ECU MERCEDES-BENZ ML350 1997 Complete Repair Manual

Raise vehicle so that the wheels are not touching the ground when operating vehicle.
A person should be sitting in the cab who is acquainted with the vehicle controls and who can initiate
appropriate measures.
When jacking up vehicle, make sure that the jack stands are positioned on solid ground and that they are
secure.
The vehicle must be securely positioned on the bearing surfaces, where necessary anti-slip bases should
be placed on the surface.
Wear closed and close-fitting work clothes.
All items of jewelry like chains or rings must be taken off.
Restrain long hair by wearing appropriate head cover.
Before commencing any work on the running engine, familiarize yourself with the location of potentially
hot parts.
When carrying out work when the engine is running do not touch any hot and rotating parts .
First aid measures for burns
Flush the skin areas affected with plenty of cold water and cover skin with sterile burn bandages. Do not
apply the bandages tightly, but rather loosely over the affected skin area. Do not use any frayed bandages
(e.g. old dressing material). Do not rub the affected skin areas.
Consult a physician immediately.
RISK OF INJURY. MOVING PARTS CAN PINCH, CRUSH OR, IN EXTREME CASES EVEN SEVER EXTREMITIES. -
AS00.00-Z-0009-01A
No parts of the body or limbs should be within the operating range of the mechanism when moving
components.
Risk of injury
When working on components which can be moved either by hand, by means of electric motors, or
hydraulically/pneumatically via linkage, serious injuries can occur to body parts being trapped, crushed or
severed.
Safety instructions/precautions
Monitor hazard area.
Secure area against unauthorized access when parts are in motion.
Never touch the mechanism of a component while it is being actuated by electric motors via STAR
DIAGNOSIS or by direct actuation (terminal 30).
Choose a test cable of sufficient length.
RISK OF DEATH CAUSED BY VEHICLE SLIPPING OR TOPPLING OFF OF THE LIFTING PLATFORM. - AS00.00-Z-0010-
01A

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Align vehicle between the columns of the lifting platform and position the four support plates at the
lifting platform support points specified by the vehicle manufacturer.
RISK OF ACCIDENT AND INJURY
Please make sure that:
The vehicle is centered lengthwise and crosswise between the lifting platform columns.
The support plates on the lifting platform support points are all positioned at the same height.
The vehicle is first raised a few inches (wheels are still touching the ground) and the position and fit of
the support plates and lift points are checked before raising the vehicle to the full lifted position.
The vehicle is not raised off the lifting platform plates when components are being supported.
If the arms of the lifting platform or the support plates are not positioned properly, or if components of the
vehicle are supported so that the vehicle raises off the platform, then the vehicle can slip off the platform and
cause life-threatening injuries to you or other people.
Before removing axles and assemblies from the vehicle, make sure the vehicle is secured to the platform or that
sand bags are used to balance the vehicle out.
Otherwise the vehicle could tip because of the uneven distribution of weight. This could cause life-threatening
injuries to you or other people.
RISK OF INJURY CAUSED BY FINGERS BEING JAMMED OR PINCHED WHEN REMOVING, INSTALLING OR
ALIGNING HOODS, DOORS, TRUNK LID/ REAR-END DOOR OR SLIDING ROOF. - AS00.00-Z-0011-01A
When moving components, ensure that no body parts or limbs are within the operating range of moving
parts.
Risk of injury
When working on hoods, doors, trunk lids/tailgates and sliding roofs and on their connecting mechanisms,
serious injuries can occur due to cutting, jamming or pinching of body parts like fingers and hands.
Safety instructions/precautions
Be careful when working in hazardous areas.
When moving components, secure the movement area of the mechanism to prevent interference.
Use special tool or other means to ensure safe distance to dangerous areas. NOTE: In Germany, lift platform operators must observe the following regulations and
guidelines: "Berufsgenossenschaftvorschrift (BGV) D29 fur Hebebuhnen" and
the guidelines issued by the lift platform manufacturer. In other countries,
operators must comply with all relevant statutory and accident prevention
regulations.

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Wear protective gloves
RISK OF INJURY FROM FINGERS BEING PINCHED OR JAMMED WHEN WORKING ON GAS STRUTS UNDER
PRESSURE - AS00.00-Z-0012-01A
Remove and install gas struts only in relaxed position and on components which have been secured
properly.
Injury hazard
Risk of injury from pinching or crushing when working on gas struts under pressure.
When removing and installing gas struts not in the relaxed position injury can result to body parts from
pinching, crushing or jamming.
Rules of behavior/protective measures
Remove and install gas struts only in relaxed position (pressure or thrust rod completely extended).
Support components held by gas strut (tailgates, doors, trunk lids, seat frame, etc.) in position by suitable
means before removing gas struts.
Replace damaged retaining clips or keepers.
When moving components secure motion area of mechanism against reaching in.
RISK OF INJURY & RICK OF POISONING - AS00.00-Z-0013-01A
Depressurize the hydraulic system completely before starting any work on the system. Wear protective
clothing and eye protection.
Possible hazards
Risk of injury
When disengaging hydraulic lines without first depressurizing the system, dangerous skin or eye injuries may
occur due to the very high pressures (in excess of 200 bar). If hydraulic fluid, particularly central hydraulic fluid
(especially harmful), comes into contact with unprotected skin, this may cause damage to the skin.
Risk of poisoning
If hydraulic fluid is swallowed, this may lead to poisoning symptoms such as headache, giddiness, abdominal
pain, vomiting, diarrhea, cramps and unconsciousness.
Protective measures/guidelines
When commencing work on hydraulic systems, these must be depressurized; the system must be drained
if necessary.
Do not pour hydraulic fluid into beverage containers.

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Ensure sufficient ventilation, especially in the case of central hydraulic fluid.
Ensure that only authorized persons have access to hydraulic fluid.
Immediately seal disconnected leads and hoses, and the connections to the assemblies, with blind plugs.
Wear protective gloves, protective clothing and eye protection.
If protective gloves cannot be worn, the following points must be noted:
Only expose skin to hydraulic fluid for as brief a period as possible; in the event of contact with skin,
clean skin with soap and water.
In the event of contact with clothing, replace clothing as rapidly as possible.
First-aid measures
Have the person affected drink plenty of water with activated charcoal additive.
After swallowing large volumes, seek the attention of a physician.
If hydraulic fluid gets into the eyes, immediately rinse the eyes with plenty of clean water/eye rinsing
bottle.
In the event of injuries to the skin or eyes due to a jet of hydraulic fluid, immediately seek the attention of
a physician.
RISK OF INJURY. RUBBER MOUNTS AND BEARING PARTS CAN SUDDENLY COME LOOSE DURING
INSTALLATION/REMOVAL AND SHOOT WILDLY THROUGH THE AIR. - AS00.00-Z-0014-01A
Shield hazard area with suitable catch device (basket, grate box). Also ensure that no unauthorized
persons are present in the hazard area.
Risk of injury
When installing and removing tight transverse control arm mounts, the rubber mounts can be put under
extremely high tension. If one of the mounts is released suddenly it can shoot out of the installation bore hitting
and injuring anyone in the immediate area.
Safety precautions/instructions
When pressing parts in and out ensure that no one is in the immediate vicinity and therefore in the hazard
area except for the person performing the work.
Also secure the pressing point (hazard area) with a suitable catch device (basket, grate box).
When pressing out loosen mount by tapping a number of times with a hammer. Press out in a number of
intervals relieving the pressure in between.
RISK OF EXPLOSION FROM PRESSURIZED SPRAY CANS - AS00.00-Z-0015-01A
Protect cans from direct sunlight and temperatures above 50°C

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ventilated. Secure power supply cables. Avoid sources of fire in working area.
Potential risks
Risk of injury
Contact with hot objects without suitable protective clothing causes severe burns to the skin and eyes.
Melted, spraying and dripping soldering tin can cause injuries to skin and eyes.
Electric shock may occur if network or high-voltage lines become scorched or cut by sharp objects.
Risk of poisoning
Caused by inhaling the vapors of the soldering additives, in particular fluxes.
Fire hazard
Caused by igniting combustible materials and objects located close to the soldering equipment.
Safety instructions/precautions
Wear suitable protective work clothing and protective gloves.
Wear safety glasses.
Protect power supply cable against heat and sharp edges.
Create safe work surface for putting down hot tools and objects.
Do not use soldering tool in wet or damp environments.
Avoid unintentional operation.
Switch off equipment after use.
Do not work on parts that are under voltage.
Use available soldering fume extractors.
Only perform soldering operations in well-ventilated rooms.
Keep combustible objects away from the workplace.
When working with soldering materials, do not eat, drink, smoke, and sniff. Keep well away from food.
First aid measures
Do not rub affected areas of the skin; pour plenty of lukewarm water over affected areas and cover over
with sterile bandages.
Move unconscious victim immediately to fresh air and provide artificial respiration, if necessary.
With severe injuries, call a doctor immediately.
SELF-DIAGNOSTIC SYSTEM
CONNECTING AND USING TEST EQUIPMENT - AD00.00-P-1000AZ

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4. Check that cable connector has snapped into place all the way round. Secure cable connectors in vehicle to prevent them rattling.
Fig. 392: Locating Cable Connectors

PROTECT REPAIR AREA AFTER CABLE REPAIRS - AR00.19-P-0100-08A
Protection of repair area with heat-shrinkable tube
1. Slide heat-shrinkable tube over the repair area.
2. Heat the heat-shrinkable tube us ing hot air blower until it lies evenly against the repair area.
Fig. 393: Heating Heat
-Shrinkable Tube
PROTECT REPAIR AREA AFTER CABLE REPAIRS - AR00.19-P-0100-08B
Protect repair area using corrugated hose.
1. Place corrugated hose over repair area.
2. Wrap insulatin
g tape around corrugated hose at both ends.

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Risk of poisoning caused
by inhaling fumes when
working with heat-
shrinkable tubing.glasses with side
protection and protective
gloves.
Risk of injury caused by
burns to skin and eyes,
risk of poisoning caused
by inhaling fumes during
soldering.Wear protective gloves,
protective clothing and
safety glasses. Ensure
that the work area is
adequately ventilated.
Secure power supply
cables. Avoid sources of
fire in working area.AS00.19-Z-0002-01A
Notes on replacement of
safety-relevant and special
componentsModel 124, 126, 129,
140, 163, 164, 168, 169,
170, 171, 199, 202, 203,
208, 209, 210, 211, 215,
216, 219, 220, 221, 230,
240, 245, 251, 414, 461
as of 1.4.94, 463AH00.19-P-1000-08A
Assessment of damage in
wiring harnesses AH00.19-P-1000-05A
Notes on crimping AH00.19-P-1000-09A
Notes on soldering AH00.19-P-1000-10A
Notes regarding plug
connections AH00.19-P-1000-06A
Advantages of repairing
wiring harnesses AH00.19-P-1000-03A
Repair methods for wiring
harnesses AH00.19-P-1000-04A
Notes on soft soldering AH00.19-P-1000-07A
Notes on cable protection AH00.19-P-1000-11A
Removing contacts from
plugs and connectors AR00.19-P-0120A
Repairing wiring harness
using solder connectors AR00.19-P-0100-09A
Repair wiring harness by
crimping AR00.19-P-0100-03A
Repair flat conductor
wiring harness by
crimpingModel 164, 211, 216,
219, 221, 251AR00.19-P-0100-10A
Repair wiring harness by
crimping (with watertight
connections) AR00.19-P-0100-04A
Repairing cable harness AR00.19-P-0100-05A

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the side jacking points.
Fig. 639: Identifyin g Lifting At Rear

RAISING, JACKING UP VEHICLE - AR00.60-P-1000GH
MODEL 163
Fig. 640: Raising, Jacking Up Vehicle

Fig. item, etc.Work instructions
Lethal injuries are
possible if vehicle slips
off of lifting platformAlign vehicle between the
four lifting platform pillars
and position the four
support plates at the hoist
mounting points specified
by the vehicle
manufacturer.AS00.00-Z-0010-01A
Danger of accident
through self-acting
movement of the vehicle
when jacked up Risk of
injury through intrusion
into engine compartment
or driveline where rotating
parts pose a serious
hazard.Make sure that the jack
stands are securely
positioned. Authorized
person should occupy
driver's seat. Wear closed
and close-fitting work
clothes. Do not grasp hot
or rotating parts.AS00.00-Z-0008-01A

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Workshop equipment
MAINTENANCE
PREFACE - AP00.20-P-0000-01C
These "Service Documents" contain all the maintenance operations for the basic and national versions of the
following models:
Model 170, 129, 140, 202 as of 1.6.97
Model 210 as of 1.3.97
Models 163, 168, 203, 208, 209, 215, 220, 230
Type 414
This maintenance manual became necessary with the introduction of the Active Service System (ASSYST). It
contains all maintenance operations for vehicles with the Active Service System (ASSYST) and is divided into
the two volumes 4 and 4.1.
The system for demand-related complete vehicle maintenance is described in the Introduction into Service
manual "Active Service System (ASSYST)".
If the support plates are
not properly mounted
(012) at the vehicle's
designated jacking points
(1, 2) damage may occur
to the side sill covers (3).
The vehicle should be
secured against tipping or
falling off the platform
when removing any units.
Lifting vehicle with
inspection pit lift or
garage jack
Inspection pit lift.
AR00.60-P-1000-01GH
*WE58.40
-Z-1002-05A
1Forward jacking points
2Rear jacking points
3Side sill covers
011Lifting platform *WE58.40-Z-1001-05A
012Support platesAll four support plates
must be extended to an
equal distance (Dimension
X).
WE58.40-Z-1001-05ATwo-post lifting platform
WE58.40-Z-1002-05APit lift

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SAFETY PRECAUTIONS FOR NEW VEHICLES THAT ARE BEING PUT IN STORAGE - AP00.70-P-1000ZZ
MODELS all
and rear axle
Frame
New vehicles in the
context of this description
are vehicles for which no
inspection has been carried
out to date. For other
vehicles, the instructions
in the Specifications for
Service Products apply
In areas in which
extremely high corrosive
attacks can be expected
from experience, the
measures given here are
not always sufficient even
for new vehiclesExport countries
In these cases, proceed in
accordance with
Specifications for Service
products.
Treatment of battery if
vehicle taken out of
service AR54.10-P-0006EA
Treatment of tire inflation
pressure if vehicle taken
out of serviceFor vehicles which will be
stored for longer than 2
months, the tire inflation
pressure should be
increased to approx. 4 bar
to prevent flattening of the
contact surface.
Treatment of break system
if vehicle taken out of
serviceWarm up service brake so
that adhering moisture at
the brake disks and the
brake pads evaporates.
This prevents the brake
pad from becoming stuck
to the brake disks.
Release parking brake.
The vehicle must be
secured by engaging a
gear/park pawl or by using
wedges.
Treatment of fuel system
if vehicle taken out of To protect the fuel tank
from corrosion, we

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