MERCEDES-BENZ ML350 1997 Complete Repair Manual

Order No. 6515 6246 13 Part No. 163 584 28 83 USA Edition B 2001

2003 ACCESSORIES/SAFETY EQUIPMENT
Mercedes-Benz - Air Bag Restraint Systems
DESCRIPTION & OPERATION
All models are equipped with Supplemental Restraint System (SRS). The main components of SRS are driver-
side air bag module, passenger-side air bag module, side impact air bag modules (located in doors), SRS control
module, side air bag sensors, SRS warning light, driver-side knee bolster, passenger-side knee bolster and seat
belt pretensioners or Emergency Tensioning Retractor (ETR) seat belt assembly. Additionally, some vehicles
may be equipped with head impact (curtain type) air bags.
Both SRS and ETR are electronically activated by a single control module. There are 2 thresholds which must
be exceeded to trigger an ETR action, air bag deployment, or both. If a moderately severe frontal collision
occurs exceeding first triggering threshold where protection from seat belt is sufficient, only Emergency
Tensioning Retractor (ETR) is activated if seat belt is buckled. If a moderately severe frontal collision occurs
exceeding first triggering threshold where protection from seat belt is sufficient, but seat belt is not buckled, air
bag is deployed and ETR is not activated.
If a severe frontal collision occurs exceeding second triggering threshold where protection from seat belt is
insufficient, air bag is deployed. ETR is activated if seat belt is buckled. If seat belt is not buckled, ETR is not
activated when second triggering threshold is reached. Passenger air bag will deploy even if passenger seat is
not occupied when a triggering threshold is exceeded. During certain types of collisions, the air bags will be
deploy, but ETRs will not be activated.
The side air bag on the driver-side deploys whenever the driver-side air bag module is deployed and when there
is a substantial side impact crash. The air bag on the passenger-side will activate only when a sensor (Occupied
Seat Recognition Sensor) in the passenger seat sends a signal to the SRS control module that the passenger-side
seat is occupied. Side air bags mounted in rear doors will deploy when side impacts occur that exceed preset
parameters.
Head impact air bag modules will deploy when certain side impacts occur that exceed preset parameters. Head
impact air bag will deploy independently of other air bags on side of impact.
COMPONENT LOCATIONS
COMPONENT LOCATIONS WARNING:Accidental air bag deployment is possible. Personal injury may result.
Read and follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS

before working on air bag system or related components.
ComponentLocation
AIR BAG warning lightInstrument Panel Cluster
ClockspringUnder steering wheel
Driver-side air bag moduleOn steering wheel
Emergency Tensioning Retractor (ETR)Driver-side & passenger-side lower B- & C-pillars(1)

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SERVICING
SRS AIR BAG label on driver-side door latch post indicates SRS replacement date for air bag units. All SRS
components must be thoroughly inspected, including wiring harness. Before component replacement, check for
SRS fault codes by performing system operation check. See SYSTEM OPERATION CHECK
. SRS service
life is 10 years from manufactured date or 10 years from SRS replacement date after accident related repairs are
completed.
SYSTEM OPERATION CHECK
SRS warning light indicates SRS and Emergency Tensioning Retractor (ETR) system readiness. Turn ignition
on. SRS warning light will illuminate, then turn off after approximately 4-6 seconds indicating SRS system is
functioning properly. If SRS warning light does not illuminate, illuminates while driving or is continuously
illuminated, there is a system fault. Repair malfunctioning system.
AIR BAG SAFETY PRECAUTIONS
Observe these precautions when servicing the air bag system:
When working around SRS components and before any repairs are performed, disable air bag system. See
DISABLING & ACTIVATING AIR BAG SYSTEM
.
Before straightening any damage to body, or before performing electrical arc-welding, disable air bag
system. See DISABLING & ACTIVATING AIR BAG SYSTEM
.
Always wear safety glasses and gloves when handling a deployed air bag module. Air bag module may
contain sodium hydroxide deposits which are irritating to the skin.
Always use control module and impact sensors made by same manufacturer. Using components produced
by different manufacturers could cause accidental air bag or ETR deployment.
DO NOT repair any portion of SRS wiring harness.
If any SRS component is dropped from a height greater than 1.6 feet (0.5 m), it must be replaced.
If SRS components show signs of damage, they must be replaced.
Always handle air bag module with trim cover facing away from your body.
Always place air bag module on workbench with trim cover up, away from loose objects.
Front Passenger Seat Occupied Recognition With
Automatic Child Seat Recognition (ACSR) sensorUnder passenger front seat cushion
Head impact air bag modulesDriver-side & passenger-side roof rails over front &
rear doors
Knee bolstersDriver-side and passenger-side lower instrument
panel
Passenger-side air bag modulePassenger-side instrument panel
Side impact air bag modulesIn front & rear doors
Side impact sensorsOn floor inboard of door openings
(1)On C Class, rear seat ETRs are part of seat belt buckle assemblies.

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DO NOT expose any SRS component to temperatures in excess of 212°F (100°C).
DO NOT expose any SRS component to grease, oil or cleaning agents.
DISABLING & ACTIVATING AIR BAG SYSTEM
DISABLING SYSTEM
Turn ignition off and remove key. Disconnect negative battery cable and shield cable end. Disconnect SRS
control module electrical connector.
ACTIVATING SYSTEM
Connect SRS control module electrical connector. Ensure no one is in vehicle. Turn ignition on. Connect
negative battery cable. Go to SYSTEM OPERATION CHECK
.
DISPOSAL PROCEDURES
Several situations may arise requiring some form of disposal action, including:
Scrapping a vehicle containing deployed air bag modules and ETRs.
Scrapping a vehicle with live air bag modules and ETRs.
Disposal of a live but electrically faulty air bag module and/or ETR.
Disposal of a deployed air bag module and/or ETR.
DEPLOYED AIR BAG OR ETR
Deployed air bag modules and ETRs can be disposed of like any other part.
SCRAPPED VEHICLE
Undeployed air bag modules and ETRs CANNOT be disposed of without first being deployed. Contact
manufacturer for additional information.
UNDEPLOYED AIR BAG OR ETR
Undeployed air bag modules and Emergency Tensioning Retractor (ETR) seat belts CANNOT be disposed of
without first being deployed. Contact manufacturer for additional information.
POST-COLLISION INSPECTION
When a vehicle has been involved in a collision, certain components of the passive restraint system must be
inspected or replaced. See AIR BAG/SRS COMPONENT INSPECTION & REPLACEMENT TABLES

article in the GENERAL INFORMATION section.
REMOVAL & INSTALLATION

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Removal and installation information is not available.
DIAGNOSTICS
Air bag system diagnostic information is not available. All air bag system diagnosis must be carried out using
manufacturers proprietary test equipment.
WIRE REPAIR
If any part of SRS wiring harness is damaged, DO NOT repair wiring harness, replace complete wiring harness.
WIRING DIAGRAMS
Wirin
g diagrams are not available. WARNING:Accidental air bag deployment is possible. Personal injury may result.
Read and follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS

before working on air bag system or related components.

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2004 ACCESSORIES/SAF ETY EQUIPMENT
Mercedes-Benz - Air Bag Restraint Systems
DESCRIPTION & OPERATION
The main components of Supplemental Restraint System (SRS) are dual-stage driver-side and passenger-side
air bag modules, side impact air bag modules, head impact air bag modules , SRS control module, side impact
sensors, AIR BAG warning light, driv er-side and passenger-side Emergency Tensioning Retractors (ETR). See
COMPONENT LOCATIONS
.
COMPONENT LOCATIONS
COMPONENT LOCATIONS
SERVICING
SRS AIR BAG label on driver-side door latch post indicates SRS replacement date for air bag units. All SRS
components must be thoroughly inspected, including wiring harness. Before component replacement, check for
SRS fault codes by performing system operation check. See SYSTEM OPERATION CHECK
. SRS service
life is 10 years from manufactured da te or 10 years from SRS replacement date after accident related repairs are
completed.
SYSTEM OPERATION CHECK
AIR BAG warning light indicates SRS and Emergency Te nsioning Retractor (ETR) system readiness. Turn
ignition on. AIR BAG warning light will illuminate, then turn off after 4-20 seconds indicating SRS system is
functioning properly. If AIR BAG warn ing light does not illuminate, illuminates while driving or is
continuously illuminated, ther e is a system fault. Repair malfunctioning system.
AIR BAG SAFETY PRECAUTIONS
WARNING:
Accidental air bag deployment is pos sible. Personal injury may result.
Read and follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS

before working on ai r bag system or related components.
ComponentLocation
AIR BAG warning lightInstrument Panel Cluster
ClockspringUnder steering wheel
Driver-side air bag moduleOn steering wheel
Emergency Tensioning Retractor (ETR)Driver-side & passenger-si de lower B- & C-pillars
Head impact air bag modulesDriver-side & passenger-side roof rails
Passenger-side air bag modulePassenger-side instrument panel
Side impact air bag modulesIn front & rear doors
Side impact sensorsOn floor near driver-side & passenger-side B-pillars

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Observe these precautions when servicing the air bag system:
When working around SRS components and before any re pairs are performed, disable air bag system. See
DISABLING & ACTIVATI NG AIR BAG SYSTEM
.
Before straightening any damage to body, or before performing electrical arc-welding, disable air bag
system. See DISABLING & ACTIVATING AIR BAG SYSTEM
.
Always wear safety glasses and gloves when ha ndling a deployed air bag module. Air bag module may
contain sodium hydroxide deposits wh ich are irritating to the skin.
Always use control module and impact sensors made by same manufacturer. Using components produced
by different manufacturers could cause acc idental air bag or ETR deployment.
DO NOT repair any portion of SRS wiring harness.
If any SRS component is dropped from a height greater than 1.6 feet (0.5 m), it must be replaced.
If SRS components show signs of damage, they must be replaced.
Always handle air bag module with tr im cover facing away from your body.
Always place air bag module on workbench with trim cover up, away from loose objects.
DO NOT expose any SRS component to temperatures in excess of 212°F (100°C ).
DO NOT expose any SRS component to grease, oil or cleaning agents.
DISABLING & ACTIVATI NG AIR BAG SYSTEM
DISABLING SYSTEM
Turn ignition off and remove key. Disconnect ne gative battery cable and shield cable end.
ACTIVATING SYSTEM
Ensure no one is in vehicle. Turn ignition on. Connect negative battery cable. Go to SYSTEM OPERATION
CHECK .
DISPOSAL PROCEDURES
Several situations may arise requiring so me form of disposal action, including:
Scrapping a vehicle containing deployed air bag modules and ETRs.
Scrapping a vehicle with live air bag modules and ETRs.
Disposal of a live but electrically faulty air bag module and/or ETR.
Disposal of a deployed air bag module and/or ETR.
DEPLOYED AIR BAG MODULE OR EMERGENCY TENSIONING RETRACTOR (ETR)
Deployed air bag modules and ETRs can be disposed of like any other part.
SCRAPPED VEHICLE

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Undeployed air bag modules and ET Rs cannot be disposed of without first being deployed. Contact
manufacturer for additional information.
UNDEPLOYED AIR BAG MODULE OR EMERGENCY TENSIONING RETRACTOR (ETR)
Undeployed air bag modules a nd ETR seat belts cannot be disposed of without first being deployed. Contact
manufacturer for additional information.
ON-VEHICLE DEPLOYMENT (SCRAPPED VEHICLE)
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Park vehicle outdoors with at least 33
feet (10 m) of open space around vehi cle. Disable air bag system. See DISABLING & ACTIVATING
AIR BAG SYSTEM . Place a fully-charged 12-volt batter y 33 feet (10 m) from vehicle.
2. Disconnect all air bag module and emergency tensioning retractors (ETR) connectors. See REMOVAL
& INSTALLATION . Fabricate a deployment harness using 2 wires, each 33 feet (10 m) in length.
Connect deployment harness to selected component to be deployed. Twist opposite ends of deployment
harness together to prevent accidental deployment. Dual-stage air bag modules will require 2 deployment
harnesses.
3. Ensure no one is within 33 feet (10 m) of air bag module. Untwist ends of deployment harness. Connect
wires to battery. Component should deploy. Repeat deployment procedure for remaining components.
OFF-VEHICLE DEPLOYMENT
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See
DISABLING & ACTIVATI NG AIR BAG SYSTEM
. Remove component to be deployed. See
REMOVAL & INSTALLATION
. Place component in the center of an area with at least 33 feet (10 m)
of clearance on all sides.
2. Attach component to a appropriate object, such as a tire and wheel assembly, to prevent movement.
Fabricate a deployment harn ess using 2 wires, each 33 feet (10 m) in length. Connect deployment harness
to selected component. Twist opposite ends of depl oyment harness together to prevent accidental
deployment. Dual-stage air bag modules will require 2 deployment harnesses.
3. Ensure no one is within 33 feet (10 m) of component . Untwist ends of deployment harness. Connect wires
to battery. Component should deploy. Repeat depl oyment procedure for remaining components.
POST-COLLISION INSPECTION
When a vehicle has been involved in a collisi on, certain components of the passive restraint s
ystem must be
WARNING:
Components are very hot after deployme nt. Personal injury may result.
Allow sufficient time for compone nts to cool before touching.
NOTE: Deploy only one component at a time.
WARNING: Components are very hot after deployme nt. Personal injury may result.
Allow sufficient time for compone nts to cool before touching.

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inspected or replaced. See AIR BAG/SRS COMPONENT INSPECTION & REPLACEMENT TABLES
article in the GENERAL INFORMATION section.
REMOVAL & INSTALLATION
CLOCKSPRING
Information is not available.
CONTROL MODULE
Removal & Installation E
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Turn ignition key to "O" position.
Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM
.
2. Remove center console. See Fig. 1
. Remove sound deadener. Remove ventilation duct. Disconnect
connectors from control module. Remove cont rol module bolts. Remove control module.
3. To install, reverse removal procedure. Tighten control modul e bolts to specification. See TORQUE
SPECIFICATIONS . Activate air bag system. Program control module. See DIAGNOSTICS.
WARNING:
Accidental air bag deployment is pos sible. Personal injury may result.
Read and follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS

before working on ai r bag system or related components.

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Fig. 1: Identifying Control Module
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
DRIVER-SIDE AIR BAG MODULE
Removal & Installation
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See
DISABLING & ACTIVATI NG AIR BAG SYSTEM
.
2. Using Torx Bit (126-589-00-10-00), remove bolts securing driver-side air bag module to steering wheel
from rear of steerin
g wheel. Pull driver-side air bag module away from steering wheel. Disconnect driver-

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