MERCEDES-BENZ ML430 1997 Complete Repair Manual

AR54.30-P-6031GH
Removing and installing instrument cluster housing
21.1.97

MODEL
163

P54.30-0631-06

1
Cover

2
Instrument cluster housing

3
Symbol strip

Removing, installing
1
Remove instrument cluster

AR54.30-P-6015GH

2
Unclip retaining lugs (arrows)


Installation:
The retaining lugs must lock

fully in position.

3
Remove cover (1) from instrument cluster

housing (2)

The symbol strips (3) may fall out sideways.


Installation:


Pay attention to vehicle equipment when

replacing symbol strips.

Ensure the adjusting knobs for the odometer

and electronic clock are seated correctly.

4
Install in reverse order

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR54.30-P-6015GH
Remove instrument cluster
20.1.97

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

P54.25-2680-06

Steering wheel removed for clarity

3
Upper steering column cover

12
Side covering

P54.30-0630-06

Steering wheel removed for clarity

4
Clips

5
Frames

6
Hook

7
Lug

8
Mount

9
Screw

10
Spreading clips

11
Connector

13
Mount

A1
Instrument cluster


Remove, Install

1
Disconnect ground cable of battery


To prevent unintended contact, insulate

the ground lead cable lug.

AR54.10-P-0003A

2
Unlock steering wheel and move to its lowest

position

See Operating Instructions

3
Remove upper steering column cover (3)

Risk of fracturing! Do not scratch the

steering wheel.

Only as of VIN A145273, X708319:

Loosen clips on the side and front. Gently

squeeze the cover together and pull out

between the steering wheel and instrument

panel.

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

4
Remove side covers (12)

Danger of breaking retaining lugs. Do not

damage instrument panel.


Up to VIN A145272, X708318:
3 covers:

Remove side covers first. Detach center

cover from instrument panel and rotate so

that the retaining lugs point upwards. Then

pull out to the right.

As of VIN A145273, X708319:
2 covers: First

remove the right cover, then the left. It is not

necessary to detach the connectors. The

covers can remain attached to the wiring

harness.


Long wedge

*115589035900

5
Remove frame (5) of instrument cluster

Lift clips carefully, risk of fracture.

Push the clips (4) outwards (arrow

direction A) and ease the frame down towards

the footwell (arrow direction B) until the top of

the frame disengages.

Installation:
Insert the hooks (6) of the

frame into the bracket (13) and push the

frame upwards until the clips snap into place.

Installation:
Insert the lugs (7) on the

frame into the receptacles (8) on the

instrument cluster.

6
Unscrew screws (9)

7
Remove expanding clips (10)

8
Pull instrument cluster (A1) forwards

9
Unlock, open and pull off connector (11)

10
Remove instrument cluster

Make sure the steering wheel is not

scratched.

Tilt the upper edge of the instrument

cluster towards the steering wheel and move

to the right out of the instrument panel.

11
Install in the reverse order

12
Perform function check

a

Instrument cluster (IC) diagnosis operational

check

AD54.30-P-3000A

Assembly wedge

115 589 03 59 00

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

AD54.30-P-6000-01GH
Instrument cluster, testing electrical system IC
Model 163

t
A

Scope of test

Measuring instrument/

Test connection

Operation/

Requirement
Specified value
D
Possible cause/

Remedy

1.0Instrument cluster (A1)


Voltage supply,

terminal 30

3 w

(A.3)

A1

cL
11

(A.11)

Ignition:
OFF

Remove A1

Coupling "A" (18-pin)

disconnected

11
-
14 V
D
Fuse f13 in fuse and relay

box F1

D
Cables

Value in order
#
t
1.1

1.1
Voltage supply,

terminal 15

3 w

(A.3)

A1

cL
9

(A.9)

Ignition: ON
11
-
14 V

D
Fuse f22 in fuse and relay

box F1

D
Cables

Value in order
#
t
1.2

1.2
Voltage supply,

terminal 15R

3 w

(A.3)

A1

cL
7

(A.7)

Ignition: ON
11
-
14 V

D
Fuse f10 in fuse and relay

box F1

D
Cables

Value in order
#
D
A1

Copyright DaimlerChrysler AG 05.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AD54.30-P-5000GH
Instrument cluster (IC) diagnosis troubleshooting
10.4.97

MODEL
163

Connection and use of test equipment

AD00.00-P-1000AZ

Instrument cluster diagnosis, previous

knowledge

AD54.30-P-2000GH

Explanatory notes on diagnosis

troubleshooting chart IC

AD54.30-P-5000-01GH

Display instruments controlled via CAN

troubleshooting chart IC

AD54.30-P-5000-02A

Display instruments controlled directly,

troubleshooting chart IC

AD54.30-P-5000-03A

Troubleshooting

Complaint
Possible cause
Notes
Remedy/Test step

Instrument cluster (A1) completely inoperative
Voltage supply, instrument cluster (A1)

AD54.30-P-6000-01GH

Malfunction indicator lamps or indicator lamps

inoperative
Voltage supply, instrument cluster (A1)
AD54.30-P-6000-01GH

HHT and instrument cluster cannot

communicate
Cables, instrument cluster (A1)

AD54.30-P-6000-02GH

Low brake fluid level/parking brake indicator

lamp, brake pad wear indicator lamp, ABS

MIL, malfunction indicator lamp (ETS, ASR,

ESP) come on together and speedometer

remains on lower stop.
Traction system control module (N47)

AD42.35-P-1001BZ

RPM counter, engine coolant gauge remain

on the lower stop and the low engine oil level

indicator lamp comes on.
Injection system control module (N3)

AD07.61-P-1000AZ
Low brake fluid level/parking brake indicator

lamp, brake pad wear indicator lamp, low

engine oil level indicator lamp, ABS MIL,

malfunction indicator lamp (ETS, ASR, ESP)

come on together and RPM counter, engine

coolant gauge and speedometer remain on

lower stop.
CAN faulty

AD54.30-P-6000-04GH
AD54.30-P-6000-05GH

Steering lock warning lamp (A1e40) is

continuously illuminated or is inoperative.
Cables,

steering lock switch (S97/1)

AD54.30-P-6000-06GH

Coolant level indicator disrupted
Cables,

Coolant level indicator electronic switch (S41)

Model 163 as of 3.98

AD54.30-P-6000-42GH

Copyright DaimlerChrysler AG 05.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

GF54.30-P-0002-01GC
Instrument cluster (IC), block diagram

n

P54.30-0785-06

58
Terminal 58

58d
Terminal 58d

61
Terminal 61

A1
Instrument cluster

X11/4
Data link connector (DTC readout)

a
Engine control module

b
Traction system control module

c
Engine control module inputs, e.g.

ECT sensor

d
Traction system control module

inputs, e.g. wheel speed sensors

e
Direct inputs

f
Transfer case control module (N78)

(model 163 only)

g
Gear recognition module (A61) or

automatic clutch control module

(N15/4) (model 168 only)

Copyright DaimlerChrysler AG 04.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

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

Copyright DaimlerChrysler AG 05.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR68.10-P-1040GH
Remove/install bottom section of instrument panel
13.3.97

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

P68.10-2226-09

1
Instrument panel

2
Instrument cluster cover frame

3
Combination switch with paneling

4
Bottom section of instrument panel

5
Screws in left footwell

6
Screws in right footwell

7
Bolts
15

Paneling

16
Bolt

17
Entrance lamps

A
Spreading clips

B
Guide tongues

8

Bolts

9
Bolts

10
Heater/ventilation switch

11
Instrument panel center section

12
Glove compartment

13
Parking brake release handle

14
Parking brake control cable


Remove/install

1
Shift transmission selection lever to position" 1"


Secure vehicle to prevent it moving away.

2
Disconnect ground cable of battery

AR54.10-P-0003A

3
Remove combination switch with paneling (3)

AR54.25-P-2800GH

4
Remove cover frame of instrument cluster (2)

5
Unscrew the screws (7).

3 screws up to 08/99. 1 screw as of 09/99.

6
Unscrew screws in left footwell (5) on the

lower part of the instrument panel (4)

7
Remove center section of instrument panel

(11)

AR68.10-P-1030GH

8
Remove switch unit for heater / ventilation (10)
Up to 31.08.01.

AR83.20-P-1835GH

As of 01.09.01.

AR83.40-P-6500GH

9
Unscrew screws (8, 9)

10
Remover glove compartment (12)
Up to 31.08.99.

AR68.10-P-1400GH

As of 01.09.99.

AR68.10-P-1400GI

11
Unscrew screws in the right footwell (6) on

the lower part of the instrument panel (4)

12.1
Unclip entrance lamps (17) and disconnect
electrical connectors

As of 09/99.

13.1
Remove paneling (15) and unscrew screws

(16)

As of 09/99.

14
Unclip lower part of instrument panel (4) at
the four expanding clips (A) on the instrument

panel (1)

Installation: Ensure that guide lugs (B) are

properly seated in the mounts on the

instrument panel.

15
Unhook the Bowden cable of the parking

brake (14) at the release handle of the

parking brake (13)

16
Remove bottom section of instrument panel (4)

Do not damage instrument panel when

removing and installing.

17
Install in the reverse order

18
Read diagnostic trouble code memory and

erase

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2