fuel type MERCEDES-BENZ ML430 1997 Complete Repair Manual
[x] Cancel search | Manufacturer: MERCEDES-BENZ, Model Year: 1997, Model line: ML430, Model: MERCEDES-BENZ ML430 1997Pages: 4133, PDF Size: 88.89 MB
Page 210 of 4133
160 Catalytic converter
Te ch n ica l
data Instruments
and controlsOperationDrivingInstrument
cluster displayPractical hints Car care Index
Catalytic converter
Your Mercedes-Benz is equipped with monolithic type
catalytic converters, an important element in
conjunction with the oxygen sensors to achieve
substantial control of the pollutants in the exhaust
emissions. Keep your vehicle in proper operating
condition by following our recommended maintenance
instructions as outlined in your Service Booklet.Caution!
To prevent damage to the catalytic converters, use only
premium unleaded gasoline in this vehicle.
Any noticeable irregularities in engine operation should
be repaired promptly. Otherwise, excessive unburned
fuel may reach the catalytic converter causing it to
overheat, which could start a fire.
Wa r n i n g !
As with any vehicle, do not idle, park or operate
this vehicle in areas where combustible materials
such as grass, hay or leaves can come into contact
with the hot exhaust system, as these materials
could be ignited and cause a vehicle fire.
Page 627 of 4133
160
Catalytic converter
Te ch n ica l
data
Instruments
and controls Operation
Driving Instrument
cluster display Practical hints Car care Index
Catalytic converter
Your Mercedes-Benz is equipped with monolithic type
catalytic converters, an important element in
conjunction with the oxygen sensors to achieve
substantial control of the pollutants in the exhaust
emissions. Keep your vehicle in proper operating
condition by following our recommended maintenance
instructions as outlined in your Service Booklet. Caution!
To prevent damage to the catalytic converters, use only
premium unleaded gasoline in this vehicle.
Any noticeable irregularities in engine operation should
be repaired promptly. Otherwise, excessive unburned
fuel may reach the catalytic converter causing it to
overheat, which could start a fire.
Wa r n i n g !
As with any vehicle, do not idle, park or operate
this vehicle in areas where combustible materials
such as grass, hay or leaves can come into contact
with the hot exhaust system, as these materials
could be ignited and cause a vehicle fire.
Page 1011 of 4133
207 Operation
Driving instructions
Trailer hitches
Only install a trailer hitch receiver ap-
proved for your vehicle.
For information on availability and in-
stallation, see your authorized
Mercedes-Benz Light Truck Center.
The bumpers on your vehicle are not
designed for use with clamp-type hitch-
es.
Do not attach rental hitches or other
bumper-type hitches to them.
To reduce the possibility of damage, re-
move the hitch ball adaptor from the
receiver when not in use.Electrical connections
The vehicle is prewired to accept the sev-
en-wire harness included in the
Mercedes-Benz approved trailer hitch re-
ceiver kit.
An additional four-pole conversion plug is
included in the Mercedes-Benz supplied
trailer hitch receiver kit.
For further information, see your autho-
rized Mercedes-Benz Light Truck Center.Vehicle and trailer weights and ratings
Gross Vehicle Weight Rating (GVWR) is the
maximum permissible vehicle weight:
6614 lbs (3000 kg).
Gross Vehicle Weight (GVW):
Comprises weight of vehicle including fuel,
tools, spare wheel, installed accessories,
passengers, cargo and trailer tongue. It
must never exceed the GVWR.
Gross Axle Weight Rating (GAWR) is the
maximum permissible axle weight:
Gross Trailer Weight (GTW) is the maxi-
mum permissible trailer weight to be
towed:
5000 lbs (2260 kg).
Trailer Tongue Weight Rating (TWR) is the
maximum permissible weight on the trailer
tongue:
500 lbs (225 kg) limit for Mercedes-Benz
approved hitch receiver.
front
rear
2976 lbs
3858 lbs
(1350 kg)
(1750 kg)
Page 1016 of 4133
212 OperationDriving instructionsTelephones and two-way radios
Radio transmitters, such as a portable tele-
phone or a citizens band unit should only
be used inside the vehicle if they are con-
nected to an antenna that is installed on
the outside of the vehicle.
Refer to the radio transmitter operation in-
structions regarding use of an external an-
tenna.
Catalytic converter
Your Mercedes-Benz is equipped with
monolithic-type catalytic converters, an
important element in conjunction with the
oxygen sensors to achieve substantial con-
trol of the pollutants in the exhaust emis-
sions. Keep your vehicle in proper
operating condition by following our rec-
ommended maintenance instructions as
outlined in your Service Booklet.
Emission control
Certain engine systems serve to keep the
toxic components of the exhaust gases
within permissible legal limits.
These systems, of course, will function
properly only when maintained strictly ac-
cording to factory specifications. Any ad-
justments on the engine should, therefore,
be carried out only by qualified
Mercedes-Benz Light Truck Center autho-
rized technicians. Engine adjustments
should not be altered in any way. More-
over, the specified service jobs must be
Warning!
G
Never operate radio transmitters equipped
with a built-in or attached antenna (i.e. with-
out being connected to an external antenna)
from inside the vehicle while the engine is
running. Doing so could lead to a malfunc-
tion of the vehicle’s electronic system, pos-
sibly resulting in an accident and / or
personal injury.
!To prevent damage to the catalytic con-
verters, use only premium unleaded
gasoline in this vehicle.
Any noticeable irregularities in engine
operation should be repaired promptly.
Otherwise, excessive unburned fuel
may reach the catalytic converter,
causing it to overheat and start a fire.
Warning!
G
As with any vehicle, do not idle, park or op-
erate this vehicle in areas where combusti-
ble materials such as grass, hay or leaves
can come into contact with the hot exhaust
system, as these materials could be ignited
and cause a vehicle fire.
Page 2105 of 4133
GF54.30-P-2002A
Display instruments, location / task / 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
Display
Type of data transmission
D
Outside temperature indicator (A1p4)
D
Fuel level gauge (A1p2)
D
Engine oil pressure gauge (A1p3), only
model 129 and model 140
D
Low windshield washer fluid level
indicator lamp (A1e13), model 163 as of
01.09.01
Direct lines
GF54.30-P-3004A
D
Total mileage odometer (A1h4)
D
Electronic speedometer (A1p8)
D
Tachometer (A1p5)
D
Coolant temperature gauge (A1p1)
D
Active service system (ASSYST)
D
Gear indicator (A1p12), only model 168
CAN data lines
GF54.30-P-3005A
D
Electronic clock
Internal
GF54.30-P-3011A
Copyright DaimlerChrysler AG 04.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1
Page 2162 of 4133
IGNITION COILS, LOCATION - GF15.10-P-3102-01A
Fig. 5: Identifying Cylinder 1 To 6 Ignition Coil - Location On Engine 112
Spark plugs, locationOne or two spark plugs are
located in the cylinder head
per cylinder.
Spark plugs, taskThe spark plugs ignite the
suctioned and compressed
fuel-air mixture due to arcing
between the electrodes.
Spark plugs, designIn the manufacturer's specific
type symbols, all the spark
plug features are assigned (e.
g. heat rating, shape of
seating, thread, width across
flats, electrode material,
spark position).
Spark plugs, functionThe ignition voltage travels to
the spark plugs from directly
connected ignition coils or
over the ignition lines from
the ignition coils causing
arcing in the air gap between
the center and ground
electrodes.
2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 8 © 2006 Mitchell Repair Information Company, LLC.
Page 2667 of 4133
Overview of authorized reworking on wiring harnesses
into the body
Lines get pinched in clamps
or trim parts
Fatigue Lines routed or secured
incorrectly
Excessive stress
Open circuit in wiring
Corrosion Due to contact with acids or
aggressive fluids (e.g. brake
fluid, antiseize, coolant
additives, fuels, lubricants),
water penetration due to
defective seals, use of high
pressure cleaner
Wiring harness covered in
paint after paint repair
Hardening of insulation due
to contact with an
incompatible agent (e.g.
solvent)
Line open circuit, contact
pairing not longer conductive
(transition resistances)
Insulation and wires
damaged
Lines or connections to
contacts
High line resistance
Components with sharp
edges
Corrosion
Assembly fault Use of incorrect tools, e.g.
wrong crimper or wrong
release tool
Damaged contacts or lines
through use of unsuitable test
tools (e.g. probes)
Lines pinched or screwed in
Loose contacts in plug
connections
Wrong contacts crimped
Undesirable transition
resistances
Open circuit in wiring, short-
circuit
Insulation damaged
Type of faultRemedial action
Faulty contact part
Contact part
missing
wrong part
deformed
Install new contact part
Contact part not engaged properlyLatch contact part, then check, and replace if
necessary
Not all individual wires are crimpedCut off contact part and install new part
Insulation also crimpedCut off contact part and install new part
Conductor not far enough in contact partCut off contact part and install new part
2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 22 © 2006 Mitchell Repair Information Company, LLC.
Page 3191 of 4133
Valve seal not okay :
#
3
Remove/install/replace valve seal.
AR05.30-P-3500B
Cause 6:
Remedy 6:
00 001 70
1.5 mm hole missing on individual right
cylinder head covers at connection to
crankcase ventilation.
1
Check cylinder head cover
Up to production 06/1999.
Crankcase ventilation out of order, engine can
sludge up and consume oil as a result
Cylinder head cover not okay:
#
2
Remove/install/replace cylinder head
cover.
ENGINE
112
Air cleaner positioned on engine
side.
ENGINE
113
Air cleaner positioned on engine
side.
AR01.20-P-5014BV
ENGINE
112
Air cleaner positioned on engine side
ENGINE
113
Air cleaner positioned on engine side
AR01.20-P-5014B
Cause 7:
Remedy 7:
00 001 70
Engine oil sludging due to excessively long
engine oil change intervals
Service information: Oil sludge
SI18.00-P-0010A
If the service interval according to
ASSYST is exceeded, the engine oil sludges
up sooner or later depending on the oil
quality, type of operation and operating time.
Engine consumes oil.
See Service Information.
1
Print out ASSYST printout.
2
Check oil change intervals
3
Inform vehicle owner.
4
Remove/install/replace piston rings.
AR03.10-P-7311BV
Disassemble and clean sludged engines
completely because dirty oil usually gets into
clean-oil side due to clogged oil filter.
Cause 8:
Remedy 8:
00 001 70
Piston rings sticky or have coke deposits from
engine oils (e.g. API-S in USA) in connection
with regionally poor fuel quality.
Always use engine oils according to
Specifications for Operating Fluids 229.3, do
not add special additives to engine oil and fuel
BB00.40-P-0229-03A
1
Remove/install/replace piston rings.
AR03.10-P-7311BV
Cause 9:
Remedy 9:
00 001 70
Piston ring wear due to excessive
contamination/dust (model 163) through air
intake system.
1
Remove/install/replace gaskets on air
intake line and distribution element of
partial load ventilation.
e.g. due to incorrect assembly after
workshop visit or embrittlement of gaskets
The distribution element with optimized
material will be available as of 11/ 2000 as a
standard feature.
2
Remove/install/replace intake module.
Exterior oil loss, e.g. due to cast iron
porosity on left side of crankcase in area of
engine support is not considered to be oil
consumption
In the event of a customer complaint
regarding the engine oil consumption, always
determine the oil consumption definitely
because the oil indicator lamp can come on
due to other causes (e.g. defective oil sensor).
Commercially available tools
(see Workshop Equipment Manual)
Number
Designation
Make (e. g.)
Order number
WH58.30-Z-1009-05A
Flexible inspection light
Scope of supply 1 (complete unit):
-glass fiber optical fiber
-light projector
-230 V, storage case
-operating instructions
-graphics protocol
Richard Wolf GmbH
Pforzheimerstr. 32
D-75438 Knittlingen
Karl Storz GmbH
Mittelstr. 8
D-78532 Tuttlingen
1.00565.00
80902
WH58.30-Z-1010-05A
Flexible inspection light
Scope of delivery 2 (for workshops which already have an approved
Wolf or Storz inspection light):
-storage case
-operating instructions
-pictures protocol
Richard Wolf GmbH
Pforzheimerstr. 32
D-75438 Knittlingen
Karl Storz GmbH
Mittelstr. 8
D-78532 Tuttlingen
7.05065.00
K03506AJ
Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2
Page 3480 of 4133
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
Copyright DaimlerChrysler AG 04.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1
Page 3481 of 4133
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
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