MERCEDES-BENZ ML430 1997 Complete Repair Manual

GF54.30-P-2001A
Indicator / warning displays, function
24.10.96

MODEL
129, 140 as of 1.6.96,

163, 168, 170,

202 as of 1.8.96,

208 up to 31.7.99,

210 as of 1.6.96 up to 30.6.99

The table below lists the various warning alarms and indications

according to type (visual/acoustic) and their actuation (direct/CAN).

Visual warning and indicator signals actuated over direct lines:
D
Left turn signal indicator lamp (A1e1)

D
Right turn signal indicator lamp (A1e2)

D
High beam indicator lamp (A1e3)

D
Fuel reserve warning lamp (A1e4)

D
Brake fluid / parking brake warning lamp (A1e7) (except model

163)

D
Low windshield washer fluid level warning lamp (A1e13) (as of

01.09.01 also valid for model 163)

D
Low engine coolant level warning lamp (A1e11) (except model

168, model 163 as of 3.99)

D
Coolant level and temperature warning lamp (A1e11) (only model

168 as of 9.99 and only coolant level function)

D
Generator charge indicator/warning lamp (A1e5)

D
Seat belt warning lamp (A1e9)

D
Seatbelt/backrest lock warning lamp (A1e9)

D
Exterior lamp failure indicator lamp (A1e14)

-----------------------------------------------------------------------------------------
D

Hydraulic fluid level warning lamp (A1e37)

D
ADS warning lamp, suspension (A1e27)

D
Steering lock warning lamp (A1e40) (only

I
)

D
SRS airbag malfunction indicator lamp (A1e15)

D
AIRBAG OFF indicator lamp (A1e56), only model 163 except

I

Also refer to document: Indicator and warning signals triggered

over CAN data lines
Acoustic warning and indicator signals actuated over direct

lines:
D
Turn signal ticker

D
Seat belt reminder

D
Switched-on lights reminder

D
Key warning

D
Soft top warning, only model 170


Also refer to document: Acoustic warnings, function

Acoustic warning and indicator signals actuated over CAN data

lines:
D
Parking brake warning

D
Vehicle speed warning

D
Vehicle speed limit warning

D
Gear warning, only model 168


Also refer to document: Acoustic warnings, function

Indicator and warning signals triggered over

direct lines

GF54.30-P-3002A

Indicator and warning signals triggered over

CAN data lines

GF54.30-P-3003A
Acoustic warnings, function
GF54.30-P-3010A

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GF54.30-P-3003A
Indicator/warning messages triggered via CAN data buses, function
24.10.96

MODEL
129, 140 as of 1.6.96,

163, 168, 170,

202 as of 1.8.96,

208 up to 31.7.99,

210 as of 1.6.96 up to 30.6.99

Indicator and warning displays triggered via CAN

Low brake fluid level/parking brake indicator lamp (A1e7)
The parking brake signal comes from the traction system

control module.

The brake fluid signal comes directly from the switch (S11)

(except model 163).

Brake pad wear indicator lamp (A1e6)

The parking brake signal comes from the traction system

control module (N47)

Low engine oil level indicator lamp (A1e12)

The oil level signal comes from the injection system control

module (N3).

For vehicles with ASSYST, also refer to document: ASSYST

engine oil monitoring.

Preglow indicator lamp (A1e16)

The signal comes directly from the injection system control

module (N3).

Coolant level and temperature warning lamp (A1e11) model 168

only as of 9.99
The coolant temperature signal comes from the injection

system control module (N3)

-----------------------------------------------------------------------------------------
ABS MIL (A1e17)

The parking brake signal comes from the traction system

control module (N47).

"CHECK ENGINE" MIL (A1e26),


I
only

The signal comes from the injection system control module (N3)

ETS (A1e35) or ASR (A1e22) or ESP (A1e42) MIL
Lamp illuminated if there is a fault in the respective system.

The signal comes from the traction system control module

(N47).

ETS (A1e36) or ASR (A1e21) or ESP (A1e41) warning lamp
The lamp indicates that the respective system is active.

The signal comes from the traction system control module

(N47).

-----------------------------------------------------------------------------------------

Severe leak warning (

I
as of 97 only)

The fuel reserve indicator lamp (A1e4) flashes. The signal

comes from the injection system control module (N3).

The warning takes place at the earliest 30 minutes after cold

start with the engine idling and the vehicle stationary.

Also refer to document: Purge system with leak test, function
Fog lamps indicator lamp (A1e57), model 163 only except
I
)

The signal comes from the All-activity module (AAM, N10)

"LOW RANGE" indicator lamp (A1e53), model 163 only
The signal comes from the transfer case control module (N78)

Active service system (ASSYST)
Engines 112, 113, 611 (engines with oil

sensor)

GF00.20-P-2009A

Engine oil monitoring, function
Model 210 as of 01.03.97 with engine M111,

OM602, OM604, OM605 and OM606

As of 06.97 models 129, 140, 170, 202 except

engines 112, 113, 611

(Valid for engines with low oil level switch).
GF00.20-P-2009B

Displaying coolant temperature, function
Model 168 as of 9.99

GF54.30-P-3020GC

Purge system with leak test, function

GF47.30-P-3016L

Bus systems, overall function

GF54.00-P-0004A

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GF54.30-P-3002A
Indicator and warning signals triggered over direct lines, function
24.10.96

MODEL
129, 140 as of 1.6.96,

163, 168, 170,

202 as of 1.8.96,

208 up to 31.7.99,

210 as of 1.6.96 up to 30.6.99

Indicator and warning signals

Indicator lamps for left turn signal (A1e1) and right turn signal

(A1e2)
The signal in models 129, 140, 170, 202 comes from the

combination relay (turn signals with trailer coupling, rear

window defroster, wiper motor, anti-theft alarm system)

(N10/2), and in model 210 from the multifunction control

module (N10-1) or the driver's side signal acquisition and

actuation module (SAM) (N10/1).

In model 168 the entire turn signal control is located in the

instrument cluster (A1).

Brake fluid / parking brake warning lamp (A1e7)

The signal for the brake fluid comes direct from the brake fluid level switch (S11) (except model 163).

(The signal for the parking brake comes over CAN.)

Low windshield washer fluid level warning lamp (A1e13) except

models 163 and 168
See

document: Coolant/washer fluid level voltage coding, task /

function

-----------------------------------------------------------------------------------------
Low windshield washer fluid level warning lamp (A1e13) as of

01.09.01 for model 163
See document: Displaying washer fluid level, function

Low engine coolant level warning lamp (A1e11) except models

163 and 168
See

document: Coolant/washer fluid level voltage coding, task /

function

Low engine coolant level warning lamp (A1e11) model 163 as of

3.99
See

document: Displaying coolant level, function

Coolant level and temperature warning lamp (A1e11) model 168

as of 9.99
See

document: Displaying coolant level, function

Fuel reserve warning lamp (A1e4)
When the reserve fuel level is reached, this lamp lights up and

goes out again only after refueling is detected. If the vehicle is

refueled with the ignition ON, refueling is detected only if at

least 7 liters of fuel are added.

-----------------------------------------------------------------------------------------

AIRBAG OFF indicator lamp (A1e56), only model 163 except

I

The signal comes from the emergency tensioning retractor

(ETR) control module with airbag (AB, N2/2)

Generator charge indicator/warning lamp (A1e5)

See document: Terminal 61 and terminal 61e, charge indicator

lamp, exterior lamp failure, function

Seatbelt/backrest lock warning lamp (A1e9)

The seat belt warning lamp is only used in a few national

versions, and is actuated direct by a seat belt buckle switch
(normally closed contact). After engine start, the lamp flashes

for a short time (approx. 6 seconds).

In model 129 if this lamp fails to go out after flashing briefly, but

continues to shine constantly, then the seat backrest is not

locked.
Exterior lamp failure indicator lamp (A1e14)

The signal comes from the lamp failure monitor

See document: Terminal 61 and terminal 61e, charge indicator

lamp, exterior lamp failure, function
Hydraulic fluid level warning lamp (A1e37)
The signal comes direct from the ADS level control oil level

switch (S44).

ADS warning lamp, suspension (A1e27) The signal comes from the ADS control module, suspension
(N51).

SRS airbag malfunction indicator lamp (A1e15)
The signal comes from the emergency tensioning retractor

(ETR) control module with airbag (AB, N2/2)

Voltage coding of coolant / windshield washer

fluid level, function
Except models 163 and 168

GF54.30-P-3006A

Displaying coolant level, function
Model 163 as of 3.99

GF54.30-P-3028GH

Model 168 as of 9.99

GF54.30-P-3028GC

Terminal 61 and terminal 61e, charge

indicator lamp, exterior lamp failure, function

GF54.30-P-3007A

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AH40.10-P-9411-01A
Information on tires/rims
Model 124, 129, 140, 163, 168, 169,

170, 171, 199, 201, 202, 203, 208, 209,
210, 211, 215, 219, 220, 230, 240, 414,
450, 452,
639


Tires

D
For service conversions, the tire/disc wheel specifications and

dimensions should be compared with the entries in the
registration papers.

D
When mounting tires, the tires and rims must be carefully

matched in order to guarantee the concentricity of the wheel.

Identification of matching points on:

- Tires with a colored dot on the outside of the tire,

- Sheet steel disk wheel by a colored dot or punch mark on the

outside of the wheel,

- Perform this operation at the valve stem hole on light-alloy

disk wheels

With an additional paint spot or punch mark in the rim base

for the 140 Model Series.

D
Always replace the rubber valve.

-----------------------------------------------------------------------------------------
D

Damaged and defective tires must always be replaced. The

repair methods employed in the tire trade are not approved by

Mercedes-Benz. Small nicks (<0.8mm) on the tire's sidewall do

not usually pose a cause for concern, and continued use of

such tires is approved

D When replacing just one tire, install it on the front of the vehicle.

This does not apply to vehicles with different tires of varying

specifications on the front and rear wheels.

D
Only use tires listed in the valid Service Information bulletins

and repair instructions.

D
If the permissible maximum speed of an M+S tire is below the

maximum speed of the vehicle, an appropriate adhesive plate

must be attached in the driver's field of view.

-----------------------------------------------------------------------------------------

D
Tires permissible for higher speeds may be used.

D
Always fit all rims with tires of the same design, make and

version.

-----------------------------------------------------------------------------------------
D

Run in new tires for approx. 100 km at moderate speed.

D
Handed tires must be installed according to the arrow on the

side wall of the tire.

D
Tires are subject to an aging process with negative effects on

the properties of the tire. In order to ensure optimum

effectiveness in winter, M+S tires should not be used for longer

than 3 years.

-----------------------------------------------------------------------------------------

Tire pressure

(For specified values see tire pressure table in the fuel filler flap, on

the Vaneo BM 414 see B-pillar on the passenger side).
Too low tire pressure increases the rolling resistance and increases

the flexing energy of the tire. This causes the critical temperature limit

to be exceeded (carcass detachment) and destroys the tire. Respond

to loss of tire pressure by determining the source and replacing the

tire as indicated.

Cleaning

Using a spray wand with high-pressure nozzles to clean the wheel

can lead to tire damage. Such damage occurs especially on the tire

side walls. The following should be observed when using flat jet

nozzles:

D
Maintain a minimum distance of 300 mm

D
Do not direct the water jet at a single point on the surface of the

tire for any length of time.

-----------------------------------------------------------------------------------------
Mounting in bearings

Before putting into storage, clean tires thoroughly and check for
damage and adequate tread depth. Mark the position and running

direction of the tires with chalk. Do not store tires outdoors. Under the

influence of sunlight, heat, moving air and ozone the rubber looses

elasticity and strength, ages more quickly and becomes cracked.

Storage areas should be dry, cool and dark. Avoid drafts by keeping

doors and windows closed as much as possible. Do not bring tires

into contact with gasoline, oil or other greases as they dissolve the

rubber.

Disposal

Collection, storage and disposal should be performed in accordance

with the legal requirements and the company's own regulations.

-----------------------------------------------------------------------------------------

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Rims
D
When changing wheels, for instance, when replacing steel

wheels with light-alloy rims, ensure that the wheel bolts

required for the spare wheel are stored in a clearly visible

location.

D
Since December 1994 models 202 and 124 with special

equipment light alloy disk wheels, are supplied with a sheet

steel spare wheel instead of a light alloy spare wheel. The

necessary wheel bolts are included with the steel spare wheel.

D
Only use approved Mercedes-Benz rims of the same version.

D
Reinforced steel rims are identified by a sticker on the wheel

disc.

D
The wheel bolts on steel and light-alloy rims should always be

tightened to the specified tightening torque using a torque
wrench.

It is not necessary to retorque the lug bolts after approximately

100 to 500 km.
D

The seat for the tire bead must display no corrosion marks.

D
Before inserting a new rubber valve, clean the contact surfaces

on the disk wheel.

On sheet steel-disk wheel wheel trims must be fitted to support

the rubber valve.


Damaged or deformed rims must not be repaired.

Tire pressure monitor
D
Before replacing a tire, check the date of manufacturer of the

wheel sensor: wheel sensors which are more than 5 years old

must be replaced.

D
Use STAR DIAGNOSIS to read out the actual values of the tire

pressure monitor. Check the remaining life of the wheel sensor

battery, replace the wheel sensor if necessary.

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AR46.40-P-0400-01GH
Detaching and attaching inner clamp

P46.40-0264-01

Remove
1
Remove inner clamping collar (11a) with side-cutting pliers.

Install
2
Mount new clamping collar (11a) and tension using conventional clamp pliers.

3
Check hose clamp (11a) for correct seat.

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AR68.40-P-0001GI
Remove/install inside rearview mirror
23.4.01

MODEL
163.136 /154 /172 #A as of 145273,

163.136 /154 /172 #X as of 708319,

163.113 /128 /157 /174 /175

P68.40-2042-06

1
Inside rearview mirror

2
Automatic dimming connector

B38
Rain sensor


Remove/install

1
Turn inside rearview mirror (1) 90 and press

against mirror housing at side.

Danger of breaking windshield.Do not

damage rain sensor (B38), if present.

2.1
Disconnect automatic dimming

connector (2).

Only with automatically dimming inside

rearview mirror, code 249a.

3
Install in the reverse order

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AR54.30-P-6049-02Z
Installing bulbs

129 589 00 09 00129 589 01 09 00

Pin socket
Pin socket

P54.30-0012-01

Insert bulbs and turn to the right using special tool.

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AR54.30-P-6049GH
Removing and installing bulbs of instrument cluster
21.1.97

MODEL
163

P54.30-0632-06

Instrument cluster

A1e1
Left turn signal indicator lamp

A1e2
Right turn signal indicator lamp

A1e3
High beam indicator lamp

A1e4
Fuel reserve indicator lamp

A1e5
Generator charge indicator lamp

A1e6
Brake pad wear indicator lamp

A1e7
Low brake fluid level/parking brake

indicator lamp

A1e8
Instrument illumination

A1e9
Seat belt reminder lamp

A1e11
Low ECL indicator lamp

A1e12
Low engine oil level indicator lamp

A1e15
SRS MIL

A1e17
ABS MIL

A1e21
ASR warning lamp

A1e26
"CHECK ENGINE" MIL

A1e35
ETS MIL

A1e36
ETS warning lamp

A1e40
Steering lock warning lamp

A1e42
ESP MIL

Removing, installing

1
Disconnect ground cable from battery

To prevent the disconnected ground cable

contacting the ground point W16/4

unintentionally, insulate ground cable terminal.

AR54.10-P-0003A

2
Remove instrument cluster

AR54.30-P-6015GH

3
Remove bulbs


AR54.30-P-6049-01Z


Installation:
Install bulbs
AR54.30-P-6049-02Z

4
Install in opposite order


129 589 00 09 00 129 589 01 09 00

Socket
Socket

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AR54.30-P-6049-01Z
Removing bulbs

129 589 00 09 00129 589 01 09 00

Pin socket
Pin socket

P54.30-0011-01

Turn bulbs to the left and remove using special tool

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