wiring MERCEDES-BENZ ML320 1997 Complete Service Manual

SERVICING
SRS AIR BAG label on driver-side door latch post indicates SRS replacement date for air bag units. All SRS
components must be thoroughly inspected, including wiring harness. Before component replacement, check for
SRS fault codes by performing system operation check. See SYSTEM OPERATION CHECK
. SRS service
life is 10 years from manufactured date or 10 years from SRS replacement date after accident related repairs are
completed.
SYSTEM OPERATION CHECK
SRS warning light indicates SRS and Emergency Tensioning Retractor (ETR) system readiness. Turn ignition
on. SRS warning light will illuminate, then turn off after approximately 4-6 seconds indicating SRS system is
functioning properly. If SRS warning light does not illuminate, illuminates while driving or is continuously
illuminated, there is a system fault. Repair malfunctioning system.
AIR BAG SAFETY PRECAUTIONS
Observe these precautions when servicing the air bag system:
When working around SRS components and before any repairs are performed, disable air bag system. See
DISABLING & ACTIVATING AIR BAG SYSTEM
.
Before straightening any damage to body, or before performing electrical arc-welding, disable air bag
system. See DISABLING & ACTIVATING AIR BAG SYSTEM
.
Always wear safety glasses and gloves when handling a deployed air bag module. Air bag module may
contain sodium hydroxide deposits which are irritating to the skin.
Always use control module and impact sensors made by same manufacturer. Using components produced
by different manufacturers could cause accidental air bag or ETR deployment.
DO NOT repair any portion of SRS wiring harness.
If any SRS component is dropped from a height greater than 1.6 feet (0.5 m), it must be replaced.
If SRS components show signs of damage, they must be replaced.
Always handle air bag module with trim cover facing away from your body.
Always place air bag module on workbench with trim cover up, away from loose objects.
Front Passenger Seat Occupied Recognition With
Automatic Child Seat Recognition (ACSR) sensorUnder passenger front seat cushion
Head impact air bag modulesDriver-side & passenger-side roof rails over front &
rear doors
Knee bolstersDriver-side and passenger-side lower instrument
panel
Passenger-side air bag modulePassenger-side instrument panel
Side impact air bag modulesIn front & rear doors
Side impact sensorsOn floor inboard of door openings
(1)On C Class, rear seat ETRs are part of seat belt buckle assemblies.

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Removal and installation information is not available.
DIAGNOSTICS
Air bag system diagnostic information is not available. All air bag system diagnosis must be carried out using
manufacturers proprietary test equipment.
WIRE REPAIR
If any part of SRS wiring harness is damaged, DO NOT repair wiring harness, replace complete wiring harness.
WIRING DIAGRAMS
Wirin
g diagrams are not available. WARNING:Accidental air bag deployment is possible. Personal injury may result.
Read and follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS

before working on air bag system or related components.

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2004 ACCESSORIES/SAF ETY EQUIPMENT
Mercedes-Benz - Air Bag Restraint Systems
DESCRIPTION & OPERATION
The main components of Supplemental Restraint System (SRS) are dual-stage driver-side and passenger-side
air bag modules, side impact air bag modules, head impact air bag modules , SRS control module, side impact
sensors, AIR BAG warning light, driv er-side and passenger-side Emergency Tensioning Retractors (ETR). See
COMPONENT LOCATIONS
.
COMPONENT LOCATIONS
COMPONENT LOCATIONS
SERVICING
SRS AIR BAG label on driver-side door latch post indicates SRS replacement date for air bag units. All SRS
components must be thoroughly inspected, including wiring harness. Before component replacement, check for
SRS fault codes by performing system operation check. See SYSTEM OPERATION CHECK
. SRS service
life is 10 years from manufactured da te or 10 years from SRS replacement date after accident related repairs are
completed.
SYSTEM OPERATION CHECK
AIR BAG warning light indicates SRS and Emergency Te nsioning Retractor (ETR) system readiness. Turn
ignition on. AIR BAG warning light will illuminate, then turn off after 4-20 seconds indicating SRS system is
functioning properly. If AIR BAG warn ing light does not illuminate, illuminates while driving or is
continuously illuminated, ther e is a system fault. Repair malfunctioning system.
AIR BAG SAFETY PRECAUTIONS
WARNING:
Accidental air bag deployment is pos sible. Personal injury may result.
Read and follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS

before working on ai r bag system or related components.
ComponentLocation
AIR BAG warning lightInstrument Panel Cluster
ClockspringUnder steering wheel
Driver-side air bag moduleOn steering wheel
Emergency Tensioning Retractor (ETR)Driver-side & passenger-si de lower B- & C-pillars
Head impact air bag modulesDriver-side & passenger-side roof rails
Passenger-side air bag modulePassenger-side instrument panel
Side impact air bag modulesIn front & rear doors
Side impact sensorsOn floor near driver-side & passenger-side B-pillars

2004 Mercedes-Benz ML350
2004 ACCESSORIES/SAFETY EQUIPMENT Merce des-Benz - Air Bag Restraint Systems

2004 Mercedes-Benz ML350
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Observe these precautions when servicing the air bag system:
When working around SRS components and before any re pairs are performed, disable air bag system. See
DISABLING & ACTIVATI NG AIR BAG SYSTEM
.
Before straightening any damage to body, or before performing electrical arc-welding, disable air bag
system. See DISABLING & ACTIVATING AIR BAG SYSTEM
.
Always wear safety glasses and gloves when ha ndling a deployed air bag module. Air bag module may
contain sodium hydroxide deposits wh ich are irritating to the skin.
Always use control module and impact sensors made by same manufacturer. Using components produced
by different manufacturers could cause acc idental air bag or ETR deployment.
DO NOT repair any portion of SRS wiring harness.
If any SRS component is dropped from a height greater than 1.6 feet (0.5 m), it must be replaced.
If SRS components show signs of damage, they must be replaced.
Always handle air bag module with tr im cover facing away from your body.
Always place air bag module on workbench with trim cover up, away from loose objects.
DO NOT expose any SRS component to temperatures in excess of 212°F (100°C ).
DO NOT expose any SRS component to grease, oil or cleaning agents.
DISABLING & ACTIVATI NG AIR BAG SYSTEM
DISABLING SYSTEM
Turn ignition off and remove key. Disconnect ne gative battery cable and shield cable end.
ACTIVATING SYSTEM
Ensure no one is in vehicle. Turn ignition on. Connect negative battery cable. Go to SYSTEM OPERATION
CHECK .
DISPOSAL PROCEDURES
Several situations may arise requiring so me form of disposal action, including:
Scrapping a vehicle containing deployed air bag modules and ETRs.
Scrapping a vehicle with live air bag modules and ETRs.
Disposal of a live but electrically faulty air bag module and/or ETR.
Disposal of a deployed air bag module and/or ETR.
DEPLOYED AIR BAG MODULE OR EMERGENCY TENSIONING RETRACTOR (ETR)
Deployed air bag modules and ETRs can be disposed of like any other part.
SCRAPPED VEHICLE

2004 Mercedes-Benz ML350
2004 ACCESSORIES/SAFETY EQUIPMENT Merce des-Benz - Air Bag Restraint Systems
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Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRE REPAIR
DO NOT repair wiring harness. Replace complete SRS wiring harn ess, if any part is damaged.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
DIAGNOSTICS
Air bag system diagnostic information is not available. All air bag system diagnosis must be carried out using
manufacturers proprietary STAR diagnostic tool.
WIRING DIAGRAMS
ApplicationFt. Lbs. (N.m)
Front ETR
Belt end fitting26 (35)
Belt height adjuster bolt18 (25)
Bolts22 (30)
Rear ETR
Belt height adjuster bolt22 (30)
Bolts22 (30)
INCH Lbs. (N.m)
Control module bolts(1)
Driver-side air bag module bolts71 (8)
Head impact air bag module bolts71 (8)
Passenger-side air bag module nuts71 (8)
Side impact sensor screws(1)
(1)Information is not available.

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Fig. 8: Air Bag System Wiring Diagram (ML350, ML500-1 Of 2)

2004 Mercedes-Benz ML350
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Fig. 9: Air Bag System Wiring Diagram (ML350, ML500-1 Of 2)

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62 Safety and SecurityOccupant safetySafety guidelines for the seat belt,
emergency tensioning device and
airbag
When you sell your vehicle, we strongly
urge you to give notice to the subsequent
owner that it is equipped with an SRS by
alerting them to the applicable section in
the Operator’s Manual.Warning
G


Damaged seat belts or belts that were
highly stressed in an accident must be
replaced and their anchoring points
must also be checked. Use only belts in-
stalled or supplied by an authorized
Mercedes-Benz Light Truck Center.


No modifications of any kind may be
made to any components or wiring of
the SRS. This includes changing or re-
moving any component or part of the
SRS, the installation of additional trim
material, badges, etc. over the steering
wheel hub, passenger front airbag cov-
er, or door trim panels, and installation
of additional electrical / electronic
equipment on or near SRS components
and wiring. Keep area between airbags
and occupants free from objects (e.g.
packages, purses, umbrellas, etc.).


Airbags and emergency tensioning de-
vices (ETDs) are designed to function on
a one-time only basis. An airbag or ETD
that was activated must be replaced.


Do not pass belts over sharp edges.
They could tear.


Do not make any modification that could
change the effectiveness of the belts.


Do n o t h a ng i te ms su ch as c o at ha n ger s
from the coat hooks or handles over the
door. These items may turn into projec-
tiles and cause head and other injuries
when curtain airbag is deployed.


An airbag system component within the
steering wheel gets hot after the airbag
has inflated. Do not touch.


Improper work on the system, including
incorrect installation and removal, can
lead to possible injury through an unin-
tended activation of the SRS.


In addition, through improper work
there is a risk of rendering the SRS inop-
erative or causing unintended airbag de-
ployment. Work on the SRS must
therefore only be performed by qualified
technicians. Contact your authorized
Mercedes-Benz Light Truck Center.


For your protection and the protection
of others, when scrapping the airbag
unit or emergency tensioning device,
our safety instructions must be fol-
lowed. These instructions are available
from your authorized Mercedes-Benz
Light Truck Center.


Given the considerable deployment
speed and the textile structure of the
airbags, there is the possibility of abra-
sions or other injuries resulting from air-
bag deployment.

200 OperationDriving instructionsStanding water
Off-road driving
Read this chapter carefully before you be-
gin off-road travel.
Familiarize yourself with the vehicle char-
acteristics and gear changing before you
attempt any difficult terrain off-road driv-
ing. We recommend that you start out with
easy off-road travel.
!Do not drive through flooded areas or
water of unknown depth. Before driving
through water, determine its depth.
Never accelerate before driving into
water. The bow wave could force water
into the engine and auxiliary equip-
ment, thus damaging them.
If you must drive through standing wa-
ter, drive slowly to prevent water from
entering the passenger compartment
or the engine compartment. Water in
these areas could cause damage to
electrical components or wiring of the
engine or transmission, or could result
in water being ingested by the engine
through the air intake, causing severe
internal engine damage. Any such dam-
age is not covered by the
Mercedes-Benz Limited Warranty.
Warning!
G
Drive slowly in unknown terrain. This will
make it easier to recognize unexpected ob-
stacles and avoid damage to the vehicle.
To help avoid the vehicle rolling over, never
turn it around on steep inclines. If the vehi-
cle cannot complete the attempted climb,
back it down in reverse gear.
Do not drive along the side of a slope (dan-
ger of vehicle rollover). The vehicle might
otherwise rollover. If in doing so the vehicle
begins to show a tendency to roll, immedi-
ately steer into a line of gravity (straight up
or downhill).
Never let the vehicle roll backwards in idle.
You may lose control of the vehicle if you
use only the service brake.
Warning!
G
Sand, dirt, mud and other material having
friction property can cause exceptional wear
and tear as well as brake failure.
Have the brakes checked for dirt build-up
and cleaned. There is otherwise a risk that
full braking power may not be available in an
emergency.

209 Operation
Driving instructions
Towing a trailer
There are many different laws, including
speed limit restrictions, having to do with
trailer towing. Make sure your rig will be le-
gal, not only for where you reside, but also
for where you will be driving. A good
source for this information can be the po-
lice or local authorities.
Note the following points, when driving
with the trailer:

In order to gain skill and an under-
standing of the vehicle’s behavior, you
should practice turning, stopping and
backing up in an area which is free from
traffic.


Before you start driving check the

trailer hitch


break-away switch


safety chains


electrical connections


lighting and tiresAdjust the mirrors to permit unobstructed
view beyond rear of trailer.


If the trailer has electric brakes, start
your vehicle and trailer moving slowly,
and then apply only the trailer brake
controller by hand to be sure the
brakes are working properly.


Always secure items in the trailer to
prevent load shifts while driving.


When towing a trailer, check occasion-
ally to be sure that the load is secure,
and that lighting and trailer brakes (if
so equipped) are functioning properly.


Take into consideration that when tow-
ing a trailer, the handling characteris-
tics are different and less stable from
those when operating the vehicle with-
out a trailer.
It is important to avoid sudden maneu-
vers.
!Do not connect a trailer brake system
(if trailer is so equipped) directly to the
vehicle’s hydraulic brake system, as
your vehicle is equipped with antilock
brakes. If you do, neither the vehicle’s
brakes nor the trailer’s brakes will func-
tion properly.iThe provided vehicle electrical wiring
harness for trailer towing has a brake
signal wire (color orange) for hook-up
to a brake controller.
You should consider using a trailer
sway control system. For further infor-
mation see your authorized
Mercedes-Benz Light Truck Center.