warning light MERCEDES-BENZ ML500 1997 Complete Repair Manual

AIR BAG RESTRAINT SYSTEM
1998 AIR BAG RESTRAINT SYSTEMS Mercedes-Benz
DESCRIPTION & OPERATION
All models are equipped with Supplemental Restraint System (SRS). The main components of SRS are a driver
air bag module, passenger air bag module, control unit, SRS warning light, driver knee bolster, passenger knee
bolster, and Emergency Tensioning Retractor (ETR) seat belt assembly. Additionally, all vehicles provide
driver-side and passenger-side impact protection by side air bags which are mounted in the driver-side and
passenger-side doors. Each of the door mounted side air bags utilize sensors which recognize lateral
acceleration durin
g side impact and signal this to the control module. See Fig. 1. NOTE: Information on ML320 is not available. For WIRING DIAGRAMS, See Fig. 32
.
WARNING:To avoid injury from accidental air bag deployment, read and carefully
follow all WARNINGS and SERVICE PRECAUTIONS
.

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Several situations may arise requiring some form of disposal action, including:
Scrapping a vehicle containing a deployed air bag module and/or ETR.
Scrapping a vehicle with a live air bag module and/or ETR.
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 module and/or ETR unit can be thrown away. None of its components are reusable. Deployed
air bag module is NOT classified as hazardous material.
SCRAPPED VEHICLE
1. Before proceeding, follow service precautions. See SERVICE PRECAUTIONS . Move vehicle
outdoors to a remote area, away from workshop and other personnel. Disconnect and shield negative
battery cable. Open all vehicle windows and doors.
2. Ensure air bag module is secured to steering wheel, and passenger air bag is secured to dash. Ensure ETR
seat belt assemblies are secured to "B" pillars and all seat belt buckles are latched. Remove loose objects
from front seat. DO NOT allow anyone inside vehicle.
3. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM
. Connect Trigger
Device (126-589-00-90-00) and Adapter Cable (126 589 21 63 00) to SRS system connector (X29/9)
located at passenger footwell area. See Fig. 5
. Move away from vehicle as far as trigger device wiring
will allow.
4. To deploy driver air bag and ETR, turn rotary knob on trigger device to position No. 1. Push battery
check pushbutton and ignition pushbutton simultaneously. Trigger light should illuminate indicating
driver air bag and ETR deployed. If trigger light is illuminated and driver air bag and/or ETR did not
deploy, driver air bag module and/or ETR is faulty. See UNDEPLOYED AIR BAG/ETR
.
5. To deploy passenger air bag detonator No. 1, turn rotary knob on trigger device to position No. 2. Push
battery check pushbutton and ignition pushbutton simultaneously. Trigger light should illuminate
indicating passenger air bag detonator No. 1 deployed. If trigger light is illuminated and passenger air bag
detonator No. 1 did not deploy, passenger air bag module is faulty. See UNDEPLOYED AIR
BAG/ETR .
6. To deploy passenger air bag detonator No. 2, turn rotary knob on trigger device to position No. 3. Push
battery check pushbutton and ignition pushbutton simultaneously. Trigger light should illuminate
indicating passenger air bag detonator No. 2 deployed. If trigger light is illuminated and passenger air bag
detonator No. 2 did not deploy, passenger air bag module is faulty. See UNDEPLOYED AIR
BAG/ETR . WARNING:An undeployed air bag module and/or ETR seat belt CANNOT be disposed
of without first being deployed. If this is not possible through procedures
outlined below, contact vehicle manufacturer for further instructions.
Perform remote deployment outdoors. Keep personnel at least 20 feet
away.

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check to ensure system is functioning properly. See SYSTEM OPERATION CHECK .
Removal & Installation (SLK 230)
1. Before proceeding, see SERVICE PRECAUTIONS . Disable air bag system. See DISABLING &
ACTIVATING AIR BAG SYSTEM . Remove ignition key. Remove top section of instrument panel.
Fold vapor barrier toward front to reveal 2 screws. Disconnect passenger-side air bag module connector.
Remove 4 screws and passenger-side air bag module.
2. To install air bag module, reverse removal procedure. Activate air bag system. Perform system operation
check to ensure system is functioning properly. See SYSTEM OPERATION CHECK
.
SYSTEM OPERATION CHECK
SRS warning light indicates air bag and Emergency Tensioning Retractor (ETR) system readiness. Turn
ignition on. SRS warning light will light, and then go out after approximately 4 seconds indicating system is
functioning properly. If SRS warning light does not light, lights up while driving or lights all the time, there is a
system fault. Repair malfunctioning system. See DIAGNOSIS & TESTING
.
SERVICE PRECAUTIONS
Observe following precautions when working with air bag systems:
When working around steering column 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.
DO NOT repair any portion of SRS wiring harness.
Always handle air bag module with trim cover 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 cleaning agents such as solvents, gasoline, lye, etc.
DO NOT connect Hand-Held Tester (6511 0001 99) to Data Link Connector (DLC) with ignition on.
Damage to HHT may result.
DO NOT connect HHT (6511 0001 99) to vehicle if a battery charger is connected to vehicle battery.
Damage to HHT may result.
DISABLING & ACTIVATING AIR BAG SYSTEM DISABLING SYSTEM
Before proceeding, follow air bag service precautions. See SERVICE PRECAUTIONS
. Turn ignition off.
Disconnect and shield negative battery cable. Remove passenger foot mat. Remove passenger footrest.
Disconnect SRS system connector (X29/9) located at passenger footwell area. See Fig. 5
. System is now
disabled.

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If any part of SRS wiring harness is damaged, DO NOT repair wiring harness, replace complete wiring harness.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
(1)
DIAGNOSIS & TESTING
Before proceeding, see SERVICE PRECAUTIONS
. The control module is capable of diagnosing airbag
system components and ETR components. If a fault is detected by the control module or system is
malfunctioning, SRS warning light will do one or more of the following:
SRS warning light goes out after 2 minutes. System fault is noted, however occupant protection is not
affected. See RETRIEVING FAULT CODES
.
SRS warning light illuminates continuously. System is faulty which may result in a non deployment or
false deployment. See RETRIEVING FAULT CODES
.
SRS warning light blinks continuously. Control module has been replaced without setting control module
parameters.
RETRIEVING FAULT CODES
1. Check vehicle fuses. Replace any blown fuses as necessary. Ensure vehicle battery voltage is 11 volts or
more. Ensure SRS warning light functions. Turn ignition off. Connect Hand-Held Tester (HHT) (965 589
00 01) to Data Link Connector (DLC).
2. DLC is located in right rear corner of engine compartment. It may be necessary to use Adapter (965 589
00 40 or 965 589 00 50) to connect HHT to DLC. After HHT displays module number and version, press
return key to start diagnosis. Using HHT, follow HHT prompts to retrieve SRS fault codes.
3. HHT will display a 3 digit fault code, and may display additional graphic information. This additional
graphic information will help in diagnosis of fault code. See Fig. 6
. During diagnosis HHT will display 4
different graphic displays informing technician if a test passes or fails, or if seat belt buckle is latched or
not latched. See Fig. 6
.
4. These
graphic displays are displayed as applicable by HHT during testing. See FAULT CODES table.
ApplicationFt. Lbs. (N.m)
Steering Wheel Hub Bolt52-66 (70-90)
INCH Lbs. (N.m)
Driver Air Bag Module Bolts (Torx)44-62 (5-7)
(1)Torque specifications are not available for clockspring assembly, control module or passenger-side
air bag module.
NOTE: After component replacement, perform a system operation check to ensure
proper system operation. See SYSTEM OPERATION CHECK
.
NOTE: Fault codes may only be retrieved using Hand-Held Tester (965 589 00 01) and
Adapter (965 589 00 40 or 965 589 00 50).

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FAULT CODES
Code (Possible Cause)
Go To Test Step (See
Fig.)
00
(SRS Control Module, N2/2)2.0
003
(Voltage Supply Circuit 15R, Low Voltage)1.0
002
(SRS Warning Light, A1e15)11.0
004
(Driver Air Bag Squib, R12/3)3.0, 4.0 (7, 9)
005
(Driver ETR Squib, R12/1)5.0
006
(Passenger ETR Squib, R12/2)7.0
007
(Passenger Air Bag Squib, R12/4)9.0, 10.0 (12, 13)
008
(Side Air Bag Squib, Driver-Side)17.0
009
(Side Air Bag Squib, Passenger- Side)18.0
016
(Driver Belt Switch, S68/3)12.0, 13.0
017
(Passenger Belt Switch, S68/3)14.0, 15.0
018
(Driver Air Bag Harness)19.0
019
(Driver Air Bag Sensor)Replace Sensor
020
(Driver Air Bag Sensor)Replace Sensor
021
(Passenger Air Bag Sensor)20.0
022
(Passenger Air Bag Sensor)Replace Sensor
023
(Passenger Air Bag Sensor)Replace Sensor
024
(Passenger Seat Occupation Signal)21, 22 (21, 22)
025
(Passenger Seat Occupation Signal)21

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CLEARING FAULT CODES
Connect Hand-Held Tester (965 589 00 01) to Data Link Connector (DLC). DLC is located in right rear corner
of engine compartment. It may be necessary to use Adapter (965 589 00 40 or 965 589 00 50) to connect HHT
to DLC. After HHT displays module number and version, press return key to start sequence. Using HHT,
follow HHT prompts to clear SRS fault codes. SRS codes are clear when ignition is turned on and SRS warning
light functions normally. See SYSTEM OPERATION CHECK
.
UNDERSTANDING DIAGNOSTIC CHART INFORMATION
SRS & ETR Diagnosis Chart Column Identification
For example, see Fig. 7
under DIAGNOSTIC TESTS. First column of chart identifies TEST STEP (1.0 for
example). Second column of chart identifies HHT fault code (017, 003 for example). First code in column is for
vehicles without side air bags. Second code in column (when listed) is for vehicles with side air bags only.
Other 5 columns are self-explanatory.
Using SRS & ETR Diagnosis Chart
For reading and understanding fault code diagnosis chart, use the following example: Read test step 3.0
(first column), HHT fault Code 002, 004 (second column). See Fig. 7
. Read TEST SCOPE/HHT
ACTUAL VALUE NO./TEXT column (third column). Driver-side air bag squib connector R12/3 is
being tested. HHT will identify if problem is with too much resistance or not enough resistance in driver-
side air bag squib circuit. Read TEST CONDITION column (fifth column). Test circuit with HHT
connected to DLC, with ignition in position "2". Read NOMINAL VALUE/HHT DISPLAY column
(sixth column). HHT will display a check or an "F". If HHT displays a check, circuit is okay. If HHT
displays an "F", go to step 3.1.
Read TEST CONNECTION (NOT FOR HHT) column (forth column). Driver-Side air bag squib
connector R12/3, terminals No. 1 and 2 are identified. Read TEST CONDITION column. Test circuit
027
(Passenger Seat Occupation Signal)22
032, 033
(Communication Interference)(1)
034
(Digital Crash Output, Harness Fault)(1)
035
(Analog Crash Output, Harness Fault)(1)
036
(Auto Child Seat Recognition Light)22.0, 23.0
(1)Test information is not available.
NOTE: To properly identify components or connectors being tested, see COMPONENT
IDENTIFICATION table.

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2 Contents
Fog lamp switch
(except Canada) ........................... 92
Fog lamp switch
(Canada only) .............................. 93
Hazard warning flasher
switch ............................................ 94
Headlamp cleaning system ............ 94
Windshield wiper/washer
switch ............................................ 95
Rear window wiper/washer ........... 96
Climate control ................................. 98
Basic setting – Heater ............... 100
Basic setting –
Air conditioner ........................... 100
Special setting ............................ 101
Dust filter .................................... 102
Air recirculation ......................... 102
Rear window defroster .............. 103
Power windows ............................... 104
Rear quarter windows ................... 106
Sliding/pop-up roof ....................... 107
Skyview Top .................................... 109
Interior lighting ..............................110
Sun visors ........................................113Illuminated vanity mirrors ........... 113
Interior ............................................. 114
Storage compartments,
armrest and cup holder ............ 114
Glove box ...................................... 115
Armrest in rear bench seat ........... 117
Ashtrays ........................................... 118
Lighter .............................................. 119
Split rear seat bench ..................... 120
Easy entry/exit feature ............. 123
Rear seat head restraints ......... 124
Third row seats .............................. 126
Removable cargo floor plates ...... 129
Enlarged cargo area .......................131
Cargo tie-down rings .....................132
Hooks ...............................................133
Partition net ....................................133
Loading instructions ......................136
Cargo area cover blind ..................137
Telephone, general .........................139
Cellular telephone ..........................139
Garage door opener ....................... 140
DrivingControl and operation of
radio transmitters ..................... 146
The first 1 000 miles
(1 500 km) ................................. 147
Maintenance ................................... 147
Tele Aid ........................................... 148
Catalytic converter ........................ 160
Emission control ............................ 161
Steering lock ................................... 162
Starting and turning off
the engine .................................. 164
Automatic transmission ............... 165
Parking brake ................................. 173
Driving instructions ...................... 174
Drive sensibly – save fuel ......... 174
Drinking and driving ................. 174
Pedals ........................................... 174
Power assistance ........................ 175
Brakes .......................................... 175
Driving off ................................... 176
Parking ........................................ 176
Tires ............................................. 177

8 Introduction
Operator’s manual
This Operator’s Manual contains a great deal of useful information. We urge you to read it carefully and familiarize
yourself with the vehicle before driving.
For your own safety and longer service life of the vehicle, we urge you to follow the instructions and warnings
contained in this manual. Ignoring them could result in damage to the vehicle or personal injury to you or others.
Vehicle damage caused by failure to follow instructions is not covered by the Mercedes-Benz Limited Warranty.
Your vehicle may have some or all of the equipment described in this manual. Therefore, you may find explanations
for optional equipment not installed in your vehicle. If you have any questions about the operation of any equipment,
your authorized Mercedes-Benz Light Truck Center will be glad to demonstrate the proper procedures.
Service and warranty information
The Service and Warranty Information Booklet contains detailed information about the warranties covering your
Mercedes-Benz, including:
•New Light Truck Limited Warranty,
•Emission System Warranty,
•Emission Performance Warranty,
•California, Maine, Massachusetts, and Vermont Emission Control System Warranty
(California, Maine, Massachusetts, and Vermont only),
•State Warranty Enforcement Laws (Lemon Laws).

33 Central locking system
Te ch n ica l
data Instruments
and controlsOperationDrivingInstrument
cluster displayPractical hints Car care Index Notes:
If doors are unlocked with the central locking switch
after activating the automatic central locking, and
neither door is opened, then the doors remain unlocked
even at vehicle speeds of approximately 9 mph
(15 km / h) or more.
If a door is opened from the inside at speeds of
approximately 9mph (15km/h) or less with the
automatic central locking activated, the door will again
be automatically locked at speeds of approximately
9 mph (15 km / h) or more.
Important!
When towing the vehicle, or with the vehicle on a
dynamometer test stand, please, note the following:
With the engine running, the vehicle doors will lock if
the left front wheel spins at vehicle speeds of
approximately 9 mph (15 km / h) or more.
To prevent vehicle door locks from locking, deactivate
the automatic central locking.Emergency unlocking in case of accident
The doors unlock automatically a short time after an
accident in which an airbag or emergency tensioning
retractor deploys (this is intended to aid rescue and
exit). However, the key must still be in the steering lock
position 1 or 2.
Additionally the hazard warning flashers turn on
automatically and the interior lights switch on for
approximately 30 minutes.

175 Driving instructions
Te ch n ica l
data Instruments
and controlsOperationDrivingInstrument
cluster displayPractical hints Car care Index Power assistance
BrakesThe condition of the parking brake system is checked
each time the vehicle is in the shop for the required
maintenance service.
If the parking brake is released and the brake warning
lamp in the instrument cluster stays on and there is no
audible warning (EBP), the brake fluid level in the
reservoir is too low.
Brake pad wear or a leak in the system may be the
reason for low brake f luid in the reservoir.
Have the brake system inspected at an authorized
Mercedes-Benz Light Truck Center immediately.
All checks and service work on the brake system should
be carried out by an authorized Mercedes-Benz Light
Truck Center.
Install only brake pads and brake fluid recommended by
Mercedes-Benz.
Wa r n i n g !
When the engine is not running, the brake and
steering systems are without power assistance.
Under these circumstances, a much greater effort is
necessary to stop or steer the vehicle.Wa r n i n g !
After driving in heavy rain for some time without
applying the brakes or through water deep enough
to wet brake components, the first braking action
may be somewhat reduced and increased pedal
pressure may be necessary to obtain expected
braking effect. Be sure to maintain a safe distance
from vehicles in front.Resting your foot on the brake pedal will cause
excessive and premature wear of the brake pads.It can also result in the brakes overheating thereby
significantly reducing their effectiveness. It may
not be possible to stop the vehicle in sufficient time
to avoid an accident.
Wa r n i n g !
If other than recommended brake pads are
installed, or other than recommended brake fluid
is used, the braking properties of the vehicle can be
degraded to an extent that safe braking is
substantially impaired. This could result in an
accident.