engine MERCEDES-BENZ ML320 1997 Complete Repair Manual

ContentsOperation......................................... 191
The first 1000 miles (1500 km) ......... 192
Driving instructions ............................ 193
Drive sensibly – save fuel ............. 193
Drinking and driving ..................... 193
Pedals .......................................... 193
Power assistance ......................... 193
Brakes .......................................... 194
Driving off..................................... 195
Parking ......................................... 196
Tires ............................................. 196
Hydroplaning ................................ 197
Tire traction .................................. 197
Tire speed rating .......................... 198
Winter driving instructions ........... 198
Standing water ............................. 200
Off-road driving ............................ 200
Trailer towing ............................... 206
Passenger compartment .............. 211
Driving abroad .............................. 211
Control and operation of
radio transmitters......................... 211
Catalytic converter ....................... 212
Emission control........................... 212
Coolant temperature .................... 213At the gas station .............................. 214
Refueling ...................................... 214
Check regularly and before
a long trip ..................................... 215
Engine compartment ......................... 217
Hood ............................................ 217
Engine oil ..................................... 218
Transmission fluid level ................ 222
Coolant ........................................ 222
Battery ......................................... 223
Windshield washer system and
headlamp cleaning system* ......... 224
Tires and wheels ................................ 226
Important guidelines .................... 226
Life of tire..................................... 227
Direction of rotation ..................... 227
Checking tire inflation pressure ... 227
Rotating wheels ........................... 228
Winter driving .................................... 230
Winter tires .................................. 230
Block heater (Canada only) .......... 231
Snow chains ................................. 231Maintenance...................................... 232
Clearing the service indicator ...... 232
Service term exceeded ................ 233
Calling up the service indicator .... 233
Resetting the service indicator .... 233
Vehicle care....................................... 234
Cleaning and care of the vehicle .. 234
Practical hints................................. 241
What to do if … .................................. 242
Lamps in instrument cluster ........ 242
Additional indicators in the
speedometer display.................... 256
Where will I find ...? ........................... 257
First aid kit ................................... 257
Vehicle tool kit ............................. 257
Spare wheel (space-saver tire) ..... 259
Unlocking / locking in an emergency . 261
Unlocking the vehicle................... 261
Locking the vehicle ...................... 262
Changing batteries in the
remote control ............................. 262
Fuel filler flap ............................... 263
Manually unlocking the
transmission gear selector lever .. 264

Contents
Opening / closing in an emergency .... 265
Sliding / pop-up roof* ................... 265
Replacing bulbs ................................. 266
Bulbs ............................................ 266
Replacing bulbs for front lamps ... 268
Replacing bulbs for rear lamps..... 270
Adjusting headlamp aim............... 272
Replacing wiper blades ...................... 273
Removing ..................................... 273
Installing ...................................... 273
Flat tire .............................................. 274
Mounting the spare wheel............ 274
Battery ............................................... 278
Disconnecting the battery ............ 279
Removing the batteries ................ 279
Charging and reinstalling
batteries....................................... 279
Reconnecting the batteries .......... 279
Jump starting ..................................... 281
Towing the vehicle ............................. 283
Front towing eye .......................... 285
Rear towing eye ........................... 285
Stranded vehicle .......................... 286Fuses .................................................. 287
Fuse box in engine
compartment ................................ 287
Auxiliary fuse box in front
passenger footwell........................ 288
Technical data.................................. 289
Spare parts service............................. 290
Warranty coverage ............................. 291
Loss of Service and Warranty
Information Booklet ...................... 291
Identification labels ............................ 292
Layout of poly-V-belt drive .................. 293
Engine ................................................ 294
Rims and tires .................................... 295
Rims and tires ............................... 295
Spare wheel .................................. 296
Electrical system ................................ 297
Main Dimensions ................................ 298
Weights .............................................. 299Fuels, coolants, lubricants etc............ 300
Capacities ..................................... 300
Engine oils .................................... 302
Engine oil additives ....................... 302
Air conditioning refrigerant ........... 302
Brake fluid .................................... 302
Premium unleaded gasoline.......... 303
Fuel requirements......................... 303
Gasoline additives......................... 303
Coolants ....................................... 304
Anticorrosion / antifreeze.............. 305
Windshield washer system and
headlamp cleaning system* ......... 307
Windshield and headlamp
washer fluid mixing ratio............... 307
Consumer information........................ 308
Uniform tire quality grading .......... 308
Temperature ................................. 309
Technical terms............................... 311Index................................................. 317

13 Introduction
Operator’s Manual
Change of address or ownership
If you change your address, be sure to
send in the “Change of Address Notice”
found in the Service and Warranty Informa-
tion Booklet, or simply call the
Mercedes-Benz Customer Assistance
Center (in the USA) at
1-800-FOR-MERCedes, or Customer Ser-
vice (in Canada) at 1-800-387-0100. It is in
your own interest that we can contact you
should the need arise.
If you sell your Mercedes, please leave all
literature with the vehicle to make it avail-
able to the next operator.
If you bought this vehicle used, be sure to
send in the “Notice of Purchase of Used
Truck” found in the Service and Warranty
Information Booklet, or call the
Mercedes-Benz Customer Assistance Cen-
ter (in the USA) at 1-800-FOR-MERCedes,
or Customer Service (in Canada) at
1-800-387-0100.Operating your vehicle outside the USA
or Canada
If you plan to operate your vehicle in for-
eign countries, please be aware that:

service facilities or replacement parts
may not be readily available,


unleaded gasoline for vehicles with cat-
alytic converters may not be available;
the use of leaded fuels will damage the
catalysts,


gasoline may have a considerably low-
er octane rating, and improper fuel can
cause engine damage.

17 Introduction
Operating safety
Operating safety
Proper use of the vehicle
Proper use of the vehicle requires that you
are familiar with the following information
and rules:

the safety precautions in this manual


the “Technical data” section in this
manual


traffic rules and regulations


motor vehicle laws and safety stan-
dards
Warning!
G
Work improperly carried out on electronic
components and associated software could
cause them to cease functioning. Because
the vehicle’s electronic components are in-
terconnected, any modifications made may
produce an undesired effect on other sys-
tems. Electronic malfunctions could
seriously impair the operating safety of your
vehicle.
See your authorized Mercedes-Benz Light
Truck Center for repairs or modifications to
electronic components.
Other improper work or modifications on the
vehicle could also have a negative impact on
the operating safety of the vehicle.
Some safety systems only function while the
engine is running. You should therefore nev-
er turn off the engine while driving.
Warning!
G
Heavy blows against the vehicle underbody
or tires / wheels, for example when running
over an obstacle, road debris or a pothole,
may cause serious damage and impair the
o per at i ng s a fet y of yo ur veh ic l e. I f y ou f ee l a
sudden significant vibration or ride distur-
bance, or you suspect that damage to your
vehicle has occurred, you should turn on
your hazard warning flashers, carefully slow
down, and drive with caution to an area
which is a safe distance from the road.
Inspect the vehicle underbody and
tires / wheels for possible damage. If the ve-
hicle appears unsafe, have it towed to the
nearest authorized Mercedes-Benz Light
Truck Center or other qualified maintenance
or repair facility for further inspection or re-
pairs.
Warning!
G
Various warning labels are attached to your
vehicle. These warning labels are intended
to make you and others aware of various
risks. You should not remove any of these
warning labels unless explicitly instructed to
do so by information on the label itself. Re-
moval of any of these labels may cause you
and others to be unaware of certain risks
which may result in an accident and / or per-
sonal injury.

25 At a glance
Instrument cluster
Item
Page
1
Gauge for
Coolant tempera-
ture
117
Outside tempera-
ture
118
Fuel reserve
warning lamp
252
2
Knob for
Activating instru-
ment cluster
116
Adjusting intensity
of instrument lamps
116
Main odometer
117
Trip odometer
readout / reset
118
Activating Flexible
Service System
(FSS) indicator
232
Item
Page
3
Left indicator lamps
with:¿Brake Assist
System
(BAS) / Electronic
Stability Program
(ESP) malfunction
warning lamp
246
{Electronic Traction
System (4-ETS) mal-
function indicator
lamp
252
-Antilock Brake Sys-
tem (ABS) malfunc-
tion warning lamp
242
2Brake pad wear in-
dicator lamp
254
:Low engine oil level
warning lamp
253
Item
Page
/Low engine coolant
level warning lamp
249
êLow range indicator
lamp
252
?Engine malfunction
indicator lamp
248
4
Speedometer with:v4-ETS (Electronic
Traction
System)/Electronic
Stability Program
(ESP) warning lamp
251
Trip / main
odometer
117
Display for Flexible
Service System
(FSS)
232
Engine oil level indi-
cator
219

33 Getting started
Unlocking
Steering lock positions
0For removing key
The steering is locked when the key is
removed from the steering lock. If
necessary, move steering wheel
slightly to allow the locking mechanism
to engage.
1Unlocking steering
Power supply to some electrical con-
sumers, such as seat adjustment.
2Ignition (power supply for all electrical
consumers) and driving position
3Starting position
Warning!
G
When leaving the vehicle, always remove the
key from the steering lock and lock the vehi-
cle. Do not leave children unattended in the
vehicle, or with access to an unlocked vehi-
cle. Unsupervised use of vehicle equipment
may cause an accident and / or serious per-
sonal injury.iThe key can only be withdrawn in
position0.
If necessary, move steering wheel
slightly to allow the key to be turned
clockwise to position1.
A warning sounds when the driver’s
door is opened and the key is in steer-
ing lock position0 or1.
The key can only be removed from the
steering lock with the gear selector le-
ver in positionP.
!To prevent accelerated battery dis-
charge and a possible dead battery, al-
ways remove the key from the steering
lock when the engine is not in opera-
tion.

40 Getting startedAdjusting
Mirrors
Adjust the interior and exterior rear view
mirrors before driving so that you have a
good view of the road and traffic condi-
tions.Interior rear view mirror

Manually adjust the interior rear view
mirror.
Exterior rear view mirrors
!Do not drive the vehicle until you have
properly locked the steering column.
If the indicator lamp_ (
page 26)
comes on while the engine is running,
the steering column is not locked prop-
erly.
Warning!
G
In the case of an accident, liquid electrolyte
may escape the mirror housing if the mirror
glass breaks.
Electrolyte has an irritating effect. Do not al-
low the liquid to come into contact with
eyes, skin, clothing, or the respiratory sys-
tem. In case it does, immediately flush af-
fected area with water, and seek medical
help if necessary.
Warning!
G
Exercise care when using the passenger
side exterior rear view mirror. The mirror
surface is convex (outwardly curved surface
for a wider field of view). Objects in mirror
are closer than they appear. Check your in-
side rear view mirror or glance over your
shoulder before changing lanes.!Electrolyte drops coming into contact
with the vehicle paint finish can only be
completely removed while in their
liquid state and by applying plenty of
water.

46 Getting startedDrivingStarting the engine Automatic transmission
Gearshift pattern for automatic
transmissionPPark position with gear selector lever
lock
RReverse gear
NNeutral
DDrive position
More information can be found in the
“Controls in detail” section (
page 119).Starting

Make sure the gear selector lever is set
toP.

Do not depress the accelerator.

Turn the key in the steering lock to
position3 and hold until the engine
starts (
page 33).

Depress the brake pedal.
The gear selector lever lock is released.
For information on turning off the engine,
see “Turning off engine” (
page 54).
Warning!
G
Inhalation of exhaust gas is hazardous to
your health. All exhaust gas contains carbon
monoxide, and inhaling it can cause uncon-
sciousness and lead to death.
Do not run the engine in confined areas
(such as a garage) which are not properly
ventilated. If you think that exhaust gas
fumes are entering the vehicle while driving,
have the cause determined and corrected
immediately. If you must drive under these
conditions, drive only with at least one win-
dow fully open.

47 Getting started
Driving
Starting difficulties
If the engine does not start as described,
carry out the following steps:
Turn key in starter to position0 and re-
peat starting procedure.
Remember that extended starting at-
tempts can drain the battery.

Get a jump start (
page 281).
If the engine does not start after several
starting attempts, there could be a mal-
function in the engine electronics or in the
fuel supply system.

Notify an authorized Mercedes-Benz
Light Truck Center.Parking brake
1Parking brake pedal
2Release handle

Release the parking brake by pulling on
handle2.
The indicator lampÉ in the instru-
ment cluster goes out.
Driving

Depress the brake pedal.

Place the gear selector lever in
positionD orR.

Release the brake pedal.

Carefully depress the accelerator
pedal.
Warning!
G
When leaving the vehicle, always remove the
key from the steering lock and lock the vehi-
cle. Do not leave children unattended in the
vehicle, or with access to an unlocked vehi-
cle. Children could release the parking
brake, which could result in an accident
and / or serious personal injury.
iWait for the gear selection process to
complete before setting the vehicle in
motion.

48 Getting startedDrivingAfter a cold start, the automatic transmis-
sion shifts at a higher engine revolution.
This allows the catalytic converter to reach
its operating temperature earlier.
More information can be found in the “Op-
eration” section (
page 191).
For information on off-road driving, see
“Driving instructions” (
page 200).
Switching on headlamps
The combination switch is located on the
left of the steering column.Combination switch1 Off
2Low beam headlamps on
3High beam lamps on
Turn the switch toõ.
Low beam headlamps on.
!If you hear a warning signal when driv-
ing off, you have forgotten to release
the parking brake.
Release the parking brake.Warning!
G
It is dangerous to shift the gear selector
lever out ofP orN if the engine speed is
higher than idle speed. If your foot is not
firmly on the brake pedal, the vehicle could
accelerate quickly forward or in reverse. You
could lose control of the vehicle and hit
someone or something. Only shift into gear
when the engine is idling normally and when
your right foot is firmly on the brake pedal.
Warning!
G
On slippery road surfaces, never downshift
in order to obtain braking action. This could
result in drive wheel slip and reduced vehi-
cle control. Your vehicle’s ABS will not pre-
vent this type of loss of control.!Place the gear selector lever in
positionR only when the vehicle is
stopped in order to avoid damaging the
transmission.!Do not run cold engine at high engine
speeds. Running a cold engine at high
engine speeds may shorten the service
life of the engine.