MERCEDES-BENZ ML430 1997 Complete Repair Manual

SI47.10-P-0007A
Service Information: Procedure for fuel tank leaks
14.8.03

MODEL
124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 460, 461, 463

If a fuel tank has a leak which was caused by an accident with

another vehicle, bottoming out, etc., this
cannot
be claimed as a

warranty/goodwill case.

We
explicitly
state here that repair measures

(e.g. welding, bonding, etc.) on fuel tanks made out of sheet metal or

plastic are not permissible.
The fuel tank is always to be replaced when leaks are determined

which have been caused by damage to the upper or lower sides of

the fuel tank.

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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

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SI91.60-P-0002A
Service information on immobilization of a passenger-side airbag where a

rearward mounted (reboard) child seat is fitted
17.3.99

MODEL
124, 126, 129, 140, 163, 168, 170, 202, 203, 208, 210, 215, 220, 463

Modification notes

18.11.00

Supersedes Service Information SI91.60-P-0002A dated

15.11.00
Remove the SI SI91.60-P-0002A from your file

It is recommended to place the child seat in the rear area if

possible.

If, in exceptional cases, the owner wishes a rearward mounted child
seat to be expressly attached on the front passenger seat, the front

passenger airbag should be immobilized.


As a general rule, there is no approval for immobilizing the front

passenger airbag on models fitted with ACSR, which is visible from

the "airbag OFF" indicator light in the center console. On such

models, an MB child seat with ACSR should be used for safety and

cost reasons.

-----------------------------------------------------------------------------------------


On models fitted with seat belt force limiter, it is essential for

safety reasons to

D
program the front passenger ETR to "NO".

D
unplug the connector at the front passenger ETR.


No provision is made for immobilizing the seat occupied

recognition, the automatic child seat recognition (ACSR), as well as

the side airbag and window airbag.

In the event that it is necessary to immobilize the seat occupied

recognition and automatic child seat recognition (ACSR), for example

if a Recaro seat is installed, this can be carried out in exceptional

cases after agreement has been obtained from GSP/SPS, tel. 07031

/ 90 - 81815.

-----------------------------------------------------------------------------------------


After immobilizing the front passenger airbag or additionally the

ETR, it is essential to

D
have the customer sign the confirmation after immobilization.

D
affix a sticker at a clearly visible point in the area of the front

passenger airbag.

D
affix a sticker in the Owner's Manual, in the section Airbag.

Carry out the remaining procedure as stated below.

-----------------------------------------------------------------------------------------
Deactivation can be reversed at any time.

Immobilization and re-activation must be entered in the

vehicle documents!

The vehicle should be presented in such a case to a technical

inspection center (DEKRA, TÜV). The completed confirmation

should be submitted to the vehicle registration authorities for

entry.

-----------------------------------------------------------------------------------------

Perform version coding / procedure
Model

Version
Coding with HHT
2)

or STAR Diagnosis tool (DAS)
Unplug

connector of

passenger side

airbag
3)

Unplug

connector of

passenger side

emergency
tensioning
retractor
Insert

replacement resistor
3)

Passenger-side

airbag
NO

Passenger side
emergency
tensioning

retractor NO

124
All
--X-X

126
All
--X-X

129
up to 06/93
--X-X

129
as of 07/93 without ACSR
X-X--

140
up to 06/93
--X-X

140
as of 07/93 without ACSR
X-X--

140
as of 07/93 with ACSR
1)
-----

163
up to VIN 145263
--X-X

163
as of VIN 145264
-----

168
All
-----

170
without ACSR
XXXX-

170
with ACSR
1)
-----

202
without seat belt force limiter
X-X--

202
as of 06/97
4)
XXXX-

202
with ACSR
1)
-----

203
All
-----

208
All
-----

210
without ACSR
XXXX-

210
with ACSR
1)
-----

215
All
-----

220
All
-----

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463
All
-----

1)
Recognition: existing "airbag Off" warning light in center

console.

2)
With HHT functions menu point 5 Coding Reboard child seat. If

only the passenger side airbag is de-activated, then program
menu point Vehicle equipment.
3)

Depending on model and version, unplug one or two

connectors at the passenger side airbag and insert the

corresponding replacement resistors.

4)
Without ACSR, with seat belt force limiter.

Immobilizing passenger side airbag certificate
Model 124, 126, 129, 140, 163 up to VIN

145263, 170, 202, 210


Have customer sign certificate after

immobilization

OF91.60-P-1000-01A

Cancel immobilization

D
To re-activate the passenger side airbag remove the ignition

resistor at the cable.

D
Fit together connector at passenger side airbag.

D
Fit together connector at passenger side ETR (on models fitted

with seat belt force limiter).
D

Use HHT or STAR Diagnosis tool (DAS) to re-program

passenger side airbag and passenger side ETR in the SRS

control module to "YES".

D
Remove sticker on passenger side airbag and render invalid in
Owner's Manual.

D
Complete re-activation on certificate after immobilization.

D
If re-activated, delete de-activation in vehicle documents.

Parts ordering notes
Part no.

Designation
Quantity

140 868 00 50
Ignition resistor (replacement resistor)
as required

140 817 15 20
Sticker (without seat belt force limiter)
2

210 817 20 20
Sticker (with seat belt force limiter)
2

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Page 2

SI18.00-P-0010A
Service Information: oil sludge
26.3.01

ENGINE
111 in MODELS 124, 163, 170, 202, 203, 208, 210

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

ENGINE
112, 113 in MODEL 463

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

ENGINE
137 in MODEL 215, 220

ENGINE
166 in MODEL 168

Oil sludging in gasoline engines with ASSYST maintenance

system

Recently we have determined that time and time again oil

sludging occurs in gasoline engines with an ASSYST maintenance

system.

Oil sludging can lead to the following complaints:
D
engine oil consumption

D
engine smoke (white/blue)

D
influencing of oil level indicator

D
clogged oil filter, engine oil thickened like jelly

D
Check engine lamp illuminated

D
oil sludge visible during assembly job, e.g. in oil filter, in cylinder

head covers, condensation sludging
(engine 166) etc.

-----------------------------------------------------------------------------------------
The following list of causes may lead individually or as a combination
to engine oil sludging:

D
Crankcase ventilation inoperable, function orifices, bores,

passages in cylinder head cover, cylinder head, crankcase etc.

are mechanically sealed. A nonfunctioning crankcase

ventilation boosts loads on the engine oil through organic

nitrates. The risk of oil sludging increases.

The mechanical condition of the engine is always to be

checked, i.e. all engine oil drain orifices on the cylinder head

and crankcase and all crankcase ventilation ducts must be free

of obstacles. Crankcase breather lines may not be kinked.
Check the ventilation bores in the cylinder head covers.

-----------------------------------------------------------------------------------------

D
The engine oil used does not comply with the specifications in

Sheet 229.1 or 229.3 of the Specifications for Service Products.

The additive process, e.g. dirt-carrying capability, neutralization

capability and oxidation resistance as well as the quality of the

base stock influence sludging time.

Use of engine oils with best possible resistance to formation of

sludge, i.e. use only tested and approved engine oils (from

Sheet 229.1 or 229.3). The best protection is afforded by the

engine oils on Sheet 229.3, which fulfill more stringent

specifications with regard to preventing sludge and deposits
(see Sheet 221.0, page 11). These oils have a distinctly better

anti-sludge characteristic than other engine oils.

D
Sludging after adding a fuel or engine oil special additive.

Do not use fuel or engine oil special additives. More information

hereto is available on Sheet 219.0 of the Specifications for

Service products. Reference to customer not to use special

additives.

D
Engine oil change not performed according to ASSYST

specifications. At driven distances

exceeding > approx. 3000 km, engine oil sludging may occur.

-----------------------------------------------------------------------------------------
Comply with engine oil and filter change as under ASSYST

specifications. Observe remaining distance.

D
Fuel grade lies outside standard (regionally contingent). If

contaminated, deficient fuel is used, then engine oil sludging

may occur even where approved engine oil is used.

Operation with fuel, e.g. as under DIN EN 228. Clarify refueling

behavior of customer. If engine operation regional, is

temporarily possible with deficient oil only, then the startup

distance has to be individually reduced, i.e. the oil change

temporarily performed at an interval of, e.g. 10,000 km.

D
Radiator antifreeze penetration into engine oil, e.g. through an

internal engine leak (cylinder head gasket, casting porosity).

The engine oil sludges within a short period. The crankcase

ventilation clogs up and stops functioning. Condensation

sludging clogs up the oil separator cells

(engine 166).
Rectify coolant leakage. Clean all sludged engine parts, in

particular the crankcase ventilation parts. If the occurrence

repeats, and casting porosity is suspected, e.g. replace

crankcase.

-----------------------------------------------------------------------------------------

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Measures for slightly sludged engine:

Oil and filter change. Purge engine, i.e. normal engine operation

in neutral, or while driving, using oil from Sheet 229.3, 228.3, or

228.5. Drain off scavenging oil after purging process (approx. 1

hour). Repeat purging process if necessary. Refill using engine oil

from Sheet 229.3, or 229.1. The first oil change after clearing the

sludge should be performed after approx. 10,000 km or beforehand;

when doing so use engine oil from Sheet 229.3.

Measures for severely sludged engine:

Engines with severe oil sludging and caking onto engine parts

and into bores have to be dismantled and mechanically cleaned.

Tough sludge residue must not enter the clean side of the oil circuit,

as otherwise, e.g. the piston oil spray and the hydraulic

compensation elements may have their functionality impaired. Refill

using engine oil from Sheet 229.3, or 229.1.

The first oil change after sludging should be performed after approx.

10,000 km; when doing so use engine oil from

Sheet 229.3.
Warranty/goodwill regulations

If in combination with engine oil sludging a warranty/goodwill claim is

submitted, then a regular documentation of maintenance must be

presented. The ASSYST printout is to be filed carefully for further

reference.

Oil sludging in combination with an exceeded oil change interval, or

because of special additives in the fuel/engine oil are costs to be

borne by the customer.

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GF77.20-P-0001GH
Sliding /pop-up roof, function
28.2.97

MODEL
163 with CODE (414a) Electric glass sliding/pop-up roof

P77.20-0381-06

1
Close sliding/pop-up roof (SR)

2
Open sliding roof

3
Close pop-up roof

4
Open pop-up roof

M12
Sliding/pop-up roof (SR)

S13/2
Switch (SR)
The sliding /pop-up roof is a combination of a sliding roof and pop-up

roof. It is controlled by the motor for the
sliding /pop-up roof drive

assembly (M12)
located on the sliding roof frame below the

overhead control panel.

Two types of control are possible:

D
Opening/closing sliding roof (sliding roof opens toward rear)

D
Opening/closing pop-up roof

The sliding and pop-up roof cannot be opened simultaneously.

Operation is controlled by the
sliding/pop-up roof switch (S13/2)
in

the overhead control module.

-----------------------------------------------------------------------------------------
The following functions can be controlled with the switch:

D
Closing
sliding /pop-up roof (1 or 3); the sliding roof or pop-up

roof is closed depending on which is open.

D
Opening
sliding roof (2); if the pop-up roof is open it is closed

previously.

D
Opening
pop-up roof (4); if the sliding roof is open it is closed

previously.

-----------------------------------------------------------------------------------------


Sliding/pop-up roof (SR), location of

components

GF77.20-P-0001-01GH

Closing sliding/pop-up roof (SR), function

GF77.20-P-2002GH

Opening pop-up roof, function

GF77.20-P-2003GH

Opening sliding roof, function

GF77.20-P-2004GH

Sliding/pop-up roof (SR) lock-up recognition,

function

GF77.20-P-3000GH

Sliding/pop-up roof (SR) position

measurement, function

GF77.20-P-3001GH

Synchronizing sliding/pop-up roof (SR),

function

GF77.20-P-3002GH

Desynchronizing sliding/pop-up roof (SR),

function

GF77.20-P-3003GH

Sliding/pop-up roof, location/purpose/
design/function

GF77.20-P-4100GH

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Page 1

AR68.30-P-4610GH
Removing and installing spare wheel cover
28.4.99

MODEL
163.174

P68.30-2161-06

1
Spare wheel cover front section

2
Retaining straps

3
Electric air pump

4
Screws

5
Spare wheel mount

6
Bracket

7
Screws


Removal, installation

1
Remove cargo space cover

See Owner's Manual.

2
Loosen retaining straps (2) and remove spare

wheel cover front section (1)

3
Remove spare wheel


*BA40.10-P-1002-01A

4
Remove electric air pump (3)

5
Unscrew screws (4) and remove spare wheel

mount (5)

6
Remove bracket (6)

Turn in clockwise direction until bracket

(6) releases at D-pillar.

7
Remove rear wall on spare wheel cover

2 screws.

8
Install in opposite order


Wheels

Number

Designation
Model

163.174

BA40.10-P-1002-01A
Bolt for spare wheel on inside of spare wheel mount
Nm
50

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Page 1

AR68.30-P-4610GH
Removing and installing spare wheel cover
28.4.99

MODEL
163.174

P68.30-2161-06

1
Spare wheel cover front section

2
Retaining straps

3
Electric air pump

4
Screws

5
Spare wheel mount

6
Bracket

7
Screws


Removal, installation

1
Remove cargo space cover

See Owner's Manual.

2
Loosen retaining straps (2) and remove spare

wheel cover front section (1)

3
Remove spare wheel


*BA40.10-P-1002-01A

4
Remove electric air pump (3)

5
Unscrew screws (4) and remove spare wheel

mount (5)

6
Remove bracket (6)

Turn in clockwise direction until bracket

(6) releases at D-pillar.

7
Remove rear wall on spare wheel cover

2 screws.

8
Install in opposite order


Wheels

Number

Designation
Model

163.174

BA40.10-P-1002-01A
Bolt for spare wheel on inside of spare wheel mount
Nm
50

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AR68.30-P-4610GH
Removing and installing spare wheel cover
28.4.99

MODEL
163.174

P68.30-2161-06

1
Spare wheel cover front section

2
Retaining straps

3
Electric air pump

4
Screws

5
Spare wheel mount

6
Bracket

7
Screws


Removal, installation

1
Remove cargo space cover

See Owner's Manual.

2
Loosen retaining straps (2) and remove spare

wheel cover front section (1)

3
Remove spare wheel


*BA40.10-P-1002-01A

4
Remove electric air pump (3)

5
Unscrew screws (4) and remove spare wheel

mount (5)

6
Remove bracket (6)

Turn in clockwise direction until bracket

(6) releases at D-pillar.

7
Remove rear wall on spare wheel cover

2 screws.

8
Install in opposite order


Wheels

Number

Designation
Model

163.174

BA40.10-P-1002-01A
Bolt for spare wheel on inside of spare wheel mount
Nm
50

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Page 1