charging MERCEDES-BENZ ML500 1997 Complete User Guide

247 Practical hints
What to do if …
Problem
Possible cause
Suggested solution
¿
The yellow BAS / ESP malfunc-
tion indicator lamp comes on
while driving.
The charging voltage has fallen below
10 volts. The BAS and the ESP have switched
off.
When the voltage is above this value
again, the BAS and ESP are operational
again.
If necessary, have the generator and
the battery checked.
¿
The yellow BAS / ESP malfunc-
tion indicator lamp comes on
while driving.
The BAS or the ESP is malfunctioning.

Continue driving with added caution.

Have the BAS / ESP checked at an au-
thorized Mercedes-Benz Light Truck
Center as soon as possible.
Failure to follow these instructions
increases the risk of an accident.

254 Practical hintsWhat to do if …Problem
Possible cause
Suggested solution
#
The red charge indicator lamp
comes on when the engine is
running.
The battery is no longer charging.
Possible causes:

alternator malfunctioning


broken poly-V-belt

Stop immediately and check the
poly-V-belt.
If it is broken

Do not continue to drive, before the
poly-V-belt is replaced.
Notify an authorized Mercedes-Benz
Light Truck Center.
2
The yellow brake indicator lamp
comes on during braking or after
starting the engine.
The brake pads are worn down.

Have the system checked at an autho-
rized Mercedes-Benz Light Truck
Center.
!Brake pad thickness must be visually
checked by a qualified technician at the
intervals specified in the Service book-
let.

279 Practical hints
Battery
Disconnecting the battery
Depress parking brake firmly or move
gear selector lever to positionP.

Turn off all electrical consumers.

Remove key from the steering lock.

Open the hood (
page 217).

Disconnect the battery negative lead.

Remove the cover from the positive ter-
minal.

Disconnect the battery positive lead.
Removing the batteries
Remove the screw securing the bat-
tery.

Remove the battery support and brack-
et. Take out the battery.
Charging and reinstalling batteries
Charge battery in accordance with the
instructions of the battery charger
manufacturer.

Reinstall the charged battery. Follow
the previously described steps in re-
verse order.
Reconnecting the batteries
Turn off all electrical consumers.

Connect the positive lead and fasten its
cover.

Connect the negative lead.
Warning!
G
With a disconnected battery

you will no longer be able to turn the key
in the steering lock


the gear selector lever will remain
locked in positionP
Warning!
G
Never charge a battery while still installed in
the vehicle. Gases may escape during charg-
ing and cause explosions that may result in
paint damage, corrosion or personal injury.
!Never invert the terminal connections!!The battery, its filler caps and the vent
tube must always be securely installed
when the vehicle is in operation.

319 Index
Rear passenger compartment 141
Rear window defroster 133
Residual heat utilization 140
Residual ventilation 140
Switching off 137
Switching on 137
Automatic headlamp mode 108
Automatic interior lighting control
Activating 113
Deactivating 113
Automatic locking when driving 93
Automatic transmission 119
Accelerator position 123
Emergency operation (Limp Home
Mode) 124
Gear ranges 121
Gear selector lever position 122
Gear shifting malfunctions 124
Kickdown 123
Manual shifting 120
One-touch gearshifting 120Selector lever position 119
Towing a trailer 124
Transmission fluid 222
B
BabySmart
TM
Airbag deactivation system 70
Compatible child seats 70, 311
Self-test 70
BabySmart
TM airbag deactivation
system 311
Backrest tilt 35
Backup lamps 267, 270
Bulbs 267
BAS 78, 311
Malfunction indicator lamp 245, 246,
247
Warning lamp 245, 246, 247
Batteries, remote control
Changing 262
Batteries, vehicle 223
Battery discharged
Jump starting 281Battery indicator lamp
Indicator lamp 254
Battery, vehicle 223, 278
Charging 279
Disconnecting 279
Reconnecting 279
Reinstalling 279
Removing 279
Bi-Xenon headlamps* 311
Blocking
Rear door window operation 73
Brake assist system (BAS) 311
Brake fluid 302
Brake lamp bulbs 267
Brake lamp, high mounted 267
Brake pad wear
Indicator lamp 254
Brakes 194
Warning lamp 244
Break-in period 192

320 IndexBulbs, replacing 266
Additional turn signals 266
Backup lamps 267
Brake lamps 267
Fog lamps 266
Front fog lamp 270
Front lamps 266
High beam 266
High mounted brake lamp 267, 271
License plate lamps 267, 271
Low beam 266
Parking lamps 266, 267, 269
Rear fog lamp 267
Rear fog lamps 270
Rear side marker lamp bulbs 270
Side marker lamps 266, 267, 269
Standing lamps 266, 267
Tail lamp assemblies 267, 270
Turn signal lamps 266, 267, 269C
CAC (Customer Assistance Center) 311
Calibrating compass 188
California
Important notice 11
Calling up
Service indicator 233
CAN system 311
Capacities
Fuels, coolants, lubricants, etc. 300
Cargo area cover blind* 161
Closing 161
Installing 162
Opening 161
Removing 161
Cargo area see Cargo compartment 89
Cargo compartment
Liftgate 89
Lighting 114
Tie-down rings 158Cargo floor plates 162
Installing 163
Removing 162
Storing 162
Cargo tie-down rings 158
Catalytic converter 212
CD-changer* 258
Center console 27
Lower part 28
Upper part 27
Central locking
Automatic 93
From inside 93
Switch 94
Unlocking from inside 93, 94
Central locking switch 94
Certification label 292
Charge indicator lamp 254
Charging
Vehicle battery 279

1998-2005 ENGINE
Air Intake, Turbo Charging - 163 Chassis
BASIC KNOWLEDGE
AIR INTAKE, FUNCTION - GF09.00-P-3000A
ENGINE 112 (except 112.960 /961) without supercharger
Fig. 1: Identifying Air Intake Components
- Without Supercharger
INTAKE MANIFOLD, LOCATION - GF09.20-P-3102-01A
Shown on ENGINE 113
PurposeReducing intake noises
Design/function
A Helmholtz resonator (branching filter) with a volume of about 0.6 liters, is installed
to reduce the intake noises. This is active in the engine speed range from approx. 3500
- 4500 rpm. As a side effect the air flow in this engine speed range is improved at the
hot film mass air flow sensor and the measurement of the air mass is thus more
accurate.


2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:57 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.
me
Saturday, October 02, 2010 3:17:00 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.

Fig. 2: Identifying Variable Intake Manifold - Shown On Engine 113
INTAKE MANIFOLD, FUNC TION - GF09.20-P-3102-02A
Engine 112, 113
Section through variable intake manifold in cylinder plane
Fig. 3: Identifying Intake Manifold Function
- Section Through Variable Intake Manifold In Cylinder
Plane
When the engine is started and at low engine speeds the variable flaps are open. The intake air flows along the
shortest path and thus reaches the cylinder with low friction losses from the distributor volume.
At an en
gine load of more than 50% from approx. 1750 rp m up to approx. 3900 rpm the variable flaps are

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:57 PMPage 2 © 2006 Mitchell Repair Information Company, LLC.

closed. The intake air must flow through the whole intake pipe. Its length is selected in such a way that the
pressure waves, produced by the inducting pistons, arrive at the right moment at the open intake valves for the
next induction stroke. The result is improved cylinder charge and thus an increase in torque.
At higher engine speeds (e.g. from 3900 rpm) the actuation to the variable intake manifold switchover valve is
interrupted - the variable flaps open as a result of the spring force. Through the shortened route the pressure
waves arrive in time even at higher rotational speeds before the closing of the intake valves to the combustion
chamber.
INTAKE MANIFOLD, DESIGN - GF09.20-P-3102-03A
Shown on ENGINE 112
Fig. 4: Identifying Intake Manifold Components
- Shown On Engine 112
The intake manifold is assembled out of several magnesium pressure castings. When fitted together, they
produce the individual intake manifolds and the air collecting volume. The parts are sealed off to each other by
plastic. The intake manifold cannot be disassembled.
The individual intake manifolds each approx. 800 mm long, are arranged in a spiral shape around the air
collecting volume. A single intake manifold is assigned to each cylinder.
Each single intake manifold has a further opening to the air collecting volume in the middle. These can be
opened or closed by means of variable flaps which pivot through approx. 60°.
The variable flaps are attached to steel shafts. One shaft is installed for each bank of c
ylinders. The

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:57 PMPage 3 © 2006 Mitchell Repair Information Company, LLC.

interconnected flap shafts are closed by means of vacuum by the intake manifold switchover diaphragm unit.
When the variable intake manifold switchover valve is open, the vacuum is supplied from a vacuum reservoir
with check valve in the intake manifold. The reservoir volume is designed for about 5 operations without
renewed evacuation.
The variable flaps open by means of spring force.
INTAKE MANIFOLD, LOCATION/TASK/DESIGN/FUNCTION - GF09.20-P-3102A
ENGINE
112.910 /911 /912 /913 /914 /916 /917 /920 /921 /922 /923 /940 /941 /942 /943 /944 /946 /947 /949 /953 /954 /9
5
ENGINE 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /967 /966 /968 /969
Fig. 5: Identifying Intake Manifold Design/Function

Intake manifold,
location GF09.20-P-3102-
01A
Intake manifold, taskOptimizing engine torque curve by means of two different
intake manifold lengths
Intake manifold,
design GF09.20-P-3102-
03A
Intake manifold,
function GF09.20-P-3102-
02A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:57 PMPage 4 © 2006 Mitchell Repair Information Company, LLC.

TESTING & REPAIR
INTAKE MANIFOLD CONNECTION DIAGRAM - AR09.20-P-1310-01A
Connection schema intake manifold Engine 112
Fig. 6: Intake Manifold Connection Diagram
- Connection Schema Intake Manifold - Engine 112
INTAKE MANIFOLD CONNECTION DIAGRAM - AR09.20-P-1310-01AA
Connection diagram of intake manifold engine 112 with USA version code 494a

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:57 PMPage 5 © 2006 Mitchell Repair Information Company, LLC.