MERCEDES-BENZ ML350 1997 Complete Repair Manual

Fig. 4: Connecting Hand Held Tester Scan Tool To OBD-II Data Link Connector
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING
Starter malfunctions may cause a Di agnostic Trouble Codes (DTCs) to be stored in Motor Electronics
Sequential Fuel Injection (ME-SFI) sy stem. After repairs are completed check for and erase any DTCs stored in
(ME-SFI) system. See appropriate SE LF-DIAGNOSTICS article in ENGINE PERFORMANCE. If cause of
starter malfunction is not engine pe rformance related, replace starter.
REMOVAL & INSTALLATION
STARTER
Removal & Installation
1. Disconnect and shield negative battery cable. See BATTERY DISCONNECT/CONNECT under
SERVICE PRECAUTIONS.
2. Remove nut (2) for inner fender. See Fig. 5
. Pull front and rear section of inner fender (1) downward.
Move inner fender away inward and downward. Pull toward outside over wheel. DO NOT damage fender
cutout or paint.
3. On vehicles with 112 engine, remove nut (6) at shield (5) of left engine mount and take out shield. See
Fig. 6
.
4. On all vehicles, disconnect circuit 30 (1) and circuit 50 (2) cables from starter. See Fig. 6
. Remove bolts
(3) for starter-to-crankcase. Take starter (M1) out to the side.
5. If replacing starter on vehicles with manual transmission, check ring gear at flywheel for wear and
damage. If replacing starter on vehicles with auto matic transmission, check ring gear on drive plate for
wear and damage. Repair or repl ace damaged parts as necessary.
6. To install, reverse removal proce dure. Replace bolts with locking splines, micro-encapsulated bolts and
self-locking nuts. Mating thread of mi cro-encapsulated bolts must be cleaned to remove all residue of old
bolt locking compound. Tighten fasteners to specification. See TORQUE SPECIFICATIONS
. Connect
battery. See BATTERY DISCONNECT/CONNECTunder SERVICE PRECAUTIONS.
NOTE: Numbers and letters in text refe
r to numbers and letters in figures.

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Starters - 163 Chassis
me
Saturday, October 02, 2010 3:19:47 PMPage 9 © 2006 Mitchell Repair Information Company, LLC.

Fig. 5: Removing Inner Fender
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Starters - 163 Chassis
me
Saturday, October 02, 2010 3:19:47 PMPage 10 © 2006 Mitchell Repair Information Company, LLC.

Fig. 6: Removing Starter
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
OVERHAUL
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
NOTE: Manufacturer does not r ecommend overhaul of starter.
ApplicationFt. Lbs. (N.m)

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Starters - 163 Chassis
me
Saturday, October 02, 2010 3:19:47 PMPage 11 © 2006 Mitchell Repair Information Company, LLC.

WIRING DIAGRAMS
See STARTING SYSTEM wiring diagram in appr opriate SYSTEM WIRING DIAGRAMS article in
ELECTRICAL.
Engine Mount-To-Engine Carrier48 (65)
Ground Cable-To-Body13 (18)
Starter-To-Crankcase31 (42)
INCH Lbs. (N.m)
Circuit 30 Connection Nut124 (14)
Circuit 50 Connection Nut53 (6)

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Starters - 163 Chassis
me
Saturday, October 02, 2010 3:19:47 PMPage 12 © 2006 Mitchell Repair Information Company, LLC.

AD54.30-P-6000-06GH
Steering lock switch, testing electrical system

of IC
Model 163

t
A

Scope of test

Measuring instrument/

Test connection

Operation/

Requirement
Specified value
D
Possible cause/

Remedy

1.0
Steering lock switch

(S97/1)

o

A1

bL
14

(A.14)

Ignition:
OFF

Disconnect coupling "A"

(18-pin)

Steering locked

Steering unlocked

<
1
W

> 20 k
W
D
Cables

D
(S97/1)

Copyright DaimlerChrysler AG 05.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR91.60-P-0660GH
Removing and installing airbag unit on steering wheel
27.2.01

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

P91.60-2339-11

up to 31.08.01

1
Airbag unit

2
Bolts

4
Connector

P91.60-2340-05

as of 01.09.01

1
Airbag unit

3
Arresting mechanism

4
Connector

5
Connector


Remove/install

Danger!


Injury hazard
when performing test and

repair work on airbags and emergency

tensioning retractorsStore airbag unit with expulsion area on top,

do not subject to temperatures above 100 °C.

Interrupt power supply when working on such

units.

AS91.00-Z-0001-01A


Important instructions for performing repair,

body work and welding on vehicles with

airbag and emergency belt tensioner units
Models 129 as of 1.7.93, 163, 168, 170, 202

as of 1.7.93, 208, 210, 414, 638, 690.6, 901,

902, 903, 904, 905

Model 461 with engine 602.983

Model 463 up to 30.11.00

Model WD141, WD241, WD341, WD641,

WD741, XD141, XD241, XD341, XD441,

XD541, XD641, XD741, YD141, YD241,

YD341, YD441, YD541, YD641, YD741

AH91.00-P-0002-01B


Legal provisions concerning handling and

storage of airbag and emergency tensioning

retractor units
Models 124, 129, 140, 163, 168, 170, 202,
203, 208, 209, 210, 211.004/ 006/ 016/ 061/

065/ 070, 215, 220, 230, 314, 316, 318, 414,

461, 463, 638, 668, 670, 690.6, 901, 902,

903, 904, 905, 950, 952, 953, 954, 970, 972,

974, 975, 976

Model WD141, WD241, WD341, WD641,

WD741, XD141, XD241, XD341, XD441,

XD541, XD641, XD741, YD141, YD241,

YD341, YD441, YD541, YD641, YD741

AH91.00-P-0004-01A

o

Notes regarding the disposal of airbag and

belt tensioner units
All models

OS91.00-P-0001-01A

1
Separate ground cable of battery

AR54.10-P-0003A

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

2
Remove screws (2)

Starting from the straight-ahead position,

turn steering wheel by 90 to obtain better

access to the bolts.


*BA91.60-P-1001-01A

Screwdriver bit

*126589001000

3
Lift airbag unit from steering wheel

4.1
Open arresting mechanism (3) on plug

connector (4)

Up to 31.08.01.

4.2
Open arresting mechanism (3) on both plug

connectors (4, 5)

As of 01.09.01.

5.1
Unplug plug connector (4) from squib

Up to 31.08.01.


Installation:
plug connector should latch

audibly.

5.2
Unplug connector (4, 5) from squib.

As of 01.09.01.


Installation:
plug connector should latch

audibly. Close arresting mechanism (3) on the

plug connectors after latching.

6
Remove airbag unit (1) out of steering wheel

If airbag unit is replaced:
#

Make airbag units unusable

AR91.60-P-0611A

7
Install in the reverse order

The steering wheel must always be

replaced after the driver airbag unit has

deployed.

8
Check automatic return of combination switch

9
Carry out diagnosis

According to specifications in diagnosis

manual.

Airbag

Number

Designation
Model 163

BA91.60-P-1001-01A
Screw for airbag to steering wheel
NM
8

126 589 00 10 00

Screwdriver bit

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

AR46.10-P-0200GH
Removing, installing contact spiral
1.3.97

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

P46.10-0460-01 P46.10-0461-01 P46.10-0399-01


Remove/install

1
Remove steering wheel

Front wheels centered

AR46.10-P-0100GH

2
Only unscrew the mounting screws (32h) until

the fanfare horns and airbag clock spring

contact (A45) can be removed

The fastening bolts also act as protection

against twisting and as an assembly aid.

3
Remove the fanfare horns and airbag clock

spring contact (A45) carefully from the jacket

tube

Installation:
Push on fanfare horns and

airbag clock spring contact (A45) as far as the

stop. In the process the recess must align

with the fixing lug (arrow)

If the clock spring contact twists out of

position, i.e., if the steering joint is removed:

#

Set the clock spring contact to center position

AR46.10-P-0200-01GH

4
Unlock plug and disconnect the connector

(38d) from the fanfare horns and airbag clock

spring contact (A45

5
Check fanfare horns and airbag clock spring

contact (A45) for damage

Visual inspection

Do not use any oil or grease!

The upper (32f) and lower part (32g) of

the clock spring contact are clipped together

and can only be separated by the effect of

high forces or due to defective assembly. If

the spring contact is assembled incorrectly,

carefully unwind and clip the upper and lower

parts together. Be careful not to trap or bend

the spring contact (32e).

6
Install in the reverse order

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR46.10-P-0100GHRemoving and installing steering wheel
1.3.97

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

P46.10-0449-11
P46.10-0450-01 P46.10-0458-01 P46.10-0459-01

Modification notes

10.9.03

Connecting quiescent current retention unit deleted
Step 1

10.9.03
Reference to adjusting toe on front axle replaced by

reference to chassis alignment check
Step 10

Removing, installing

Danger!

Risk of explosion
caused by explosive gas.

Risk of poisoning and caustic burns


caused by swallowing battery electrolyte.
Risk of injury
caused by burns to skin and

eyes from battery acid or when handling

damaged lead-acid batteries
No fire, sparks, open flames or smoking.

Wear acid-resistant gloves, clothing and eye

protection. Pour battery electrolyte only into

suitable and appropriately marked containers.

AS54.10-Z-0001-01A


Danger!

Risk of injury
when carrying out test or repair

work on airbag or emergency tensioning

retractor units
Store airbag units with deployment side facing

up; do not expose to temperatures greater

than 100 °C. When working on these units,

disconnect the power supply.

AS91.00-Z-0001-01A


Legal provisions concerning handling and

storage of airbag and emergency tensioning

retractor units

AH91.00-P-0004-01A

o

Notes on disposing of airbag and emergency

tensioning retractor units

OS91.00-P-0001-01A

1
Disconnect ground cable from battery


Protect the ground cable to prevent

unintentional contact with the battery ground

terminal.

AR54.10-P-0003A

Notes on battery

AH54.10-P-0001-01A

2
Remove airbag unit (120) from steering wheel

(32)

AR91.60-P-0660GH


Instructions for performing repair, body work

and welding on vehicles with airbags and

ETR units

AH91.00-P-0002-01B

3
Unplug connectors (38b, 38c) for horn

4
Turn steering wheel (32) to horizontal position

(front wheels in straight-ahead position)

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

5
Remove key and engage steering lock

6
Unscrew bolt (32c)

Hold the steering wheel (32).


Installation:
Replace bolt (32c).


*BA46.10-P-1001-02A

7
Pull off steering wheel (32)

Pass cables carefully through the openings.


Installation:
Align recesses of the splines

in the steering wheel with the markings on the

steering shaft (arrows).

8
Check fanfare horns and airbag clock spring

contact (A45) for damage

The clock spring contact must not be

turned while the steering wheel is removed

otherwise it will be damaged.

Visual inspection, replace clock spring

contact if necessary:

#

Removing and installing clock spring contact

AR46.10-P-0200GH

9
Install in the reverse order

10
Carry out road test

Tests during the road test:

Turn signal canceling:

When the steering wheel is offset by

more than 1 tooth, satisfactory resetting of the

turn signal is no longer guaranteed.

Airbag indicator lamp:

The SRS indicator lamp must not light up

on full steering lock in both directions.

Steering wheel position:

If the steering wheel is crooked, adjust it

by max. 1 tooth. If the difference is greater:

#

Check toe on front axle and adjust if

necessary, see:

#

Performing chassis alignment check

AR40.20-P-0200A

Steering wheel

Number

Designation
Model 163

BA46.10-P-1001-02A
Bolt, steering wheel to steering shaft
Nm
80

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2