A-pillar
Nm
24

BA72.10-P-1002-01D
Nut for door restraining strap on

inside of door
Nm
10


Rear door

Number

Designation
MODEL

Series 163

BA72.12-P-1003-01C
Screw for door catch on B-pillar
Nm
24

Auxiliary repair materials

Number

Designation
Order number

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