MERCEDES-BENZ ML350 1997 Complete Repair Manual

AR68.10-P-1400GH
Remove/install glove compartment
4.2.97

MODEL
163.136 /154 /172 #A up to 145272

P68.10-0515-05

1
Striker eye

2-7
Screws

8-9
Stop buffer

10
Glove compartment

E13/1
Glove compartment lamp


Remove/Install

1
Open glove compartment lid

2
Unclip glove compartment lamp (E13/1) and

disconnect connector

3
Remove striker eye (1)


Installation:
Check adjustment.Refer to:
#

Adjust glove compartment lid.

AR68.10-P-1300GH

4
Unscrew screws (2-7)

5
Pry glove compartment (10) out of arrest at

bottom and pull out

6
Install in the reverse order

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AR68.10-P-1220GH
Disassembling and assembling glove compartment lid
4.2.97

MODEL
163.136 /154 /172 up to 31.8.99

P68.10-0518-06

1
Stop lever

2
Inner section

3
Screw for catch

4
Glove compartment catch

5
Screw for inner section

6
Insert

7
Glove compartment lid

8
Hinge

9
Spring for catch

10
Pin for catch


Disassembly, assembly

1
Remove glove compartment lid

AR68.10-P-1200GH

2
Unclip stop lever (1) from inner section (2)

3
Remove hinges (8) on inner section (2)

Remove hinge pins

4
Unscrew screws (3) from lock (4)

5
Unscrew screws (5) from glove compartment

inner section (2)

5 each.

6
Remove inner section (2)

7
Remove insert (6) from inner section (2)

8
Unhook glove compartment catch (4) and

spring (9)

9
Remove glove compartment catch (4) from

glove compartment lid (7)

Drive out pin (10).

Installation:
Observe installation position for

spring (9).

10
Install in opposite order

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GF54.30-P-2017A
HHT interface, location/task
7.7.99

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

The instrument cluster has diagnostic capabilities. In other words,

diagnosis is possible using a hand held test (HHT). The instrument

cluster therefore has a line (K-line) which is connected to the data

link connector (X11/4).
The instrument cluster, including the Active Service System

(ASSYST), is tested with the HHT. The following functions can be

selected:

D
Control module version

D
Error memory

D
Actual valves

D
Controls

D
Manual transmission adaptation:
- variant coding

- settings

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AD00.00-P-2000-03C
Connect hand-held tester (HHT), read out

diagnostic trouble code memory
Model 163 up to 31.08.01

Model 168

Workshop equipment/MB testers
(see Workshop Equipment Manual)

WE58.40-Z-1001-06A
Hand-held tester (HHT), order number 6511 0001 99

WE58.40-Z-1002-06A
Test cable (multiplexer)

WE58.40-Z-1009-06A
Adapter cable (HHT) for test connector (X11/4, 16-pin), order number 6511 0090 99

P42.35-0234-06

1
Connect hand-held tester (087) to

diagnosis test connector (X11/4) in

interior using test cable (multiplexer)

(094) and adapter cable (107) .

2
Switch on ignition.

3
According to instructions in display :

a)
Read out/erase fault memory

b)
Read out actual values

c)
Perform actuations

d)
Program control modules

4
Disconnect HHT.

087
Hand-held tester (HHT)

094
Test cable (multiplexer)

107
Adapter cable (HHT) for datalink

connector (X11/4, 16-pin)

X11/4
Diagnostic data link connector

Note system-specific deviations listed in respective diagnosis

description in chapter entitled "Diagnosis Previous Knowledge".
Stored faults possibly caused by cables being disconnected during

testing or by simulation must be erased from the fault memory once

the work is completed.

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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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AP82.10-P-8260GH
Check and correct headlamp adjustment
2.7.97

MODEL
163

a=Marking for low beams

b=Marking for high beams

c=Marking for fog lamps

P82.10-0212-02


Check

1
Drive vehicle to level surface
The vehicle level must not change when the

brakes are applied.

Vehicle must be in ready-for-the-road

condition (unladen weight, fuel tank full or

proper additional weight).

Correctly adjust tire pressure.

Load driver's seat with 75 kg or a person

(except USA)

2
Align headlamp adjustment tester to vehicle

and adjust height according to marking in lens

Follow the operating instructions for

headlamp beam setting equipment exactly

*WH58.30-Z-1002-09A


Danger!

Risk of accident
from vehicle starting off by

itself when engine running.
Risk of injury


suffered in the form of bruises or burns to the

hands when reaching in while the engine

cranks or runs
Secure vehicle to prevent it from moving off

by itself.

Wear closed and close-fitting work clothes.

Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

3
Run engine and switch on low beam

4
Check headlamp range control for proper

function
(except USA)


The light beams from both headlamps should

change uniformly

5
Set headlamp range control switch to position 0

6
Check low beams
Adjust if necessary (except USA)

AP82.10-P-8260-01A


Due to the common reflector unit, the low

beams, high beams and fog lamps are

adjusted simultaneously.

US version:
#

See "Owner's Manual"

7
Check high beam adjustment

AP82.10-P-8260-02A

8
Check fog lamps

AP82.10-P-8260-04A

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e.g.)
Order number

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WH58.30-Z-1002-09A
Headlamp adjuster
Robert Bosch GmbH

Franz Oechsle Str. 4

D-73207 Plochingen,

Germany

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AD54.30-P-6000-02GH
HHT interface test electrics IC

t
A

Scope of test

Measuring instrument/

Test connection

Operation/

Requirement
Specified value
D
Possible cause/

Remedy

1.0
HHT interface

Connection between A1

and data link connector

(DTC readout) (X11/4)

X11/4

15
wb

A1

L
11

(B.11)

Ignition:
OFF

Remove A1

Coupling "B" (12-pin)

disconnected

T
5
W D
Cable

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AF18.00-P-8045A
High oil consumption, blue smoke
26.10.99

ENGINE
112 in MODEL 129, 163, 202, 208, 210

ENGINE
112 in MODEL 463

Modification notes

18.11.99

Supersedes STIP 18.40-004 dated 5.11.97
Remedy revised

Damage code
Cause
Remedy

01 241 B2
Cast iron crust in oil drain duct on right

cylinder head, inner rear
1
Remove right cylinder head.
#

In case of complaint oil drain duct is filled

with engine oil.

Engine 112 in model 129, 202, 208, 210
AR01.30-P-5800B

Engine 112.942 in model 163.154

AR01.30-P-5800MV

Engine 112.945 in model 463

AR01.30-P-5800GV

2
Remove present cast iron crust.

Use sharp edged 10 mm punch. The cast

iron crust (approx. 11x17x1 mm) is located

approx. 50 mm below the upper cylinder head

separating surface.

3
Install right cylinder head
#

Engine 112 in model 129

AR01.30-P-5800B

Engine 112 in model 202, 208, 210

AR01.30-P-5800BA

Engine 112.942 in model 163.154

AR01.30-P-5800MV

Engine 112.945 in model 463

AR01.30-P-5800GV

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AF18.00-P-8044D
High oil consumption
12.3.01

ENGINE
112 in MODEL 129, 163, 170, 202, 203, 208, 210, 220

ENGINE
113 in MODEL 129, 163, 202, 208, 210, 215, 220

ENGINE
112, 113 in MODEL 463

Damage code
Cause
Remedy

Studies on engines 112/113 due to

excessive engine oil consumption have
indicated to date that excessive engine oil

consumption is not a general subject, but

rather can result from various causes.

The causes listed below may cause

excessive engine oil consumption individually

or in combination.

For commercially available tools for see

Workshop Equipment Manual

Cause 1:
Remedy 1:

00 001 70
Cast iron crust in right cylinder head behind

oil drain opening
1
Remove cast iron crust

AF18.00-P-8045A

Cause 2:
Remedy 2:

00 001 70
V-shaped material flaws (rough unhoned

points) on individual cylinder liners

Up to production 08/2000.
1

Check cylinder liners with piston at

bottom dead center.

#

Inspect cylinders with light probe

AR01.00-P-0200AU


*WH58.30-Z-1009-05A


*WH58.30-Z-1010-05A


*WH58.30-Z-1027-05A

Cylinder barrels not okay:
#
2
Remove/install/replace engine or

shortblock.

Cause 3:
Remedy 3:

00 001 70
Single oil scraper rings with ring tension at

lower tolerance limit.

Up to production 06/1999.
1

Perform oil consumption test drive over

approx. 500 km.

AR18.00-P-0025AV
Exclude all other types of faults.

2
Remove/install/replace piston rings.

Install cleaned pistons with new piston

rings in the same cylinder.

Install piston rings with optimized ring

tension.

These piston rings are available as

replacement parts under the normal

replacement part number.

Cause 4:
Remedy 4:

00 001 70
Individual (right) cylinder heads with inner

porous points to air injection duct.
1
Check left/right cylinder bank.

If a cylinder bank is oily:
#
2
Remove/install/replace only this cylinder

head.

ENGINE
112 in MODEL 220, 210, 208, 202,

129

ENGINE
113 in MODEL 220, 210, 208, 202,

129
AR01.30-P-5800B

ENGINE

112.942 in MODEL 163.154

ENGINE
113.942 in MODEL 163.172

ENGINE
113.981 in MODEL 163.174 AR01.30-P-5800MV

ENGINE

112.945, 113.962 in MODEL 463

AR01.30-P-5800GV

Cause 5:
Remedy 5:

00 001 70
Individual engines with missing valve seals on

individual cylinders
1
Remove valve springs on affected

cylinder.

AR05.30-P-3500B

In this case, usually one cylinder is oily, oil

runs through valve cone into cylinder when

valve is open.

2
Check valve seal.

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