ECU MERCEDES-BENZ ML350 1997 Complete Repair Manual

AR68.10-P-1040GH
Remove/install bottom section of instrument panel
13.3.97

MODELS
163.113 /128 /136 /154 /157 /172 /174 /175

P68.10-2226-09

1
Instrument panel

2
Instrument cluster cover frame

3
Combination switch with paneling

4
Bottom section of instrument panel

5
Screws in left footwell

6
Screws in right footwell

7
Bolts
15

Paneling

16
Bolt

17
Entrance lamps

A
Spreading clips

B
Guide tongues

8

Bolts

9
Bolts

10
Heater/ventilation switch

11
Instrument panel center section

12
Glove compartment

13
Parking brake release handle

14
Parking brake control cable


Remove/install

1
Shift transmission selection lever to position" 1"


Secure vehicle to prevent it moving away.

2
Disconnect ground cable of battery

AR54.10-P-0003A

3
Remove combination switch with paneling (3)

AR54.25-P-2800GH

4
Remove cover frame of instrument cluster (2)

5
Unscrew the screws (7).

3 screws up to 08/99. 1 screw as of 09/99.

6
Unscrew screws in left footwell (5) on the

lower part of the instrument panel (4)

7
Remove center section of instrument panel

(11)

AR68.10-P-1030GH

8
Remove switch unit for heater / ventilation (10)
Up to 31.08.01.

AR83.20-P-1835GH

As of 01.09.01.

AR83.40-P-6500GH

9
Unscrew screws (8, 9)

10
Remover glove compartment (12)
Up to 31.08.99.

AR68.10-P-1400GH

As of 01.09.99.

AR68.10-P-1400GI

11
Unscrew screws in the right footwell (6) on

the lower part of the instrument panel (4)

12.1
Unclip entrance lamps (17) and disconnect
electrical connectors

As of 09/99.

13.1
Remove paneling (15) and unscrew screws

(16)

As of 09/99.

14
Unclip lower part of instrument panel (4) at
the four expanding clips (A) on the instrument

panel (1)

Installation: Ensure that guide lugs (B) are

properly seated in the mounts on the

instrument panel.

15
Unhook the Bowden cable of the parking

brake (14) at the release handle of the

parking brake (13)

16
Remove bottom section of instrument panel (4)

Do not damage instrument panel when

removing and installing.

17
Install in the reverse order

18
Read diagnostic trouble code memory and

erase

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AR07.52-P-1465A
Remove/install intake air temperature sensor
16.2.99

ENGINE
604, 611.960 /961 /962, 612.961 /962 /963 /967, 613.961 /960, 628.960

P15.18-2021-11

Shown on Engine 613.961

1
Tie strap

2
Connector

3
Locking arm

4
Sealing ring

B17
Intake air temperature sensor


Remove/Install

1
Cut through cable strap (1) at locking arm (3)


Installation:
Replace tie strap.

2
Unplug plug (2) at intake air temperature

sensor (B17)

The connector secures simultaneously the

snap-in brackets of the intake air temperature

sensor (B17).

3
Unlatch intake air temperature sensor (B17)

at the mount

Press together snap-in brackets (arrows)

and detach intake air temperature sensor

(B17).


Do not unlatch or latch intake air

temperature sensor (B17) with put on plug,

otherwise the snap-in brackets will be over-

tensioned and therefore damaged.

Replace intake air temperature sensor (B17)

with defective snap-in brackets.

4
Replace seal ring (4)

5
Install in the reverse order

6
Read diagnostic trouble code memory and

erase
Stored faults possibly caused by previous

simulation or by cables disconnected in the

process of installation or testing must be

processed and erased in the DTC memories

once all work is completed.

a

Connect Hand-Held Tester (HHT) and read

out DTC memory
Engine 611 up to 6.99

See
#

AD00.00-P-2000-03A

Diagnosis Manual Diesel Engine Volume 1.2

Engine 611 as of 7.99, 611.962, 612, 613, 628

See
#

STAR DIAGNOSIS

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Fig. 13: Identifying Instrument Panel Bottom Section Components

Remove/install
1Shift transmission selection lever to
position "1" Secure vehicle to prevent it
moving away.
2Disconnect ground cable of battery AR54.10-P-
0003A
3Remove combination switch with
paneling (3) AR54.25-P-
2800GH
4Remove cover frame of instrument cluster
(2)
5Unscrew the screws (7). 3 screws up to 08/99. 1 screw as of
09/99.
6Unscrew screws in left footwell (5) on the
lower part of the instrument panel (4)
7Remove center section of instrument
panel (11) AR68.10-P-
1030GH
Remove switch unit for heater / AR83.20-P-

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Interior Equipment - 163 Chassis
me
Saturday, October 02, 2010 3:35:21 PMPage 20 © 2006 Mitchell Repair Information Company, LLC.

Safety belts/emergency tensioning retractors
Luggage nets
Child seats
Fig. 57: Identifying Assembly Wedge (110 589 03 59 00)

Fig. 58: Identifying Torx Bit Set (000 589 01 10 00)

REMOVE/INSTALL PANELING IN FOOTWELL - AR68.30-P-4010GH
MODELS 163.113 /128 /136 /154 /157 /172 /174 /175
rear-end door.
8Remove floor covering (3) to rear Installation: Install floor covering
below side paneling.
Assembly wedgeFig. 57
9Install in the reverse order
NumberDesignationModel 163 up to 08/99Model 163 as of 09/99
BA91.40-P-1001-01DBelt end fitting screwNm3535
NumberDesignationModel Series
163
BA68.50-P-1001-
02ABolt securing cargo retainer br acket to loading compartment
floorNm24
NumberDesignationModel Series 163
BA91.20-P-1001-01ABracket for child seat anchorage on load compartment floorNm24

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB In terior Equipment - 163 Chassis
me
Saturday, October 02, 2010 3:35:22 PMPage 57 © 2006 Mitchell Repair Information Company, LLC.

Number
Designation
Model

Series 163

BA68.50-P-1001-02A
Bolt securing cargo retainer bracket to loading

compartment floor
Nm
24


Child seats

Number

Designation
Model

Series 163

BA91.20-P-1001-01A
Bracket for child seat anchorage on load

compartment floor
Nm
24

000 589 01 10 00

Torx bit set

Assembly wedge

110 589 03 59 00

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T 774L OHNE MARKTAUFTEILUNG
P 774L OHNE MARKTAUFTEILUNG
P 774P E-FAHRZEUG TYP W164 DE40
P 775L BRASILIEN
T 775L BRASILIEN
P 775P E-FAHRZEUG TYP W164 DE40
P 776 RADABDECKUNG FUER AMG -RAEDER
P 776P E-FAHRZEUG TYP W164 DE40
P 777 ENDSCHALLDAEMPFER IN AMG - DESIGN
P 777L CHILE
T 777L CHILE
P 777O SILVER ARROW - METALLICLACK
P 777P E-FAHRZEUG TYP W164 DE40
P 777U SILVER ARROW - METALLICLACK
P 778A STOFF SCHIEFERGRAU BUNT
P 778P E-FAHRZEUG TYP W164 DE40
T 779L ECUADOR
P 779L ECUADOR
P 779P E-FAHRZEUG TYP W164 DE40
P 780A STOFF HERAKLION
P 780P E-FAHRZEUG TYP W164 DE40
P 781A STOFF HERAKLION - MULTI-SCHWARZ
T 781L GUAYANA, REP.
P 781L GUYANA REPUBLIK
P 781O TIERRA DEL FUEGO GREY MIDDLE - METALLICLACK
P 781P E-FAHRZEUG TYP W164 DE30
P 781U TIERRA DEL FUEGO GREY MIDDLE - METALLICLACK
P 782 AMG-SPEICHENRAEDER 18" STERLING SILBER
P 782A STOFF HERAKLION - MULTI-BLAU
P 782P E-FAHRZEUG TYP W164 DE40
P 783 AMG-RAEDER MIT AMG-SPORTFAHRWERK
P 783L GUYANA FRANZOESISCH
T 783L GUAYANA, FRANZ.
P 783P E-FAHRZEUG TYP W164 E35
P 784L PG/US SONSTIGE
T 784L PG/US SONSTIGE
P 784P E-FAHRZEUG TYP W164 DE40
P 785L KOLUMBIEN
T 785L KOLUMBIEN
P 785P E-FAHRZEUG TYP W164 E35
T 786L AMERIKA PG
P 786L AMERIKA PG
P 786P E-FAHRZEUG TYP W164 E50
P 787A STOFF HERAKLION - MULTI-ROT
P 787L PARAGUAY
T 787L PARAGUAY
P 787P E-FAHRZEUG TYP W164 E50
P 788 AMG-SPORTFAHRWERK M. 4 AMG-LM-FELGEN U.BREITREIFEN
P 788P E-FAHRZEUG TYP W164 E55
P 789 AMG-SPORTFAHRWERK M. 4 AMG-LM-FELGEN U.BREITREIFEN
P 789L PERU
T 789L PERU
P 789P E-FAHRZEUG TYP W164 DE40
P 790 AMG-SPEICHEN-RAEDER 18 ZOLL MIT MISCHBEREIFUNG
P 790K BAUMUSTER SRT204
P 790L AMERIKA-SONSTIGE
T 790L AMERIKA-SONSTIGE
P 790O ALASKA WHITE - METALLICLACK
P 790U ALASKA WHITE - METALLICLACK
P 791 AMG-RAEDER 18 ZOLL RUNDUM
T 791L SURINAM
P 791L SURINAM
P 792 AMG-SCHEIBENRAD-DESIGN MIT MISCHBEREIFUNG
P 793 AMG-RAEDER 8,5 X 18 ET 25 245/40 MEHRTEILIG
T 793L URUGUAY

GF77.20-P-2003GH
Opening pop-up roof, function
19.2.97

MODEL
163 with CODE (414a) Electric glass sliding/pop-up roof

Function prerequisites

D
Voltage not too low or too high

D
Switch-on conditions for convenience control fulfilled

D
Sliding/pop-up roof synchronized

Function

When
switch (SHD, S13/2)
is actuated continuously, circuit 30 is

switched through to the
sliding/pop-up roof (M12)
and the pop-up

roof opens.

The function "Open pop-up roof" is executed as long as

D
switch (SHD, S13/2)
is actuated and

D
the pop-up roof has not yet reached the end position and

D
lock-up is not recognized.


If the sliding/pop-up roof is desynchronized, it moves only in the pop-

up roof direction each time the
switch (SHD, S13/2)
is actuated. This
means that it is possible to move to the zero
position for synchronizing. After successful

synchronization
, the

sliding/pop-up roof can be controlled again without limitation.

Vehicles
up to 11.99:

The power for the
sliding/pop-up roof (M12)
is supplied via a

fuse directly to c. 30.

The power for the
switch (SR, S13/2)
is supplied via the

convenience relay (F1k14)
, which is actuated by the all-

activity module (AAM, N10).

Vehicles
as of 12.99:

The power for the
sliding/pop-up roof (M12)
is supplied via a

fuse directly to c. 30. The power for the
switch (SHD, S13/2) is

supplied via a lead to the
extended-activity module (EAM,

N10/1) , this power is switched through only when the switch-on

conditions for the convenience control are fulfilled and the EAM

is coded accordingly.


Closing sliding /pop-up roof, function

GF77.20-P-2002GH


Sliding /pop-up roof lock-up recognition,
function

GF77.20-P-3000GH


Sliding /pop-up roof position measurement,

function

GF77.20-P-3001GH


Synchronizing sliding /pop-up roof, function

GF77.20-P-3002GH


Convenience control

GF72.29-P-2002GH


All-activity module (AAM)
up to 11.99

GF54.21-P-4100GH

Extended-activity module, location/

purpose/design/function
as of 12.99

GF54.21-P-4107GK

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Page 1

3.1
Remove viscous fan (1)

Engine 112.942 /970 and 113.942.

Right-hand thread!

AR20.40-P-5660C

3.2
Remove electric fan

Only Engine 113.965 /981.

AR20.40-P-5000GH
4.1
Pull off plate clamps of fan shroud (2)

Only for Engine 112.942, from 5/98.

5.1
Remove fan shroud (3)

Only for Engine 112.942 /970 und

113.942. Unscrew the bolts at bottom of fan

shroud for this step


Installation:
If installing a new radiator

with integral power steering pump oil cooler, a

new fan shroud is required if a radiator

without integral oil cooler was previously
installed.

6
Remove headlamp (7).

AR82.10-P-4730GH

7
Remove radiator crossmember (8)

AR62.30-P-2300GH

8
Detach coolant line (4, 6) and expansion

reservoir coolant line (5) at the radiator


Installation:
Replace the hose clamps on

the radiator fitting for the coolant hose, as

they could cause damage to the screw/thread.

Hose clamp

*BA20.20-P-1004-01A

9
Remove the rubber seal on radiator (9)

10.1
Remove oil line (return line of radiator
!

power steering pump expansion reservoir)

(18) and oil line (feed line of steering gear

!

radiator) (19)

From 5/98 only, seal off the connections.

Set of plugs

*129589009100

11
Unscrew ATF lines (10) at the radiator

Seal off the connections.


*BA20.20-P-1001-01A


*BA20.20-P-1003-01A

Set of plugs

*129589009100

12.1
Detach the connector from the fan and
remove the fan grille (11)

Only for Engine 112.942 /970 and 113.942.

13
Unscrew the condenser from the radiator
Do not disconnect the lines.

14
Remove fasteners (20) and damper rubber

(21)

The damper rubber (21) is designed to

prevent possible vibrations between the

condenser and radiator (15) during off-road

driving.

15
Remove air conditioning system fluid

reservoir (14) from the radiator

Place aside with the lines connected.

Detach the condenser from the radiator.

16
Remove radiator (15)

When installing, the spigots on the

radiator must be inserted in the rubber

grommets in the bottom crossmember.

Installation:
On Model 163.154 with

Engine 112.942 before VIN end number

043553, when installing a new radiator with

integral power steering pump oil cooler,

additional operations are required, if they

have not already been carried out:

#
v

Retrofit the bracket for the oil cooler line of

the power steering pump

SM46.30-P-0002A

k

Radiator with integral oil cooler for the power

steering pump

BT20.20-P-0001-01A

17
Detach air guides (12)

Replace the clamps on air guides (13).

18
Install in the reverse order

19
Pour in coolant

AR20.00-P-1142HA

20
Check the headlamp setting and correct if

necessary

e

Check and adjust the headlamp setting

AP82.10-P-8260GH

Danger!

Risk of accident
caused by vehicle starting

off when engine is running.
Risk of injury


caused by contusions and burns when

working in engine during starting procedure
Secure the vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.

Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

21
Check the oil level in the automatic

transmission and correct if necessary

AR27.00-P-0101A

22
Check the cooling system for leaks

AR20.00-P-1010HA


Radiator, coolant hoses

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Page 2

AR20.40-P-5000M
Remove/install electric fan
24.8.99

ENGINE
612.963 in MODEL 163.113

P20.40-2015-06

Shown on Model 163.113 with

Engine 612.963

1
Clutch

2
Electrical lines circuit 30

3
Clips

4
Captive nuts

5
Bolts

M4/7
Electric suction fan engine and AC

with integrated control


Remove/Install


Danger!
Risk of injury
to
fingers being jammed or

squeezed
when removing and installing or

aligning hoods, doors, trunk lid/tailgate or

sliding roof.
When moving components, ensure that no

body parts or limbs are within the operating

range of moving parts.

AS00.00-Z-0011-01A


Danger!
Risk of death.
Death may result if vehicle

slips or topples from the lifting platform.
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.

AS00.00-Z-0010-01A

1
Place the vehicle on lifting platform

AR00.60-P-1000GH

2
Open engine hood and raise to vertical position

Have second person secure hood.

AR88.40-P-1000GI

3
Connect quiescent current retention device


*WH58.30-Z-1005-09A

4
Disconnect ground cable of battery

AR54.10-P-0003A

5
Detach coupling (1) at electrical connector of

fan

6
Disconnect electrical lines circuit 30 (2) at
electric fan

7
Unclip wiring harness from bracket

8
Remove front part of noise encapsulation

AR94.30-P-5400GH

9
Detach clamps (3) at bottom side of electric fan

10
Unscrew screws (5)

11
Remove captive nuts (4)

12
Unhinge electric suction fan engine and AC

with integrated control (M4/7) at top of

radiator and take out toward bottom


Installation:
Insert retaining lugs of

electric fan into the mounts at radiator.

13
Install in the reverse order

Commercially available tools

Number

Designation
Make (e. g.)
Order number

WH58.30-Z-1005-09A
CMP 12.2 quiescent current retention unit
Hans Zeheter

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Page 1

Danger!

Risk of injury
to skin and eyes suffering

scalding from contact with hot coolant spray.
Risk of poisoning
from swallowing coolant.
Do not open cooling system unless coolant

temperature is below 90 °C. Open cap slowly

and release the pressure. Do not pour coolant

into beverage bottles.

Wear protective gloves, protective clothing

and eye protection.

AS20.00-Z-0001-01A

1
Open engine hood and raise to vertical position

Have second person secure hood.

AR88.40-P-1000GI

2
Connect no load current retention unit


*WH58.30-Z-1005-09A

3
Disconnect battery ground cable

AR54.10-P-0003A

4
Remove trim panel of cylinder head cover

AR01.20-P-5014-02B


*BA01.20-P-1002-01A


*BA01.20-P-1003-01A

5
Remove bottom part of noise encapsulation

at front

AR94.30-P-5400GH

6
Remove electric fan (1)

Remove toward bottom.

AR20.40-P-5000M

7
Drain coolant

At radiator.

AR20.00-P-1142M


Notes on coolant
All engines

AH20.00-N-2080-01A

8
Remove charge air cooler (110/2)

AR09.41-P-6817MM

9.1
Attach guard plate for radiator/condenser

With automatic air conditioning, code

581a and AC system or Tempmatic USA,

code 580.

Attach additional AC condenser in the

vehicle.

y

Guard plate for radiator/condenser
Engine 606 in model 124,
Engine 606.961 in model 140,

Engine 112, 113, 604, 605, 611.960 in

MODEL 202,

Engine 602.983, 612.966 in MODEL 461,

Engine 628.962, 612.965, 606.964, 112.945,

113.962/ 982 in MODEL 463,

Engine 111, 112, 611.962, 612.962 in model

203,

Engines 112, 113, 611.961, 612.961, 613.961

in MODEL 210,

Engine 112 in model 170,

Engine 112 in MODEL 220,

Engine 113 in MODEL 211, 215, 220,

Engine 112 in MODEL 208,

Engine 112, 612.963, 628.963 in MODEL 163,
Engine 112.923 /943, 113.961 in MODEL 129,

Engine 137, 275 in MODEL 215, 220,

Engine 613.960, 628.960 in MODEL 220,

Engine 113.992 in model 230.474,

Engine 271 in model 209, 203,

Engine 285.950 in model 240.078 /178,

Engine 612.967 in model 209.316,

Engine 648 in model 220

Engine 112.951 in model 639.601/603/

605/701/703/705/801/803/805

Engine 646.983/984 in model 639.601/

603/605/701/703/705/801/803/805

Engine 646.982 in model

639.601/603/605/701/703/705

WF58.50-P-0110-01A

10
Remove seal rail (11)

11
Extract steering oil from reservoir

Hand pump

*210589007100

12.1
Disconnect power steering oil line (return line

radiator

!
power steering pump supply

reservoir) (18)

Seal connections.


Installation:
Install new sealing rings.


*BA46.30-P-1012-01A


Clamp

*000589543700

Set of stop plugs

*129589009100

12.2
Disconnect power steering oil line (feed line of

steering gear

!
radiator) (19)


Clamp

*000589543700

Set of stop plugs

*129589009100

Hexagon socket wrench

*WH58.30-Z-1001-06A

Hexagon socket wrench

*WH58.30-Z-1002-06A

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Page 2