MERCEDES-BENZ ML350 1997 Complete Repair Manual
Manufacturer: MERCEDES-BENZ, Model Year: 1997, Model line: ML350, Model: MERCEDES-BENZ ML350 1997Pages: 4133, PDF Size: 88.89 MB
Page 2101 of 4133
AR01.20-P-5014-02B
Remove/install cylinder head cover trim
Crankcase ventilation, cylinder head cover
Number
Designation
Engine
612.961/
962/967
Engine
612.963
Engine
612.965/
966
Engine
612.990
BA01.20-P-1002-01A
Screw of trim panel of cylinder head cover
to cylinder head cover
NM
101010
8
BA01.20-P-1003-01A
Screw attaching cover panel to charge air
distribution pipe
NM
101010
-
P01.20-2018-11
1
Unscrew bolts (3, 4).
Installation:
Pay attention to tightening torques
.
2
Pull out trim panel (2) of charge air distribution pipe to the side.
Installation:
Insert shackles of trim panel (2) into the rubber
mounts (5), so that the trim panel (2) is not damaged.
3
Take off trim panel (1) of cylinder head cover.
Installation:
Ensure the trim panel is correctly installed; ensure
no lines are trapped.
4
Install in reverse sequence.
Illustrated on Engine 612.961
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Page 2102 of 4133
BT27.60-P-0003-01A
Deletion of lever for shift lock cable ignition
lock at transmission
k
TRANSMISSION
722.700 ## as of 0129631 as of 24.1.01,
722.701 ## as of 0132072 as of 8.2.01
P27.60-0421-01
1
Shift lock lever ignition lock
2
Shift lock lever brake pedal
Because of the deletion of the shift lock cable ignition lock the lever for the shift lock cable ign
ition
lock (1) at the transmission is likewise deleted.
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Page 2103 of 4133
BT27.60-P-0001-02A
Deletion shift lock cable ignition lock to
transmission
k
TRANSMISSION
722.7 in MODEL WDB168.### ## as of 548031 as of 10.1.01
P27.60-2187-06
1
New ignition lock cable
2
Shift lock cable
For cost-saving reasons the shift lock cable of
the ignition lock to transmission is
discontinued. A cable from the ignition lock to
the brake pedal is used in its place.
Consequently, it is only possible to
withdraw the ignition key when the brake
pedal is depressed
.
The new ignition lock cable (1) does no
longer require to be adjusted.
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Page 2104 of 4133
OF91.60-P-1000-01A
Disconnecting airbag, certificate
After the front passenger airbag or emergency tensioning retractor
has been deactivated it must be ensured that the declaration is
signed by the customer.
Reconnection should be stamped and signed on the declaration by
the Mercedes-Benz service station performing the work.
a mb
Declaration
after disconnecting front passenger airbag on request by customer
I have explicitly requested the operation of the passenger airbag and
the passenger emergency tensioning retractor with belt force limiter
to be deactivated.
I have been informed that due to this measure the additional passive
safety guaranteed by the front passenger airbag as well as the front
passenger emergency tensioning retractor with belt force limiter is no
longer available and thereby increases the injury hazard for the
passenger.
Particularly body regions such as head, neck and chest can be
affected by reduced restraint. Direct contact with passenger
compartment components can occur more probably.
I hereby forego all claims against DaimlerChrysler AG that arise from
the deactivation of the passenger airbag and the passenger
emergency tensioning retractor with belt force limiter, whatever the
legal reason for the claim.
Moreover, I acknowledge that I am obligated to indicate to
passengers, any subsequent owner of the vehicle or any person
using the vehicle that this protective function has been deactivated
as well as the associated hazards.
A sticker has been attached to the passenger airbag which may be
removed only when the passenger airbag is reactivated by a
Mercedes-Benz service station.
Disconnection is to be noted in the registration papers.
......................................................................
Date/signature of customer
.....................................................................
Date/stamp/signature/Mercedes-Benz service station
Customer address:
...........................................................................
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis ident no.:....................................................................
Reactivation of the passenger airbag should be accomplished only by
a Mercedes-Benz service station.
Reactivation:....................................................................
Date/stamp/signature/Mercedes-Benz service station
s
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Page 2105 of 4133
GF54.30-P-2002A
Display instruments, location / task / function
24.10.96
MODEL
129, 140 as of 1.6.96,
163, 168, 170,
202 as of 1.8.96,
208 up to 31.7.99,
210 as of 1.6.96 up to 30.6.99
Display
Type of data transmission
D
Outside temperature indicator (A1p4)
D
Fuel level gauge (A1p2)
D
Engine oil pressure gauge (A1p3), only
model 129 and model 140
D
Low windshield washer fluid level
indicator lamp (A1e13), model 163 as of
01.09.01
Direct lines
GF54.30-P-3004A
D
Total mileage odometer (A1h4)
D
Electronic speedometer (A1p8)
D
Tachometer (A1p5)
D
Coolant temperature gauge (A1p1)
D
Active service system (ASSYST)
D
Gear indicator (A1p12), only model 168
CAN data lines
GF54.30-P-3005A
D
Electronic clock
Internal
GF54.30-P-3011A
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Page 2106 of 4133
AD54.30-P-3000-03A
Display instruments/multi-function display
function check IC
Display
instruments
The display instruments must indicate according to operating
conditions.
Phototransistor (models 202, 208, 210)
Point a beam of light at the phototransistor with a pocket lamp, the
display illumination of the LCD displays (outside temperature, trip
odometer, total mileage recorder and electronic clock) must get
brighter.
Instrument cluster with multi-function display
If there are malfunctions (e.g. brake linings worn, coolant level too
low, exterior lamp failure etc.) or system faults (anti-lock brake
system faulty, supplemental restraint system faulty) the warning
display with warning information is inserted in place of outside
temperature, odometer, total mileage recorder and electronic clock.
The warning information is displayed in yellow or red depending on
the fault and a warning tone also sounds.
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Page 2107 of 4133
GF54.30-P-3028GH
Displaying coolant level, function
28.6.99
MODEL
163 as of 1.3.99
Function prerequisite
Engine: ON
Function
If the coolant level drops below the minimum mark the low ECL
indicator lamp (A1p11) is illuminated.
To record the coolant level the instrument cluster (A1) is connected
direct to the
coolant level indicator electronic switch (S41)
via two
cables. The
coolant level indicator electronic switch (S41)
consists of two electrodes.
D
If the
level is correct
both electrodes are immersed in the
coolant. The coolant serves as a dielectric between the
electrodes.
D
If the coolant level is below the minimum mark the electrodes of
the sensor are no longer immersed in the coolant. There is only
air between the electrodes as a dielectric. Evaluation
The instrument cluster (A1) sends test pulses to the sensor for
a period of one millisecond. These pulses are deformed
differently depending on the dielectric (air or coolant).
The instrument cluster (A1) evaluates the pulse shape and, if
the coolant level is below the minimum (electrodes are
completely in air), actuates the low ECL indicator lamp (A1p11)
after a delay of
approx. 60 seconds
.
The delay serves to prevent the indicator lamp flickering due to
the coolant moving from side to side on corners or off-road.
Diagnosis
Diagnosis is carried out, as described in the Diagnosis Manual, via
the simulation of the
coolant level indicator electronic switch (S41)
by a resistance.
Coolant level switch,
location/task/design/function
GF54.30-P-4103GH
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Page 2108 of 4133
GF00.20-P-2010B
Displaying service, function
25.3.99
MODEL
129 as of 1.8.99
MODEL
163 as of 1.1.00
MODEL
168 as of 1.9.99
MODEL
170 as of 1.12.99
MODEL
202 as of 1.8.99
Display of service to be performed
In addition to the various service displays, the service work to be
performed (A or B) also appears.
The service symbol (wrench) appears once or twice in the display for
this purpose.
The service symbol appears
D
once
for service
A
D
twice
for service B
.
A service A is always followed by a service B.
Following a service B, the next service must be calculated
taking into account the kilometer readings. If the distance of the
current service interval is less than 22 000 km, the next service
is service A, otherwise service B.
This calculation is now performed
automatically
in the
instrument cluster (A1).
The path of the service displayed A or B can be processed in
the service sheet without the need for a calculation.
There is no external difference in the instrument clusters with
and without the service display.
If service A (one service symbol) is displayed, it is then
necessary to ensure by means of the
production date
or the
control unit identifier
, that the vehicle in question is in fact a
vehicle
with service display
. If this is not the case, the service
must be determined as specified in the service sheet.
The table below shows from which control unit identifier the
instrument cluster features the service display:
The control unit identifier can be read with the HHT under menu point
"Control unit version".
Model
Control unit identifier
129
2/04
163
3/04
168
3/20
170
2/23
202
0/20
Displaying remaining service function
GF00.20-P-2007A
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Page 2109 of 4133
AR82.20-P-0110GH
Removing and installing front dome lamp
13.3.97
MODEL
163
P82.20-0400-11
1
Overhead control panel
2
Bulb
3
Socket
4
Dome lamp switch
5
Screws
6
Reflector housing
Removal, installation
1
Remove overhead control panel (1)
AR82.20-P-1100GH
2
Remove bulb (2)
3
Release socket (3) for bulb (2) by pressing in
The bulb socket is clipped to the overhead
control panel.
4
Pull dome lamp switch (4) off of reflector
housing (6)
5
Unscrew screws (5) from reflector housing (6)
on left and right on overhead control panel (1)
6
Pry reflector housing (6) out of overhead
control panel (1)
Avoid damaging reflector housing
7
Reinstall in opposite order
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Page 2110 of 4133
AR72.10-P-2100GH
Remove/install door catch
11.2.97
MODEL
163.113 /128 /136 /154 /157 /172 /174 /175
P72.10-0483-01
1
Bolt
2
Mount for seal
3
Seal
4
Bracket
5
Door retaining strap
6
Nut
P72.10-0484-01
Removing, installing
1
Remove door lining
Front door
AR72.10-P-1000GH
Rear door
AR72.12-P-1010GH
2
Pull foil off of inner door panel in front area
Installation:
Replace damaged foil.
3
Unscrew screw (1) on door retraining strap
Avoid damaging paint.
Installation:
Apply glue to screw.
*BR00.45-Z-1013-02A
*BA72.10-P-1001-01D
*BA72.12-P-1003-01C
4.1
Pull seal (3) off of door retaining strap (5)
Up to 08/99.
5
Close crank window
6
Unscrew nuts (6) from door retaining strap
Hold door retaining strap to prevent it
from falling into the door
*BA72.10-P-1002-01D
7
Remove door retaining strap through
installation opening in inner door panel
Pull rubber out of retaining clip at bottom
of window guide rail and move along door
catch.
Installation:
Install window guide rail
correctly.
8
Install in the reverse order
Front door
Number
Designation
MODEL
Series 163
BA72.10-P-1001-01DBolt, door catch at A-pillar
Nm
24
BA72.10-P-1002-01D
Nut for door restraining strap on
inside of door
Nm
10
Rear door
Number
Designation
MODEL
Series 163
BA72.12-P-1003-01C
Screw for door catch on B-pillar
Nm
24
Auxiliary repair materials
Number
Designation
Order number
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