MERCEDES-BENZ ML350 1997 Complete Repair Manual

Risk of injury
When working with heat-shrinkable tubing, excessive temperatures may cause burns to skin and eye.
Risk of poisoning
When working with heat-shrinkable tubing, vapors may be produced which lead to symptoms of poisoning such
as coughing, headaches, dizziness and nausea. Moreover, irritation may occur to the respiratory paths and eyes.
Safety precautions/instructions
Work only in well ventilated rooms.
Avoid overheating the heat-shrinkable tubing.
Stop heat-shrinking immediately if the shrink hose becomes blistered or charred or shows other signs of
damage.
Do not inhale the vapors.
Avoid contact with melted shrink tubing.
Wear safety glasses with side protection and protective gloves.
First aid measures
When eyes or skin come in contact with melted shrink tubing
Flush the affected area immediately with plenty of water for approx. 15 minutes.
Treat affected areas like burn wounds. Do not remove any burned parts.
Contact physician or medical service.
When vapor is inhaled:
Take victim to fresh air.
Keep victim calm and cover with a blanket.
Contact physician or medical service.
Fire protection measures
Suitable extinguishing agents
Water mist, general-purpose foam, powder, carbon dioxide
Protective equipment for firefighters (compressed air equipment, oxygen apparatus, chemical resistant
protective clothing)
RISK OF INJURY & RISK OF POISONING - AS00.19-Z-0002-01A
Wear protective gloves, protective clothing and safety glasses. Ensure that the work area is adequately

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 236 © 2006 Mitchell Repair Information Company, LLC.

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

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 237 © 2006 Mitchell Repair Information Company, LLC.

MODELS 124, 129, 140, 163 up to 30.11.99, 163 as of 1.9.01, 168, 170, 201, 202, 208, 210, 215, 220
EXPLANATION OF SYMBOLS FOR TESTERS AND COMPONENTS - AD00.00-P-2000-01A
0.0 [] 1Key to diagnostics
symbols AD00.00-P-2001A
0.0 [] 2Diagnosis assignmentexcept models 215, 220AD00.00-P-2002A
0.0 [] 3Connect test equipment
diagnosisexcept model 215AD00.00-P-2003A
0.0 [] 4Diagnostic procedureonly for vehicle systems
that can be diagnosed using
STAR DIAGNOSISAD00.00-P-2004A
DescriptionLogoDescriptionLogoDescriptionLogo
ABS Adapter Battery Short-circuit
35-pin socket
box Direct current
generator Short-circuit to
ground
126-pin socket
box Direct current
motor Open-circuit
Function
generator Capacitor Multimeter
alternating
voltage type of
measurement
Hand-Held
Tester Coil Multimeter
resistance type of
measurement
Pulse counter Resistance Function
generator square-
wave signal shape
Lambda control
tester Ground Function
generator
sinusoidal signal
shape
Pressure gauge In order Oscilloscope
Multimeter Fault Adapter cable
with light-
emitting diode
Decade resistor Greater than > Multimeter direct
current type of
measurement
Bridge Less than < Multimeter
alternating
current type of
measurement

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 238 © 2006 Mitchell Repair Information Company, LLC.

ASSIGNMENT OF DATA LINK CONNECTOR - AD00.00-P-2000-02C
Hazardous
voltage Short-circuit to
positive
Multimeter direct
voltage type of
measurement
Brake lining
wear indicator Plug Socket
DescriptionLogoDescriptionLogoDescriptionLogo
Program heating
(1st cut-in time) Air up and down Air Drying
Program heating
(2nd cut-in time) Standard setting Cooling mode
(standard setting)
Cut-in time Economy setting Air conditioning
Off
Time of day
display Air to center and
side outlet Air conditioning
On/Off (USA
only)
Instant heat Minimum air
volume Off (no air
supply)
Return flow Maximum air
volume ° Celsius
Supply Automatic blower
control ° Fahrenheit
Air upwards Defrosting Residual heat
Air upwards,
downwards,
doors Automatic mode
Air downwards Recirculated air

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 239 © 2006 Mitchell Repair Information Company, LLC.

Fig. 326: Identifying Data Link Connector
CONNECTING HAND-HELD TESTER (HHT), READING OUT FAULT MEMORY - AD00.00-P-2000-03A
Commercially available tools
1. Connect Hand-Held Tester (087) with test cable (Multiplexer) (094) to data link connector (DTC readout)
(X11/4).
2. Switch on ignition.
3. According to instructions on display:
a. Read out/erase fault memory
b. Read out actual values
c. Perform actuations
d. Program control modules
4. Disconnect HHT.
NumberDesignation
WH58.30-Z-1036-13AHandheld tester (HHT)651 100 01 99
WH58.30-Z-1037-13ATest cable (multiplexer)651 100 40 99

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 240 © 2006 Mitchell Repair Information Company, LLC.

Fig. 327: Connecting Hand-Held Tester (HHT) For Reading Out Fault Memory
Observe system-specific deviations which are listed for the appropriate diagnosis description in the chapter
"Advanced Information on diagnosis".
Stored faults which can be caused by disconnected cables or a simulation during test work must be erased in the
fault memory upon completion of the work.
CONNECT HAND-HELD TESTER (HHT), READ OUT DIAGNOSTIC TROUBLE CODE MEMORY - AD00.00-P-2000-03C
Model 163 up to 31.08.01
Model 168
Commercially available tools
1. Connect hand-held tester (087) to diagnosis test connector (X11/4) in interior using test cable
(multiplexer) (094) and adapter cable (107).
2. Switch on ignition.
3. According to instructions in display:
a. Read out/erase fault memory
b. Read out actual values
c. Perform actuations
d. Program control modules
4. Disconnect HHT.
NumberDesignation
WH58.30-Z-1036-13AHandheld tester (HHT)651 100 01 99
WH58.30-Z-1037-13ATest cable (multiplexer)651 100 40 99
WH58.30-Z-1044-13AAdapter cable (HHT) for datalink connector (X11/4, 16-pin)

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 241 © 2006 Mitchell Repair Information Company, LLC.

Fig. 328: Connecting Hand-Held Tester (HHT) For Read Out Diagnostic Trouble Code Memory
Note system-specific deviations listed in respective diagnosis description in chapter entitled "Diagnosis
Previous Knowledge".
Stored faults possibly caused by cables being disconnected during testing or by simulation must be erased from
the fault memory once the work is completed.
CONNECT STAR DIAGNOSIS AND READ OUT FAULT MEMORY - AD00.00-P-2000-04A
Fig. 329: Connecting STAR DIAGNOSIS For Read Out Fault Memory (Illustrated On Model 210)

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 242 © 2006 Mitchell Repair Information Company, LLC.

Fig. 330: Connecting STAR DIAGNO SIS For Read Out Fault Memory (Illustrated On Model 163)
Fig. 331: Connecting STAR DIAGNO SIS For Read Out Fault Memory (Illustrated On Model 164.1)

Fig. 332: Connecting STAR DIAGNO SIS For Read Out Fault Memory (Illustrated On Model 461.302)


2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 243 © 2006 Mitchell Repair Information Company, LLC.

Fig. 333: Connecting STAR DIAGNOSIS For Read Out Fault Memory (Illustrated On Model 171.4)
1. Connect STAR DIAGNOSIS (0100) to diagnostic socket, on the data link connector (X11/4) or on the
data link connector (1.3) (X11/22).
2. Switch on ignition.
3. Start the Diagnosis Assistance System.
4. In the "Model" menu, select the sub menu "Other model series".
5. Go through the instructions on the screen:
Enter the control unit version.
Read fault memory, erase.
Read actual values.
Perform actuations.
Adaptation of control units
6. Disconnect STAR DIAGNOSIS (0100).
Stored faults which may be caused by disconnecting cables or by simulation during testing operations must
be deleted in the diagnostic trouble code memory following completion of the operations.
EXPLANATION OF DIAGNOSTIC SYMBOLS - AD00.00-P-2001A
MODEL 124, 129, 140, 163, 168, 170, 201, 202, 208, 210, 215, 220
DIAGNOSIS ASSIGNMENT - AD00.00-P-2002A
MODEL 124, 129, 140, 163, 168, 170, 201, 202, 208, 210
CONNECT DIAGNOSIS TESTING EQUIPMENT - AD00.00-P-2003A
MODELS 124, 129, 140, 163, 168, 170, 201, 202, 203, 208, 209, 210, 220
MODELS 211.004 /006 /016 /026 /028 /042 /043 /061 /065 /070 /076 /206 /216 /226 /242 /261 /265 /616,
215.374
Explanation of symbols for
testers and components AD00.00-P-2000-01A
Assignment of data link
connectorModels 124.034/036,
129.063/067/076, 140, 170,
202, 208, 210AD00.00-P-2000-02A
Assignment of data link
connectorModel 124 except
124.034/036,
129.060/061/066, 201AD00.00-P-2000-02B
Assignment of data link
connectorModels 163, 168AD00.00-P-2000-02C

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 244 © 2006 Mitchell Repair Information Company, LLC.

MODEL 230.474
STAR DIAGNOSIS PROCEDURAL SCHEMATIC - AD00.00-P-2004-02A
Fig. 334: Star Diagnosis Procedural Schematic
DIAGNOSTIC PROCEDURE - AD00.00-P-2004A
MODELS 124.034 /036, 129.058 /063 /067 /076, 140, 163 168, 170, 202, 203, 208, 210, 215, 220
TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: OVERALL VEHICLE - AR00.00-Z-9163AA
MODEL 163
Connect hand-held tester
(HHT), read out
diagnostic trouble code
memoryModels 124.034/036,
129.063/067/076, 140, 170,
202, 208, 210AD00.00-P-2000-03A
Connect hand-held tester
(HHT), read out
diagnostic trouble code
memoryModel 124 except
124.034/036,
129.060/061/066, 201AD00.00-P-2000-03B
Connect hand-held tester
(HHT), read out
diagnostic trouble code
memoryModel 163 up to 31.8.01, 168AD00.00-P-2000-03C
Connect STAR
DIAGNOSIS and read out
fault memoryModels 124.034/036,
129.058/063/067/076, 140,
163, 168, 170, 202, 203, 208,
209, 210, 211, 215.374, 220,
230AD00.00-P-2000-04A
STAR DIAGNOSIS procedural
schematicAD00.00-P-2004-02A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 245 © 2006 Mitchell Repair Information Company, LLC.