check engine MERCEDES-BENZ ML500 1997 Complete Repair Manual
[x] Cancel search | Manufacturer: MERCEDES-BENZ, Model Year: 1997, Model line: ML500, Model: MERCEDES-BENZ ML500 1997Pages: 4133, PDF Size: 88.89 MB
Page 3489 of 4133
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
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
Page 3498 of 4133
AF54.30-P-8400A
Instrument cluster indicates: Oil sensor defective, oil level below min. or oil level
above max. with engine running and at operating temperature. No DTC stored.
19.5.98
MODEL
129.0, 163.1, 202.0, 208.3 /4, 210.0 /2 /6, 220.0 /1 with ENGINE 112
MODEL
129.0, 163.1, 202.0, 208.3 /4, 210.0 /2, 220.0 /1 with ENGINE 113
Damage code
Cause
Remedy
54 201 90
Oil low, connector defective or coding error
1
Shut off engine and wait 2 min. (key
position 0)
Instrument cluster indicates oil sensor
defective, oil level below min. or oil level
above max. with engine warm and running.
No DTC stored in DTC memory!
2
Check oil level with oil dipstick
3
Check oil level on instrument cluster:
- Key in steering wheel lock position 2,
engine not running
- Wait until - - - - - - appears on
instrument cluster
- When this is displayed press the reset
button for the tripodometer twice within
1 sec. (display appears only after
expiration of a waiting time (max. 30
min.) depending on engine oil
temperature)
Oil level is at bottom mark on oil dipstick
and instrument cluster indicates:
-1L
, -
1,5L
or -2L
#
4
Add quantity of oil indicated on
instrument cluster display and repeat
test.
Oil level at upper mark on dipstick and
instrument cluster indicates either oil level
okay or -1L
, -
1,5L
, -2L
#
5
Recode instrument cluster
AF54.30-P-8600A
Problem still present
#
6
Check cable to oil sensor, oil sensor
connectors, control module and fuse
box (see wiring diagram) for good contact
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
Page 3740 of 4133
AR03.10-P-7311-01V
Measure end clearance of piston rings
Modification notes
12.6.02
Value in line 1001 for Engine 113.967 modified from
0.012...0.060 to 0.033...0.07 and from 0010...0.030 to
0.01...0.04
Value in BE03.10-P-1001-05B for Engine
113.967 modified
*BE03.10-P-1001-05B
Test values for piston rings
Number
Designation
Engine 112.910/
911/912
Engine 112.920/
921/922/923/940/
941/942/943/944/
945/946/947/948/
960,
113.940/941/942/
943
Engine 113.944/
980/981/982/984
BE03.10-P-1001-05B
Vertical clearance of
piston ring
Groove 1
mm
0,012...0,0600,012...0,0600,012...0,060
Groove 2
mm
0,010...0,0300,010...0,0300,010...0,030
Test values for piston rings
Number
Designation
Engine 113.960/
961/962/963/965/
968
Engine
113.967
BE03.10-P-1001-05B
Vertical clearance of
piston ring
Groove 1
mm
0,012...0,0600,033...0,070
Groove 2
mm
0,010...0,030
0,01...0,04
Commercially available tools
(see Workshop Equipment Manual)
Number
Designation
Make (e.g.)
Order number
WH58.30-Z-1008-12A
Feeler gage
Stiefelmayer
D-73734 Esslingen
59
P03.10-2034-01
1
Use the
feeler gage to measure end clearance of compression rings between
compression ring and mounting groove in the piston; replace compression rings or piston, if
necessary.
The end clearance of the oil scraper ring cannot be checked because of its three-part
design. If the compression rings are replaced, the oil scraper ring must also be replaced.
Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1
Page 3741 of 4133
AR03.10-P-7311-02V
Measure gap clearance of piston rings
Test values for piston rings
Number
Designation
Engine 112.910/
911/912
Engine 112.920/
921/922/923/940/
941/942/943/944/
945/946/947/948/
960,
113.940/941/942/
943
Engine 113.944/
980/981/982/984
BE03.10-P-1002-05B
Piston ring gap clearance
Groove 1
mm
0,200...0,3500,200...0,3500,200...0,350
Groove 2
mm
0,200...0,4000,200...0,4000,200...0,400
Test values for piston rings
Number
Designation
Engine 113.960/
961/ 962/ 963/
965/ 968/
Engine
113.967
BE03.10-P-1002-05B
Piston ring gap clearance
Groove 1
mm
0,200...0,3500,200...0,350
groove 2
mm
0,200...0,4000,200...0,400
Commercially available tools
(see Workshop Equipment Manual)
Number
Designation
Make (e.g.)
Order number
WH58.30-Z-1008-12A
Feeler gage
Stiefelmayer
D-73734 Esslingen
59
P03.10-2035-01
1
Clean cylinder contact surface.
2
Insert the two compression rings one after the other into the unworn area of the cylinder
wall and measure end clearance with
feeler gauge; replace piston rings, if necessary.
The gap clearance of the oil scraper ring cannot be checked because of its three-part
design. If the compression rings are replaced, the oil scraper ring must also be replaced.
Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1
Page 3746 of 4133
11
Oil piston pin (2) and conrod bush
12
Assemble piston (3) and conrod (4)
Install piston (3) with arrow in direction of
travel.
13
Push in piston pin (2) by hand
14
Insert circlip (1) of piston pin (2) in the groove
on piston (3)
Do not damage piston (3). Place a clean
cloth underneath.
15
Oil cleaned parts (cylinder bore, conrod
bearing journal, conrod bearing shells and
pistons)
16
Fit on tensioning strap (10) and tension
Piston ring gaps must be offset 120°.
Tensioning strap
*000589041400
17
Install piston (3) with arrow pointing in
direction of travel
Rotate crankshaft far enough so that the
connecting rod when inserting piston into
cylinder bore does not line up at the
connecting rod journal!
18
Inspect conrod bolts (6)
AR03.10-P-6111-01BV
Thread and shank length
*BE03.10-P-1001-03A
19
Install conrod bearings and fit on conrod
bearing cap (5)
The connecting rod bearing shell (7) with
oil drilling (arrow) must be mounted in the
connecting rod, otherwise the piston pin (2) is
not lubricated.
The anti-twist locks (8) of the connecting rod
bearing shells (7) must be seated in the
grooves (9) in the conrods (4) and connecting
rod bearing caps (5).
AR03.10-P-6111-06AV
The connecting rod and connecting rod
bearing cap are cracked (broken) (arrow).
They must not be installed the wrong side
round!
20
Tighten conrod bolts (6)
AR03.10-P-6111-02BV
*BA03.10-P-1001-01E
21
Rotate crankshaft
To inspect ease of operation.
22
Install oil pump
-
Ensure oil return flow check valve is
correctly located.
-
Clean strainer of oil pump.
-
Fill oil pump with engine oil before
installing so that it pumps oil when first
started.
All except models 203, 209, 211.061/065/070,
220 without 4MATIC, 230.474 /475
AR18.10-P-6020B
Model 203 without 4MATIC, 209,
211.061/065/070
AR18.10-P-6020PV
Model 203 with 4MATIC, model 220 with
4MATIC
AR18.10-P-6020PW
Model 230.474/475
AR18.10-P-6020R
23
Fit on cylinder head
Models 463.206/ 209/ 232/ 233/ 240/ 241/
243/ 244/ 245/ 246/ 247/ 248/ 249/ 250/ 254
AR01.30-P-5800GV
Engine 112 in model 129 and engine 113 in
models 129, 202, 208, 210
AR01.30-P-5800B
Engine 112 in models 170, 202, 208, 210,
220 and engine 113 in models 220,
230.474 /475
AR01.30-P-5800BA
Model 163
AR01.30-P-5800MV
Models 203, 209 with engines 112, 113
Models 211.061/065/070
AR01.30-P-5800PV
24
Fit on top part of oil pan
Model 463
AR01.45-P-7500FG
Model 230.474/475
AR01.45-P-7500R
Model 220 without 4MATIC
AR01.45-P-7500I
Model 220 with 4MATIC
AR01.45-P-7500IW
Model 210 with 4MATIC
AR01.45-P-7500FA
Model 210 without 4MATIC
AR01.45-P-7500F
Models 202, 208
AR01.45-P-7500FC
Model 203 without 4MATIC, 209 with engines
112,113
AR01.45-P-7500PV
Model 203 with 4MATIC
AR01.45-P-7500PW
Model 211.061/065/070
AR01.45-P-7500TV
Model 170
AR01.45-P-7500SV
Model 163
AR01.45-P-7500FB
Model 129
AR01.45-P-7500FD
Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 3
Page 3752 of 4133
AR46.20-P-0600GH
Removing and installing rack-and-pinion steering
1.3.97
MODEL
163.113 /128 /136 /154 /157 /172 /174 /175
P46.20-2126-09
Shown on model 163.154 (vehicles
without speed-sensitive power steering)
1
Front axle carrier
10a
Tie rod joint
21
Rubber mount
25d
Nut
25f
Steering coupling shield
30f
Return line
30i
High-pressure expansion hose
80a
Lower steering shaft
23
Rack-and-pinion steering
23a
Bolts
23h
Shim
23i
Shim
25
Steering coupling
Modification notes
10.9.03
Reference to adjusting toe on front axle replaced by
reference to chassis alignment check
Step 16.1
Removing, installing
Danger!
Risk of fatal injury
if the vehicle slips or
topples off the lifting platform
Align vehicle between the columns of the
lifting platform and position the four support
plates
at the lifting platform support points
specified by the vehicle manufacturer.
AS00.00-Z-0010-01A
Danger!
Risk of injury
with
trapped or crushed
fingers when removing and installing or
aligning hoods, doors, trunk lid/tailgate and
sliding roof.
When moving components ensure that no
body parts or limbs are in the area of
movement.
AS00.00-Z-0011-01A
1
Open engine hood
AR88.40-P-1000GI
2
Extract oil from power steering pump supply
reservoir
Hand pump
*210589007100
3
Raise vehicle
4
Remove front axle gear
AR33.30-P-0525GH
5
Press tie rod joints (10a) off steering knuckles
Installation:
Replace self-locking nuts.
AR46.40-P-0200-02C
*BA46.40-P-1001-01C
Thrust piece
*140589006300
Puller
*202589023300
6
Turn steering wheel to horizontal position
(front wheels in straight-ahead position)
7
Remove key and engage steering lock
8.1
Unplug speed-sensitive power steering
connector from timing case
On vehicles with speed-sensitive power
steering code 213a
Copyright DaimlerChrysler AG 06.07.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1
Page 3753 of 4133
9
Detach return line (30f) and high-pressure
expansion hose (30i)
Connection fittings or banjo bolts
depending on the version. Seal off line
connections with plugs.
Installation:
Replace sealing rings.
Connection fitting, return line
*BA46.20-P-1001-01D
Connection fitting, high-pressure
expansion hose
*BA46.20-P-1002-01D
Banjo bolt, return line
*BA46.20-P-1004-01D
Banjo bolt, high-pressure expansion hose
*BA46.20-P-1005-01D
Plug
*129589009100
10
Detach nut (25d) and bolt from steering
coupling (25) and pull lower steering shaft
(80a) upwards out of steering coupling (25)
Do not use force as the corrugated tube is
sensitive to lateral forces. Enlarge clamping
groove a little with a screwdriver if necessary.
Installation:
Replace nut (25d).
Installation:
Turn rack-and-pinion
steering to center position and fit steering
coupling.
AR46.20-P-0600-01GH
*BA46.10-P-1001-01D
11
Detach rack-and-pinion steering (23) from
front axle carrier (1) by unscrewing bolts (23a)
The installed position of the shims (23h,
23i) on the right-hand side, between the
rubber mount and the front axle carrier, must
be observed as the shims are of different
thicknesses.
Installation:
Attach rack-and-pinion
steering to front axle carrier.
AR46.20-P-0600-03GH
Assessing condition of steering gear when
repairing accident vehicles
AH46.20-P-9409-01A
12
Check rubber mount (21) of rack-and-pinion
steering mounting for damage
Replace rubber mount if necessary:
#
Removing rubber mounts on rack-and-pinion
steering mounting
AR46.20-P-0600-02GH
13
Install in the reverse order
14
Fill and bleed power steering pump
Engines 112, 113
AR46.30-P-0010B
Engines 111, 612, 628
AR46.30-P-0010P
15
Check steering for function and leaks
There is a grease cushion under the cover
cap. A small amount of escaping grease is to
be regarded as normal and must not be
confused with leakage.
16.1
Check toe on front axle and adjust if necessary
When installing a new rack-and-pinion
steering, see:
#
Performing chassis alignment check
AR40.20-P-0200A
Steering shaft
Number
Designation
Model 163
BA46.10-P-1001-01D
Self-locking nut, steering coupling to steering shaft
and rack-and-pinion steering
Nm
28
Steering gear
Number
Designation
Model 163
BA46.20-P-1001-01D
Screwed connection fitting from return line
to rack-and-pinion steering
Nm
15
BA46.20-P-1002-01D
Screwed connection fitting from high-
pressure expansion hose to rack-and-pinion
steering
Nm
15
BA46.20-P-1003-01D
Bolted connection, rack-and-pinion steering
to front axle carrierNm
50
BA46.20-P-1004-01D
Banjo bolt, return line to rack-and-pinion
steering
Nm
30
BA46.20-P-1005-01D
Banjo bolt, high-pressure expansion hose to
rack-and-pinion steering
Nm
30
Copyright DaimlerChrysler AG 06.07.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2
Page 3757 of 4133
3.1
Remove viscous fan (1)
Engine 112.942 /970 and 113.942.
Right-hand thread!
AR20.40-P-5660C
3.2
Remove electric fan
Only Engine 113.965 /981.
AR20.40-P-5000GH
4.1
Pull off plate clamps of fan shroud (2)
Only for Engine 112.942, from 5/98.
5.1
Remove fan shroud (3)
Only for Engine 112.942 /970 und
113.942. Unscrew the bolts at bottom of fan
shroud for this step
Installation:
If installing a new radiator
with integral power steering pump oil cooler, a
new fan shroud is required if a radiator
without integral oil cooler was previously
installed.
6
Remove headlamp (7).
AR82.10-P-4730GH
7
Remove radiator crossmember (8)
AR62.30-P-2300GH
8
Detach coolant line (4, 6) and expansion
reservoir coolant line (5) at the radiator
Installation:
Replace the hose clamps on
the radiator fitting for the coolant hose, as
they could cause damage to the screw/thread.
Hose clamp
*BA20.20-P-1004-01A
9
Remove the rubber seal on radiator (9)
10.1
Remove oil line (return line of radiator
!
power steering pump expansion reservoir)
(18) and oil line (feed line of steering gear
!
radiator) (19)
From 5/98 only, seal off the connections.
Set of plugs
*129589009100
11
Unscrew ATF lines (10) at the radiator
Seal off the connections.
*BA20.20-P-1001-01A
*BA20.20-P-1003-01A
Set of plugs
*129589009100
12.1
Detach the connector from the fan and
remove the fan grille (11)
Only for Engine 112.942 /970 and 113.942.
13
Unscrew the condenser from the radiator
Do not disconnect the lines.
14
Remove fasteners (20) and damper rubber
(21)
The damper rubber (21) is designed to
prevent possible vibrations between the
condenser and radiator (15) during off-road
driving.
15
Remove air conditioning system fluid
reservoir (14) from the radiator
Place aside with the lines connected.
Detach the condenser from the radiator.
16
Remove radiator (15)
When installing, the spigots on the
radiator must be inserted in the rubber
grommets in the bottom crossmember.
Installation:
On Model 163.154 with
Engine 112.942 before VIN end number
043553, when installing a new radiator with
integral power steering pump oil cooler,
additional operations are required, if they
have not already been carried out:
#
v
Retrofit the bracket for the oil cooler line of
the power steering pump
SM46.30-P-0002A
k
Radiator with integral oil cooler for the power
steering pump
BT20.20-P-0001-01A
17
Detach air guides (12)
Replace the clamps on air guides (13).
18
Install in the reverse order
19
Pour in coolant
AR20.00-P-1142HA
20
Check the headlamp setting and correct if
necessary
e
Check and adjust the headlamp setting
AP82.10-P-8260GH
Danger!
Risk of accident
caused by vehicle starting
off when engine is running.
Risk of injury
caused by contusions and burns when
working in engine during starting procedure
Secure the vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.
AS00.00-Z-0005-01A
21
Check the oil level in the automatic
transmission and correct if necessary
AR27.00-P-0101A
22
Check the cooling system for leaks
AR20.00-P-1010HA
Radiator, coolant hoses
Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2
Page 3762 of 4133
13
Disconnect coolant hose to coolant pump (8),
coolant hose from thermostat housing (9) and
coolant hose from coolant expansion tank
(10) at radiator
Hexagon socket wrench
*WH58.30-Z-1001-06A
Hexagon socket wrench
*WH58.30-Z-1002-06A
14
Detach air guides (12)
Installation:
Replace fastening clamps
(13)
15
Unscrew bolts (16) at condenser (17) to
radiator
Avoid deformation of condenser lines.
Do not disconnect lines.
16
Remove attachment parts (20) and rubber
shock absorber (21)
Installation:
Ensure, that the rubber
shock absorbers do not drop when installing
the radiator.
Replace fastening clamps.
17
Take off fluid reservoir of AC (14) at radiator
Place to the side with lines connected.
External torx set
*001589760900
18
Remove bracket of charge air pipe at left
radiator
Installation:
Insert bracket of charge air
pipe into the bracket at the radiator.
19
Remove radiator (15)
Installation:
When installing, the mounting
studs of the radiator must be inserted into the
rubber grommets of the lower crossmember.
20
Install in the reverse order
21
Check headlamp adjustment, correct if
necessary
e
Check and correct headlamp adjustment
AP82.10-P-8260A
22
Inspect cooling system for leaks
AR20.00-P-1010HA
23
Fill power steering pump and bleed
Danger!
Risk of accident
caused by vehicle starting
off by itself when engine is running.
Risk of
injury
caused by contusions and burns when
working in engine during starting procedure
Secure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.
AS00.00-Z-0005-01A
24
Run engine and inspect for leaks
Crankcase ventilation, cylinder head cover
Number
Designation
Engine
612.963
BA01.20-P-1002-01A
Bolt, cylinder head cover trim panel to
cylinder head cover
Nm
10
BA01.20-P-1003-01A
Bolt, cover panel to charge air distribution
pipe
Nm
10
Power steering pump
Number
Designation
Model
163.113
BA46.30-P-1012-01A
Banjo bolt, power steering oil line to radiator
Nm
30
Cooling system
Number
Designation
Engine
612.963
BF20.00-P-1001-02E
Cooling system
Total capacity
Liter
Y
11.0
Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 3
Page 3832 of 4133
SI47.10-P-0004A
Service Information: Procedure when tank is filled with incorrect fuel
19.12.00
MODEL
202 with ENGINE 611
MODEL
203 with ENGINE 611, 612, 646
MODEL
210 with ENGINE 611, 612, 613
MODEL
220 with ENGINE 613, 628, 648
MODEL
163 with ENGINE 612, 628
MODEL
168 with ENGINE 668
MODEL
209 with ENGINE 612
MODEL
211 with ENGINE 628, 646, 647, 648
MODEL
463 with ENGINE 612, 628
Modification notes
26.7.04
Engines have been added and procedure has been updated
Incorrect refueling of diesel-power vehicles with a common rail
injection system. Please be aware that if the customer fills the fuel
tank with the wrong type of fuel, this is the customer's fault and
cannot be submitted as a warranty claim.
If the diesel-powered vehicle with a common rail injection system has
been refueled with gasoline, follow the steps below:
1.
If the engine was not started after fuel tank is filled with the wrong
type of fuel, then emptying the fuel tank and cleaning the fuel low-
pressure lines should be enough to solve the problem.
2.
If the engine was started after fuel tank was filled with wrong type
of fuel:
On engines 611, 612, 613, 668:
-
On the rail, open the low pressure connection of the high
pressure pump return (plastic connection in area of pressure
regulator valve) and check connecting point in rail for chips.
On engine 646, 647, 648, 628:
-
Disconnect Y-distributor unit (return line HDP/Rail) at the output
and, with ignition ON, collect the fuel in a clean container. Check
fuel for metal shavings.
If the high pressure pump is not damaged and there are no metal
shavings in the injection system:
-
As in step 1, empty fuel as per the guidelines and clean the fuel
low-pressure lines. In addition to this, remove/install/replace the
high-pressure pump and fuel filter.
If metal shavings are found in the fuel
system or the high pressure pump drive is
damaged:
#
b
Engine runs rough, surges or does not start
ENGINE 611 in MODEL 203, 202, 210
ENGINE 612 in MODEL 163, 203, 210, 209
ENGINE 613 in MODEL 210, 220
ENGINE 628 in MODEL 163, 220, 211
ENGINE 646 in MODEL 203, 211
ENGINE 647 in MODEL 211
ENGINE 648 in MODEL 220, 211
ENGINE 668 in MODEL 168
ENGINE 612, 628 in MODEL 463
AF07.00-P-9000B
Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1