fuel cap MERCEDES-BENZ ML500 2003 W163 Owner's Manual

ContentsPractical hints.................................. 223
What to do if … .................................. 224
Lamps in instrument cluster ......... 224
Additional indicators in the
speedometer display .................... 235
Where will I find ...?............................ 236
First aid kit ................................... 236
Vehicle tool kit ............................. 237
Electric air pump (ML 55 AMG) .... 238
Spare wheel (space-saver tire) ..... 239
Unlocking/locking in an emergency .. 242
Unlocking the vehicle ................... 242
Locking the vehicle ...................... 243
Changing batteries ....................... 243
Fuel filler flap ............................... 244
Manually unlocking the
transmission selector lever .......... 245
Opening/closing in an emergency ..... 246
Sliding/pop-up roof* .................... 246
Replacing bulbs ................................. 247
Bulbs ............................................ 247
Replacing bulbs for front lamps.... 249
Replacing bulbs for rear lamps ..... 251
Adjusting headlamp aim ............... 253Replacing wiper blades ...................... 254
Removal ....................................... 254
Installation ................................... 254
Flat tire .............................................. 255
Mounting the spare wheel ............ 255
Battery ............................................... 261
Disconnecting the battery ............ 261
Removing the batteries ................ 262
Charging and reinstalling
batteries....................................... 262
Reconnecting the batteries .......... 262
Jump starting ..................................... 264
Towing the vehicle ............................. 267
Front towing eye .......................... 269
Rear towing eye ........................... 269
Stranded vehicle .......................... 270
Fuses ................................................. 271
Fuse box in engine
compartment ............................... 271
Auxiliary fuse box in front
passenger footwell ....................... 272
Technical data................................. 273
Spare parts service............................ 274
Warranty coverage ............................ 275
Loss of Service and Warranty
Information Booklet ..................... 275
Identification labels ........................... 276
Layout of poly-V-belt drive ................. 277
Engine ............................................... 278
Rims and tires ................................... 279
Rims and tires .............................. 279
Rims and winter tires* ................. 280
Spare wheel ................................. 280
Electrical system ............................... 281
Main Dimensions ............................... 282
Weights ............................................. 283
Fuels, coolants, lubricants etc. .......... 284
Capacities .................................... 284
Engine oils ................................... 286
Engine oil additives ...................... 286
Air conditioning refrigerant .......... 286
Brake fluid.................................... 286
Premium unleaded gasoline ......... 286
Fuel requirements ........................ 287
Gasoline additives ........................ 287
Coolants ...................................... 287

187 Operation
Driving instructions
Checklist before off-road driving
Tires

Check the tread depth and maintain
specified tire pressure (see tire pres-
sure label inside the fuel filler flap).


Check tires for possible damage and
remove foreign objects.


Replace missing valve caps.
Rims


Dented or bent rims can cause tire
pressure loss and damage the tire
beads. For this reason, check and, if
necessary, change rims before driving
off-road.Vehicle tool kit


Check if the vehicle jack is functional.


In all cases take the vehicle tool kit, a
strong tow rope, a shovel and a small
plank (to put under the vehicle jack on
sandy soil) with you.
Driving in steep terrain
Slope angle125° (ML 320, ML 350, ML 500)
21° (ML 55 AMG)
226°(ML 320, ML 350, ML 500)
23° (ML 55 AMG)
!Observe the following during off-road
driving:

Adjust vehicle speed to condition of
terrain. The more uneven, rutty and
steeper the terrain, the lower the
speed should be


Watch out for obstacles, such as
rocks, holes, tree stumps and ruts.


Be especially careful when driving
in unknown territory. It may be nec-
essary to get out of the vehicle and
scout the path you intend to take.


Continuous and speedy driving in
sandy soil overcomes the vehicle
rolling resistance, and helps to pre-
vent the vehicle from sinking into
the ground.


Do not initiate jumps with the vehi-
cle. It interrupts the forward mo-
mentum of the vehicle.


Always drive onto slopes with the
the engine running and the vehicle
in gear.

200 OperationAt the gas station
At the gas stationThe fuel filler flap is located on the
left-hand side of the vehicle towards the
rear. Locking/unlocking the vehicle with
the remote control automatically
locks/unlocks the fuel filler flap.

Remove the key from the steering lock.

Open the fuel filler flap1 by pulling in
direction of the arrow.

Turn the fuel cap2 to the left and hold
on to it until possible pressure is re-
leased.

Take off the cap.

Only fill your tank until the filler nozzle
unit cut out – do not top up or overfill.

Replace the fuel cap by turning it to the
right.
You will hear when the fuel cap is tight-
ened.

Close the fuel filler flap.
Warning!
G
Gasoline is highly flammable and poisonous.
It burns violently and can cause serious inju-
ry. Whenever you are around gasoline, avoid
inhaling fumes and skin contact, extinguish
all smoking materials. Never allow sparks,
flame or smoking materials near gasoline!.
!The fuel filler cap is tethered to the fuel
filler neck. Do not drop the cap. It could
damage the vehicle paint finish.!To prevent damaging the lens of the
plastic tail lamp, make certain that no
gasoline comes into contact with it.
Warning!
G
Overfilling of the fuel tank may create pres-
sure in the system which could cause a gas
discharge. This could cause the gas to spray
back out when removing the fuel pump noz-
zle, which could cause personal injury.iUse only premium unleaded gasoline
with a minimum Posted Octane Rating
of 91 (average of 96 RON / 86 MON).
Information on gasoline quality can
normally be found on the fuel pump.
More information on gasoline can be
found in the Factory Approved Service
Products pamphlet.

201 Operation
At the gas station
Check regularly and before a long trip
Open the hood (
page 202)
1Engine oil level
More information on engine oil can be
found in the “Operation” section
(
page 203).
2Coolant level
For normal replenishing, use water (po-
table water quality). More information
on the coolant level can be found in the
“Operation” section (
page 206).
3Brake fluid
More information on brake fluid can be
found in the “Technical data” section
(
page 284).4Windshield washer and headlamp
cleaning system
More information on filling the reser-
voir can be found in the “Operation”
section (
page 208).
Vehicle lighting
Check function and cleanliness. More in-
formation on replacing light bulbs can be
found in the “Practical hints” section
(
page 247).
Combination switch (
page 102).
Tire inflation pressure
More information on tire inflation pressure
can be found in the “Operation” section
(
page 211).
iLeaving the engine running and the fuel
cap open can cause the
?
lamp to
illuminate.
See also “Practical hints” section
(
page 232).

211 Operation
Tires and wheels
Checking tire inflation pressure
Correct the tire pressure only when tires
are cold.
Regularly check your tire pressure at inter-
vals of no more than 14 days.
If the tires are warm, you should only cor-
rect the tire pressure if it is too low for cur-
rent operating conditions.
A table on the fuel filler flap lists the spec-
ified tire inflation pressures for warm and
cold tires as well as for various operating
conditions.Tire pressure changes by approximately
1.5 psi (0.1 bar) per 18°F (10°C) of air
temperature change. Keep this in mind
when checking tire pressure where the
temperature is different from the outside
temperature.
Tire temperature and tire pressure are also
increased while driving, depending on the
driving speed and the tire load.Check the spare tire periodically for condi-
tion and inflation. Spare tire will age and
b e c o m e w o r n o v e r t i m e e v e n i f n e v e r u s e d ,
and thus should be inspected and replaced
when necessary.Warning!
G
If the tire pressure repeatedly drops:

Check the tires for punctures from for-
eign objects


Check to see whether air is leaking from
the valves or from around the rim
iThe pressures listed for light loads are
minimum values offering high driving
comfort.
Increased inflation pressures listed for
heavier loads may also be used for light
loads. These higher pressures produce
favorable handling characteristics. The
ride of the vehicle, however, will be
somewhat harder. Never exceed the
max. values or inflate tires below the
min. values listed in the fuel filler flap.
Warning!
G
Follow recommended inflation pressures.
Do not overinflate tires. Overinflated tires
can result in sudden deflation (blowout) be-
cause they are more likely to become punc-
tured or damaged by road debris, potholes
etc.
Do not underinflate tires. Underinflated tires
wear unevenly, adversely affect handling
and fuel economy, and are more likely to fail
from being overheated.
Do not overload the tires by exceeding the
specified vehicle capacity weight (as indicat-
ed by the label on the pillar in the driver’s
door opening). Overloading the tires can
overheat them, possibly causing a blowout.

232 Practical hintsWhat to do if …Problem
Possible cause
Suggested solution
?
The yellow “CHECK ENGINE”
malfunction indicator lamp
comes on while driving.
There is a malfunction of:

The fuel management system


The ignition system


The emission control system


Systems which affect emissions
Such malfunctions may result in excessive
emissions values and may switch the engine
to its limp-home (emergency operation)
mode.

Have the vehicle checked as soon as
possible by an authorized
Mercedes-Benz Light Truck Center.
An on-board diagnostic connector is
used by the service station to link the
vehicle to the shop diagnostics sys-
tem. It allows the accurate identifica-
tion of system malfunctions through
the readout of diagnostic trouble
codes. It is located in the front left
area of the footwell next to the park-
ing brake pedal.
The fuel cap is not closed tightly.
Check the fuel cap (
page 200).
Your fuel tank is empty.

After refuelling start the engine three
or four times in succession.
The limp-home mode is canceled. You do
not need to have your vehicle checked.
7
The indicator lamp lights up.
A BabySmart
TM child seat is installed on the
front passenger seat. The front passenger
airbag is therefore switched off.
The system is malfunctioning when there is
no BabySmart
TM child seat installed on the
front passenger seat.

Have the system checked as soon as
possible by an authorized
Mercedes-Benz Light Truck Center.

260 Practical hintsFlat tire

Detach the electric air pump.

Reinstall tire valve cap.

Store the electrical plug and the air
hose behind the flap and place the air
pump back in the rear cargo compart-
ment.
Warning!
G
Follow recommended inflation pressures.
Do not overinflate tires. Overinflated tires
can result in sudden deflation (blowout) be-
cause they are more likely to become punc-
tured or damaged by road debris, potholes
etc.
Do not underinflate tires. Underinflated tires
wear unevenly, adversely affect handling
and fuel economy, and are more likely to fail
from being overheated.
Do not overload the tires by exceeding the
specified vehicle capacity weight (as indicat-
ed by the label on the driver’s door latch
post). Overloading the tires can overheat
them, possibly causing a blowout.

279 Technical data
Rims and tires
Rims and tires
Use only tires and rims which have been
specifically developed for your vehicle and
tested and approved by Mercedes-Benz.
Other tires and rims can have detrimental
effects, such as

poor handling characteristics


increased noise


increased fuel consumption
Rims and tires
!Moreover, tires and rims not approved
by Mercedes-Benz may, under load, ex-
hibit dimensional variations and differ-
ent tire deformation characteristics
under load that could cause them to
come into contact with the vehicle
body or axle parts. Damage to the tires
or the vehicle may be the result.
iFurther information on tires and rims is
available at any authorized
Mercedes-Benz Light Truck Center. A
tire inflation pressure table is located
on the fuel filler cap of the vehicle. The
tire pressure should be checked regu-
larly and should only be adjusted on
cold tires. Follow tire manufacturer’s
maintenance recommendation includ-
ed with vehicle.
Model
ML 320, ML 350
ML 500
ML 55 AMG
Rims (light alloy)
8 J x 17 H2 ET 52
8 ½ J x 17 H2 ET 52
9 J x 18 H2 ET 52
Wheel offset
2.0 in (52 mm)
2.0 in (52 mm)
2.0 in (52 mm)
All season tires (radial-ply-tires)
255/60 R17 106 H
275/55 R17 109 V
285/50 R18 109 W
1
1Must not be used with snow chains.Rims* (light alloy)
8 ½ J x 17 H2 ET 47
8 ½ J x 17 H2 ET 47
-
Wheel offset*
1.85 in (47 mm)
1.85 in (47 mm)
-
All season tires (radial-ply-tires)*
275/55 R17 109 V
275/55 R17 109 V
-

284 Technical dataFuels, coolants, lubricants etc.
Fuels, coolants, lubricants etc.Capacities
Vehicle components and their respective
lubricants must match.Therefore use only brand tested and rec-
ommended by us.Please refer to the Factory Approved Ser-
vice Products pamphlet, or inquire at your
Mercedes-Benz Light Truck Center.
Model
Capacity
Fuels, coolants, lubricants etc.
Engine with oil filter
ML 320, ML 350,
ML 500
8.5 US qt (8.0 l)
Recommended engine oils
ML 55 AMG
8.0 US qt (7.5 l)
Recommended engine oils
Automatic transmis-
sion
9.0 US qt (8.5 l)
MB Automatic Transmission Oil
1
1MB part no. 001 989 21 03 10Transfer case
1.6 US qt (1.5 l)
(Dexron 3 or Dexron 2E)
Rear axle
1.3 US qt (1.25 l)
(Hypoid gear oil SAE 90, 85 W 90)
Front axle
1.2 US qt (1.1 l)
(Hypoid gear oil SAE 90)
Power steering
approx. 0.65 US qt (0.6 l)
MB Power Steering Fluid
Front wheel hubs
approx. 1.5 oz (43 g) each
High temperature roller bearing grease
Brake system
0.75 US qt (0.7 l)
MB Brake Fluid (DOT 4+)

285 Technical data
Fuels, coolants, lubricants etc.
Model
Capacity
Fuels, coolants, lubricants etc.
Cooling system
approx. 12.7 US qt (12.0 l)
MB Anticorrosion / Antifreeze
Fuel tank
ML 320, ML 350,
ML 500
22.0 US gal (83.0 l)
Premium unleaded gasoline:
Posted Octane 91 (Avg. of 96 RON/86 MON
ML 55 AMG
25.0 US gal (95.0 l)
Premium unleaded gasoline:
Posted Octane 91 (Avg. of 96 RON/86 MON
including a reserve of
approx. 3.2 US qt (12.0 l)
Air conditioning system
R-134a refrigerant and special PAG lubricant
oil (never R-12)
Windshield washer and
headlamp cleaning sys-
tem
8.0 US qt (7.6 l)
MB Windshield Washer Concentrate
1
1Use MB Windshield Washer Concentrate “S” and water for temperatures above freezing or MB Windshield Washer Concentrate “S” and commercially available pre-
mixed windshield washer solvent / antifreeze for temperatures below freezing. Follow suggested mixing ratios (
page 290).