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 3831 of 4133
SI47.10-P-0007A
Service Information: Procedure for fuel tank leaks
14.8.03
MODEL
124, 126, 129, 140, 163, 168, 170, 201, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240, 460, 461, 463
If a fuel tank has a leak which was caused by an accident with
another vehicle, bottoming out, etc., this
cannot
be claimed as a
warranty/goodwill case.
We
explicitly
state here that repair measures
(e.g. welding, bonding, etc.) on fuel tanks made out of sheet metal or
plastic are not permissible.
The fuel tank is always to be replaced when leaks are determined
which have been caused by damage to the upper or lower sides of
the fuel tank.
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Page 3832 of 4133
SI47.10-P-0004A
Service Information: Procedure when tank is filled with incorrect fuel
19.12.00
MODEL
202 with ENGINE 611
MODEL
203 with ENGINE 611, 612, 646
MODEL
210 with ENGINE 611, 612, 613
MODEL
220 with ENGINE 613, 628, 648
MODEL
163 with ENGINE 612, 628
MODEL
168 with ENGINE 668
MODEL
209 with ENGINE 612
MODEL
211 with ENGINE 628, 646, 647, 648
MODEL
463 with ENGINE 612, 628
Modification notes
26.7.04
Engines have been added and procedure has been updated
Incorrect refueling of diesel-power vehicles with a common rail
injection system. Please be aware that if the customer fills the fuel
tank with the wrong type of fuel, this is the customer's fault and
cannot be submitted as a warranty claim.
If the diesel-powered vehicle with a common rail injection system has
been refueled with gasoline, follow the steps below:
1.
If the engine was not started after fuel tank is filled with the wrong
type of fuel, then emptying the fuel tank and cleaning the fuel low-
pressure lines should be enough to solve the problem.
2.
If the engine was started after fuel tank was filled with wrong type
of fuel:
On engines 611, 612, 613, 668:
-
On the rail, open the low pressure connection of the high
pressure pump return (plastic connection in area of pressure
regulator valve) and check connecting point in rail for chips.
On engine 646, 647, 648, 628:
-
Disconnect Y-distributor unit (return line HDP/Rail) at the output
and, with ignition ON, collect the fuel in a clean container. Check
fuel for metal shavings.
If the high pressure pump is not damaged and there are no metal
shavings in the injection system:
-
As in step 1, empty fuel as per the guidelines and clean the fuel
low-pressure lines. In addition to this, remove/install/replace the
high-pressure pump and fuel filter.
If metal shavings are found in the fuel
system or the high pressure pump drive is
damaged:
#
b
Engine runs rough, surges or does not start
ENGINE 611 in MODEL 203, 202, 210
ENGINE 612 in MODEL 163, 203, 210, 209
ENGINE 613 in MODEL 210, 220
ENGINE 628 in MODEL 163, 220, 211
ENGINE 646 in MODEL 203, 211
ENGINE 647 in MODEL 211
ENGINE 648 in MODEL 220, 211
ENGINE 668 in MODEL 168
ENGINE 612, 628 in MODEL 463
AF07.00-P-9000B
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Page 3833 of 4133
SI91.60-P-0002A
Service information on immobilization of a passenger-side airbag where a
rearward mounted (reboard) child seat is fitted
17.3.99
MODEL
124, 126, 129, 140, 163, 168, 170, 202, 203, 208, 210, 215, 220, 463
Modification notes
18.11.00
Supersedes Service Information SI91.60-P-0002A dated
15.11.00
Remove the SI SI91.60-P-0002A from your file
It is recommended to place the child seat in the rear area if
possible.
If, in exceptional cases, the owner wishes a rearward mounted child
seat to be expressly attached on the front passenger seat, the front
passenger airbag should be immobilized.
As a general rule, there is no approval for immobilizing the front
passenger airbag on models fitted with ACSR, which is visible from
the "airbag OFF" indicator light in the center console. On such
models, an MB child seat with ACSR should be used for safety and
cost reasons.
-----------------------------------------------------------------------------------------
On models fitted with seat belt force limiter, it is essential for
safety reasons to
D
program the front passenger ETR to "NO".
D
unplug the connector at the front passenger ETR.
No provision is made for immobilizing the seat occupied
recognition, the automatic child seat recognition (ACSR), as well as
the side airbag and window airbag.
In the event that it is necessary to immobilize the seat occupied
recognition and automatic child seat recognition (ACSR), for example
if a Recaro seat is installed, this can be carried out in exceptional
cases after agreement has been obtained from GSP/SPS, tel. 07031
/ 90 - 81815.
-----------------------------------------------------------------------------------------
After immobilizing the front passenger airbag or additionally the
ETR, it is essential to
D
have the customer sign the confirmation after immobilization.
D
affix a sticker at a clearly visible point in the area of the front
passenger airbag.
D
affix a sticker in the Owner's Manual, in the section Airbag.
Carry out the remaining procedure as stated below.
-----------------------------------------------------------------------------------------
Deactivation can be reversed at any time.
Immobilization and re-activation must be entered in the
vehicle documents!
The vehicle should be presented in such a case to a technical
inspection center (DEKRA, TÜV). The completed confirmation
should be submitted to the vehicle registration authorities for
entry.
-----------------------------------------------------------------------------------------
Perform version coding / procedure
Model
Version
Coding with HHT
2)
or STAR Diagnosis tool (DAS)
Unplug
connector of
passenger side
airbag
3)
Unplug
connector of
passenger side
emergency
tensioning
retractor
Insert
replacement resistor
3)
Passenger-side
airbag
NO
Passenger side
emergency
tensioning
retractor NO
124
All
--X-X
126
All
--X-X
129
up to 06/93
--X-X
129
as of 07/93 without ACSR
X-X--
140
up to 06/93
--X-X
140
as of 07/93 without ACSR
X-X--
140
as of 07/93 with ACSR
1)
-----
163
up to VIN 145263
--X-X
163
as of VIN 145264
-----
168
All
-----
170
without ACSR
XXXX-
170
with ACSR
1)
-----
202
without seat belt force limiter
X-X--
202
as of 06/97
4)
XXXX-
202
with ACSR
1)
-----
203
All
-----
208
All
-----
210
without ACSR
XXXX-
210
with ACSR
1)
-----
215
All
-----
220
All
-----
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Page 3834 of 4133
463
All
-----
1)
Recognition: existing "airbag Off" warning light in center
console.
2)
With HHT functions menu point 5 Coding Reboard child seat. If
only the passenger side airbag is de-activated, then program
menu point Vehicle equipment.
3)
Depending on model and version, unplug one or two
connectors at the passenger side airbag and insert the
corresponding replacement resistors.
4)
Without ACSR, with seat belt force limiter.
Immobilizing passenger side airbag certificate
Model 124, 126, 129, 140, 163 up to VIN
145263, 170, 202, 210
Have customer sign certificate after
immobilization
OF91.60-P-1000-01A
Cancel immobilization
D
To re-activate the passenger side airbag remove the ignition
resistor at the cable.
D
Fit together connector at passenger side airbag.
D
Fit together connector at passenger side ETR (on models fitted
with seat belt force limiter).
D
Use HHT or STAR Diagnosis tool (DAS) to re-program
passenger side airbag and passenger side ETR in the SRS
control module to "YES".
D
Remove sticker on passenger side airbag and render invalid in
Owner's Manual.
D
Complete re-activation on certificate after immobilization.
D
If re-activated, delete de-activation in vehicle documents.
Parts ordering notes
Part no.
Designation
Quantity
140 868 00 50
Ignition resistor (replacement resistor)
as required
140 817 15 20
Sticker (without seat belt force limiter)
2
210 817 20 20
Sticker (with seat belt force limiter)
2
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Page 3835 of 4133
SI18.00-P-0010A
Service Information: oil sludge
26.3.01
ENGINE
111 in MODELS 124, 163, 170, 202, 203, 208, 210
ENGINE
112 in MODELS 129, 163, 170, 202, 203, 208, 210, 220
ENGINE
112, 113 in MODEL 463
ENGINE
113 in MODELS 129, 163, 202, 208, 210, 215, 220
ENGINE
137 in MODEL 215, 220
ENGINE
166 in MODEL 168
Oil sludging in gasoline engines with ASSYST maintenance
system
Recently we have determined that time and time again oil
sludging occurs in gasoline engines with an ASSYST maintenance
system.
Oil sludging can lead to the following complaints:
D
engine oil consumption
D
engine smoke (white/blue)
D
influencing of oil level indicator
D
clogged oil filter, engine oil thickened like jelly
D
Check engine lamp illuminated
D
oil sludge visible during assembly job, e.g. in oil filter, in cylinder
head covers, condensation sludging
(engine 166) etc.
-----------------------------------------------------------------------------------------
The following list of causes may lead individually or as a combination
to engine oil sludging:
D
Crankcase ventilation inoperable, function orifices, bores,
passages in cylinder head cover, cylinder head, crankcase etc.
are mechanically sealed. A nonfunctioning crankcase
ventilation boosts loads on the engine oil through organic
nitrates. The risk of oil sludging increases.
The mechanical condition of the engine is always to be
checked, i.e. all engine oil drain orifices on the cylinder head
and crankcase and all crankcase ventilation ducts must be free
of obstacles. Crankcase breather lines may not be kinked.
Check the ventilation bores in the cylinder head covers.
-----------------------------------------------------------------------------------------
D
The engine oil used does not comply with the specifications in
Sheet 229.1 or 229.3 of the Specifications for Service Products.
The additive process, e.g. dirt-carrying capability, neutralization
capability and oxidation resistance as well as the quality of the
base stock influence sludging time.
Use of engine oils with best possible resistance to formation of
sludge, i.e. use only tested and approved engine oils (from
Sheet 229.1 or 229.3). The best protection is afforded by the
engine oils on Sheet 229.3, which fulfill more stringent
specifications with regard to preventing sludge and deposits
(see Sheet 221.0, page 11). These oils have a distinctly better
anti-sludge characteristic than other engine oils.
D
Sludging after adding a fuel or engine oil special additive.
Do not use fuel or engine oil special additives. More information
hereto is available on Sheet 219.0 of the Specifications for
Service products. Reference to customer not to use special
additives.
D
Engine oil change not performed according to ASSYST
specifications. At driven distances
exceeding > approx. 3000 km, engine oil sludging may occur.
-----------------------------------------------------------------------------------------
Comply with engine oil and filter change as under ASSYST
specifications. Observe remaining distance.
D
Fuel grade lies outside standard (regionally contingent). If
contaminated, deficient fuel is used, then engine oil sludging
may occur even where approved engine oil is used.
Operation with fuel, e.g. as under DIN EN 228. Clarify refueling
behavior of customer. If engine operation regional, is
temporarily possible with deficient oil only, then the startup
distance has to be individually reduced, i.e. the oil change
temporarily performed at an interval of, e.g. 10,000 km.
D
Radiator antifreeze penetration into engine oil, e.g. through an
internal engine leak (cylinder head gasket, casting porosity).
The engine oil sludges within a short period. The crankcase
ventilation clogs up and stops functioning. Condensation
sludging clogs up the oil separator cells
(engine 166).
Rectify coolant leakage. Clean all sludged engine parts, in
particular the crankcase ventilation parts. If the occurrence
repeats, and casting porosity is suspected, e.g. replace
crankcase.
-----------------------------------------------------------------------------------------
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Page 3836 of 4133
Measures for slightly sludged engine:
Oil and filter change. Purge engine, i.e. normal engine operation
in neutral, or while driving, using oil from Sheet 229.3, 228.3, or
228.5. Drain off scavenging oil after purging process (approx. 1
hour). Repeat purging process if necessary. Refill using engine oil
from Sheet 229.3, or 229.1. The first oil change after clearing the
sludge should be performed after approx. 10,000 km or beforehand;
when doing so use engine oil from Sheet 229.3.
Measures for severely sludged engine:
Engines with severe oil sludging and caking onto engine parts
and into bores have to be dismantled and mechanically cleaned.
Tough sludge residue must not enter the clean side of the oil circuit,
as otherwise, e.g. the piston oil spray and the hydraulic
compensation elements may have their functionality impaired. Refill
using engine oil from Sheet 229.3, or 229.1.
The first oil change after sludging should be performed after approx.
10,000 km; when doing so use engine oil from
Sheet 229.3.
Warranty/goodwill regulations
If in combination with engine oil sludging a warranty/goodwill claim is
submitted, then a regular documentation of maintenance must be
presented. The ASSYST printout is to be filed carefully for further
reference.
Oil sludging in combination with an exceeded oil change interval, or
because of special additives in the fuel/engine oil are costs to be
borne by the customer.
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Page 3837 of 4133
GF77.20-P-0001GH
Sliding /pop-up roof, function
28.2.97
MODEL
163 with CODE (414a) Electric glass sliding/pop-up roof
P77.20-0381-06
1
Close sliding/pop-up roof (SR)
2
Open sliding roof
3
Close pop-up roof
4
Open pop-up roof
M12
Sliding/pop-up roof (SR)
S13/2
Switch (SR)
The sliding /pop-up roof is a combination of a sliding roof and pop-up
roof. It is controlled by the motor for the
sliding /pop-up roof drive
assembly (M12)
located on the sliding roof frame below the
overhead control panel.
Two types of control are possible:
D
Opening/closing sliding roof (sliding roof opens toward rear)
D
Opening/closing pop-up roof
The sliding and pop-up roof cannot be opened simultaneously.
Operation is controlled by the
sliding/pop-up roof switch (S13/2)
in
the overhead control module.
-----------------------------------------------------------------------------------------
The following functions can be controlled with the switch:
D
Closing
sliding /pop-up roof (1 or 3); the sliding roof or pop-up
roof is closed depending on which is open.
D
Opening
sliding roof (2); if the pop-up roof is open it is closed
previously.
D
Opening
pop-up roof (4); if the sliding roof is open it is closed
previously.
-----------------------------------------------------------------------------------------
Sliding/pop-up roof (SR), location of
components
GF77.20-P-0001-01GH
Closing sliding/pop-up roof (SR), function
GF77.20-P-2002GH
Opening pop-up roof, function
GF77.20-P-2003GH
Opening sliding roof, function
GF77.20-P-2004GH
Sliding/pop-up roof (SR) lock-up recognition,
function
GF77.20-P-3000GH
Sliding/pop-up roof (SR) position
measurement, function
GF77.20-P-3001GH
Synchronizing sliding/pop-up roof (SR),
function
GF77.20-P-3002GH
Desynchronizing sliding/pop-up roof (SR),
function
GF77.20-P-3003GH
Sliding/pop-up roof, location/purpose/
design/function
GF77.20-P-4100GH
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Page 3838 of 4133
AR68.30-P-4610GH
Removing and installing spare wheel cover
28.4.99
MODEL
163.174
P68.30-2161-06
1
Spare wheel cover front section
2
Retaining straps
3
Electric air pump
4
Screws
5
Spare wheel mount
6
Bracket
7
Screws
Removal, installation
1
Remove cargo space cover
See Owner's Manual.
2
Loosen retaining straps (2) and remove spare
wheel cover front section (1)
3
Remove spare wheel
*BA40.10-P-1002-01A
4
Remove electric air pump (3)
5
Unscrew screws (4) and remove spare wheel
mount (5)
6
Remove bracket (6)
Turn in clockwise direction until bracket
(6) releases at D-pillar.
7
Remove rear wall on spare wheel cover
2 screws.
8
Install in opposite order
Wheels
Number
Designation
Model
163.174
BA40.10-P-1002-01A
Bolt for spare wheel on inside of spare wheel mount
Nm
50
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Page 3839 of 4133
AR68.30-P-4610GH
Removing and installing spare wheel cover
28.4.99
MODEL
163.174
P68.30-2161-06
1
Spare wheel cover front section
2
Retaining straps
3
Electric air pump
4
Screws
5
Spare wheel mount
6
Bracket
7
Screws
Removal, installation
1
Remove cargo space cover
See Owner's Manual.
2
Loosen retaining straps (2) and remove spare
wheel cover front section (1)
3
Remove spare wheel
*BA40.10-P-1002-01A
4
Remove electric air pump (3)
5
Unscrew screws (4) and remove spare wheel
mount (5)
6
Remove bracket (6)
Turn in clockwise direction until bracket
(6) releases at D-pillar.
7
Remove rear wall on spare wheel cover
2 screws.
8
Install in opposite order
Wheels
Number
Designation
Model
163.174
BA40.10-P-1002-01A
Bolt for spare wheel on inside of spare wheel mount
Nm
50
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Page 3840 of 4133
AR68.30-P-4610GH
Removing and installing spare wheel cover
28.4.99
MODEL
163.174
P68.30-2161-06
1
Spare wheel cover front section
2
Retaining straps
3
Electric air pump
4
Screws
5
Spare wheel mount
6
Bracket
7
Screws
Removal, installation
1
Remove cargo space cover
See Owner's Manual.
2
Loosen retaining straps (2) and remove spare
wheel cover front section (1)
3
Remove spare wheel
*BA40.10-P-1002-01A
4
Remove electric air pump (3)
5
Unscrew screws (4) and remove spare wheel
mount (5)
6
Remove bracket (6)
Turn in clockwise direction until bracket
(6) releases at D-pillar.
7
Remove rear wall on spare wheel cover
2 screws.
8
Install in opposite order
Wheels
Number
Designation
Model
163.174
BA40.10-P-1002-01A
Bolt for spare wheel on inside of spare wheel mount
Nm
50
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