gas type MERCEDES-BENZ ML320 1997 Complete Repair Manual

160 Catalytic converter
Te ch n ica l
data Instruments
and controlsOperationDrivingInstrument
cluster displayPractical hints Car care Index
Catalytic converter
Your Mercedes-Benz is equipped with monolithic type
catalytic converters, an important element in
conjunction with the oxygen sensors to achieve
substantial control of the pollutants in the exhaust
emissions. Keep your vehicle in proper operating
condition by following our recommended maintenance
instructions as outlined in your Service Booklet.Caution!
To prevent damage to the catalytic converters, use only
premium unleaded gasoline in this vehicle.
Any noticeable irregularities in engine operation should
be repaired promptly. Otherwise, excessive unburned
fuel may reach the catalytic converter causing it to
overheat, which could start a fire.
Wa r n i n g !
As with any vehicle, do not idle, park or operate
this vehicle in areas where combustible materials
such as grass, hay or leaves can come into contact
with the hot exhaust system, as these materials
could be ignited and cause a vehicle fire.

160
Catalytic converter
Te ch n ica l
data
Instruments
and controls Operation
Driving Instrument
cluster display Practical hints Car care Index
Catalytic converter
Your Mercedes-Benz is equipped with monolithic type
catalytic converters, an important element in
conjunction with the oxygen sensors to achieve
substantial control of the pollutants in the exhaust
emissions. Keep your vehicle in proper operating
condition by following our recommended maintenance
instructions as outlined in your Service Booklet. Caution!
To prevent damage to the catalytic converters, use only
premium unleaded gasoline in this vehicle.
Any noticeable irregularities in engine operation should
be repaired promptly. Otherwise, excessive unburned
fuel may reach the catalytic converter causing it to
overheat, which could start a fire.
Wa r n i n g !
As with any vehicle, do not idle, park or operate
this vehicle in areas where combustible materials
such as grass, hay or leaves can come into contact
with the hot exhaust system, as these materials
could be ignited and cause a vehicle fire.

199 Operation
Driving instructions
Road salts and chemicals can adversely af-
fect braking efficiency. Increased pedal
force may become necessary to produce
the normal brake effect.
Depressing the brake pedal periodically
when traveling at length on salt-strewn
roads can bring road-salt-impaired braking
efficiency back to normal.If the vehicle is parked after being driven
on salt-treated roads, the braking efficien-
cy should be tested as soon as possible af-
ter driving is resumed.
For more information, see "Winter driving"
(
page 230).
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 control loss.
Do not engage the transfer case in position
LOW when driving on ice or packed snow. At
speeds below 18 mph (30 km / h) vehicle
steering is adversely affected by the LOW
RANGE - ABS (
page 77).
Warning!
G
Make sure not to endanger any other road
users when carrying out these braking ma-
neuvers.Warning!
G
If the vehicle becomes stuck in snow, make
sure that snow is kept clear of the exhaust
pipe and from around the vehicle with the
engine running. Otherwise, deadly carbon
monoxide (CO) gases may enter vehicle in-
terior resulting in unconsciousness and
death.
To assure sufficient fresh air ventilation,
open a window slightly on the side of the ve-
hicle not facing the wind.
Warning!
G
The outside temperature indicator is not de-
signed to serve as an ice-warning device and
is therefore unsuitable for that purpose. In-
dicated temperatures just above the freez-
ing point do not guarantee that the road
surface is free of ice.

212 OperationDriving instructionsTelephones and two-way radios
Radio transmitters, such as a portable tele-
phone or a citizens band unit should only
be used inside the vehicle if they are con-
nected to an antenna that is installed on
the outside of the vehicle.
Refer to the radio transmitter operation in-
structions regarding use of an external an-
tenna.
Catalytic converter
Your Mercedes-Benz is equipped with
monolithic-type catalytic converters, an
important element in conjunction with the
oxygen sensors to achieve substantial con-
trol of the pollutants in the exhaust emis-
sions. Keep your vehicle in proper
operating condition by following our rec-
ommended maintenance instructions as
outlined in your Service Booklet.
Emission control
Certain engine systems serve to keep the
toxic components of the exhaust gases
within permissible legal limits.
These systems, of course, will function
properly only when maintained strictly ac-
cording to factory specifications. Any ad-
justments on the engine should, therefore,
be carried out only by qualified
Mercedes-Benz Light Truck Center autho-
rized technicians. Engine adjustments
should not be altered in any way. More-
over, the specified service jobs must be
Warning!
G
Never operate radio transmitters equipped
with a built-in or attached antenna (i.e. with-
out being connected to an external antenna)
from inside the vehicle while the engine is
running. Doing so could lead to a malfunc-
tion of the vehicle’s electronic system, pos-
sibly resulting in an accident and / or
personal injury.
!To prevent damage to the catalytic con-
verters, use only premium unleaded
gasoline in this vehicle.
Any noticeable irregularities in engine
operation should be repaired promptly.
Otherwise, excessive unburned fuel
may reach the catalytic converter,
causing it to overheat and start a fire.
Warning!
G
As with any vehicle, do not idle, park or op-
erate this vehicle in areas where combusti-
ble materials such as grass, hay or leaves
can come into contact with the hot exhaust
system, as these materials could be ignited
and cause a vehicle fire.

267 Practical hints
Replacing bulbs
Rear lamps Notes on bulb replacement


Use only 12-volt bulbs of the same type
and with the specified watt rating.


Switch lights off before changing a bulb
to prevent short circuits.


Always use a clean lint-free cloth when
handling bulbs.


Your hands should be dry and free of oil
and grease.


If the newly installed bulb does not light
up, visit an authorized Mercedes-Benz
Light Truck Center.


Have the LEDs and bulbs for the follow-
ing lamps replaced by an authorized
Mercedes-Benz Light Truck Center:

Additional turn signals in the exteri-
or rear view mirrors


Bi-Xenon lamps*


Front fog lamps (vehicles with sport
package)*
Lamp
Type
6
Brake lamp
1073
(32 cp bulb)
7
Backup lamp
1073
(32 cp bulb)
8
Turn signal lamp
PY 21 W
9
Tail, parking and
standing lamp
Rear fog lamp, driv-
er’s side
P 21 / 4 W
a
Side marker lamp
W5W
b
High mounted brake
lamp
1073
(32 cp bulb)
c
License plate lamps
C 5 W
Warning!
G
Keep bulbs out of reach of children.
Bulbs and bulb sockets can be very hot. Al-
low the lamp to cool down before changing
a bulb.
Halogen lamps contain pressurized gas. A
bulb can explode if you:

touch or move it when hot


drop the bulb


scratch the bulb
Wear eye and hand protection.
Because of high voltage in xenon lamps, it is
dangerous to replace the bulb or repair the
lamp and its components. We recommend
that you have such work done by a qualified
technician.

USE OF ENGINE NO. WHEN INSTALLING RECONDITIONED ENGINES AND FACTORY-NEW REPLACEMENT
ENGINES OR CRANKCAS ES - AH01.10-P-0001-01A
All engines
The engine number has a different le gal significance in individual countries. In the Federal Republic of
Germany, for example, it has been cl assified by the legislative authorities since mid-1972 as "insignificant in
terms of traffic legi slation". It is therefore no longer included in the vehicl e title document and vehicle
registration document.
Practically all other countries continue to require the indication of the engine number on motor vehicles which
are registered in such countries. In dealing with internat ional traffic, the authorities proceed on the basis of the
provisions of the country in which the vehicle is registered.
In order to avoid any problems on the occasion of vehicl e checks or when crossing international frontiers as a
result of the lack of or in correct engine number, the fo llowing directives have to be observed when carrying out
repairs.
1. Directives for vehicles wh ich are registered in the Fe deral Republic of Germany
a. In the case of vehicles for which no engine number is indicated in the vehicle registration
document (first registration after a pprox. mid-1972), it is not necessa ry to stamp or revise an
engine number if a replacement engine or crankcase of the same type is fitted.
b. If an engine number is indicated in th e vehicle registration document , it is possible, if an
engine of the same type is fitted, to transfer the number of the removed component to the new
engine, or the appropriate authority (vehicle in spection authority, vehicle registration authority)
should be requested to delete the engine numbe r in the vehicle title document or registration
document. The German Federal Mini ster of Transport has issued appropriate ministerial orders in
Transport Gazette 1973, p. 66.
2. Vehicles which are registered outside of the Federal Republic of Germany
If a reconditioned engine or factory-new replacement engine or crankcase is fitted and this is of the
identical type, it is then necessary to adopt the engine number of the engine removed and to transfer it to
the new engine or crankcase.
For this reason, pay attention to th e particular directives stated in Para 3 for the installation of
reconditioned en
gines, crankcases and shortblocks.

Notes on application of
sealant to the timing case
cover
ENGINE 611, 612, 613, 646, 647, 648 ...AH01.40-P-
1000-01E

Information on applying
sealant to a cylinder head
gasketENGINE 112 ENGINE 113 ENGINE 112.951 ENGINE
112.976AH01.30-P-
1000-04VA
NOTE: It is possible in the case of vari ous engines only to stamp the engine
number in place when the engine is removed.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:55 PMPage 12 © 2006 Mitchell Repair Information Company, LLC.

Extract from Transpor t Gazette 1973 p. 66
(applies only to the Federal Republic of Germany)
Official Gazette of the Fede ral Minister of Transport
Directive in respect of vehicl e title document (VkBl 1972 p. 354)
Bonn, 28 December 1972
StV 2/36.15.17
Pursuant to the directive relating to the vehicle ti tle document dated 20 June 1972, Part C. No. 9.1, a dash
should be inserted at the relevant poi nt in the place of data which are no longer required in future (e.g. in the
case of the "factory number of engine") in those instances where the olde r type of title documents are used for
the preparation of the vehicle title document.
The question which is now posed is what procedure shoul d be adopted in respect of the vehicle title document
or the vehicle registration document in the event that th e factory number of the engine from the past is still
entered in the older type of title documents and a repl acement engine with a new number is now installed in the
vehicle in question. Following consul tation with the competent authorities in the regions, I now provide the
following instructions:
I. In view of the fact that the fact ory number of the engine is regarded as insignificant in respect of traffic
legislation, no change requires to be made to the vehicle documents. This also does not conflict with 27
Para 1 StVZO pursuant to which the data in the vehi cle title and registration documents constantly have
to reflect actual circumstances. This requirement namely covers only those particulars relating to actual
circumstances which are of significance in terms of traffic legislation. This is no longer the case,
however, in respect of the fa ctory number of the engine.
II. In order to spare the relevant vehicle owner any misunderstandings or indeed possible disadvantages (e.g.
on the occasion of checks when abroad), I recommend proceeding as follows:
In the event that the replacement engine installed has a different number than that entered in the title and
registration document, the figures in the column "e ngine factory number" shall be deleted and the following
endorsement made at a suitable point both in th e title as well as in the registration document:
"Entry of engine factory number no longer necessary".
If the endorsement is made close to th e deletion, it is sufficient to state:
"Entry no longer required".
The Federal Minister of Transport Ip. p.
Wagner
NOTES ON APPLICATION OF SEALANT TO CYLINDER HEAD GASKET - AH01.30-P-1000-04V

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:55 PMPage 14 © 2006 Mitchell Repair Information Company, LLC.

to burn or are part of a smoldering fire.
The scrapping of gas-filled hydraulic parts can also be handed over to a scrap dealer who carries out the
required safety measures. If accepted, the scrap dealer must sign an official declaration (see sample), in which
he/she is bound to scrap gas-filled hydraulic parts in accordance with the respective valid accident prevention
regulations.
This type of agreement however does require that it is absolutely impossible to retrieve shock absorbers from
the scrap which can then be subsequently repaired. Any such devices therefore need to be damaged to
permanently disable them for any reuse. To this end it is sufficient to bang the shock absorber pipe on a hard
edge, to make a dent in it with a light hammer blow or to crush it slightly in a vise.
On no account should the piston rod be bent, this may cause an accident!
If agreements to render gas-filled hydraulic parts harmless, cannot be made with a scrap dealer, then the
specified safety measures must be performed by the owner. For accident prevention reasons, safety glasses and
gloves must be worn as protection against any escaping gas and oil as well as drill shavings. The balance holes
are to be drilled with as little operating speed as possible. Any escaping oil is to be collected.
Fig. 647: Sheet Metal And Metal Scrap Declaration Form

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:57 PMPage 532 © 2006 Mitchell Repair Information Company, LLC.

Valve seal not okay :
#
3
Remove/install/replace valve seal.

AR05.30-P-3500B

Cause 6:
Remedy 6:

00 001 70
1.5 mm hole missing on individual right

cylinder head covers at connection to

crankcase ventilation.
1
Check cylinder head cover

Up to production 06/1999.

Crankcase ventilation out of order, engine can

sludge up and consume oil as a result

Cylinder head cover not okay:
#
2
Remove/install/replace cylinder head

cover.

ENGINE
112

Air cleaner positioned on engine

side.

ENGINE
113

Air cleaner positioned on engine

side.
AR01.20-P-5014BV

ENGINE

112

Air cleaner positioned on engine side

ENGINE
113

Air cleaner positioned on engine side

AR01.20-P-5014B

Cause 7:
Remedy 7:

00 001 70
Engine oil sludging due to excessively long

engine oil change intervals
Service information: Oil sludge

SI18.00-P-0010A

If the service interval according to

ASSYST is exceeded, the engine oil sludges

up sooner or later depending on the oil

quality, type of operation and operating time.

Engine consumes oil.

See Service Information.

1
Print out ASSYST printout.

2
Check oil change intervals

3
Inform vehicle owner.

4
Remove/install/replace piston rings.

AR03.10-P-7311BV

Disassemble and clean sludged engines

completely because dirty oil usually gets into

clean-oil side due to clogged oil filter.

Cause 8:
Remedy 8:

00 001 70
Piston rings sticky or have coke deposits from

engine oils (e.g. API-S in USA) in connection

with regionally poor fuel quality.

Always use engine oils according to

Specifications for Operating Fluids 229.3, do

not add special additives to engine oil and fuel

BB00.40-P-0229-03A

1
Remove/install/replace piston rings.

AR03.10-P-7311BV

Cause 9:
Remedy 9:

00 001 70
Piston ring wear due to excessive

contamination/dust (model 163) through air

intake system.
1
Remove/install/replace gaskets on air

intake line and distribution element of

partial load ventilation.

e.g. due to incorrect assembly after

workshop visit or embrittlement of gaskets
The distribution element with optimized

material will be available as of 11/ 2000 as a

standard feature.

2
Remove/install/replace intake module.

Exterior oil loss, e.g. due to cast iron

porosity on left side of crankcase in area of

engine support is not considered to be oil

consumption

In the event of a customer complaint

regarding the engine oil consumption, always

determine the oil consumption definitely

because the oil indicator lamp can come on

due to other causes (e.g. defective oil sensor).

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e. g.)
Order number

WH58.30-Z-1009-05A
Flexible inspection light
Scope of supply 1 (complete unit):

-glass fiber optical fiber

-light projector

-230 V, storage case

-operating instructions

-graphics protocol
Richard Wolf GmbH

Pforzheimerstr. 32

D-75438 Knittlingen

Karl Storz GmbH

Mittelstr. 8

D-78532 Tuttlingen
1.00565.00

80902

WH58.30-Z-1010-05A
Flexible inspection light

Scope of delivery 2 (for workshops which already have an approved

Wolf or Storz inspection light):

-storage case

-operating instructions

-pictures protocol
Richard Wolf GmbH

Pforzheimerstr. 32

D-75438 Knittlingen

Karl Storz GmbH

Mittelstr. 8

D-78532 Tuttlingen
7.05065.00

K03506AJ

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

The blower regulator then controls the blower motor operating voltage, depending on the actual measured in-car
temperature and the selected target temperature
(0-12 V). This facilitates blower speed control of 0-100 %.
DUST FILTER, LOCATION - GF83.10-P-2104-01GH
The dust filter (1) is behind the instrument panel bottom section at the passenger side in the heater/evaporator
housing.
Fig. 7: Identifying Dust Filter

REAR VENTILATION, FUNCTION - GF83.10-P-2105-01GC
Function
The louvered-type flaps in the rear vent open from the pressure of the air flowing through the vehicle and allow
it to exit.
If a vacuum is present in the vehicle, as happens when driving with a window or the sliding roof open, the flaps
close automatically due to the force of gravity. This prevents exhaust gases, dust and moisture from being
sucked in.
REAR VENTILATION, LOCATION - GF83.10-P-2105-02GH
The rear vents (1) are located on the left and right behind the rear bumper.

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:14 PMPage 14 © 2006 Mitchell Repair Information Company, LLC.