1997 MERCEDES-BENZ ML320 brake
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poisoning from swallowing
coolant.Wear protective gloves, protective
clothing and eye protection.
1Drain coolantEngine 111 in MODEL 163.AR20.00-P-
1142HG
Engines 112 /113 in MODEL 163.AR20.00-
P-1142HA
Engine 628.963 in MODEL 163.128.AR20.00-P-
1142HB
Engine 612.963 in MODEL 163.113.AR20.00-P-
1142M
2.1 Detach
brake line
from the
front end of
the radiator
Only required for right-hand steering.
3.1 Detach
ignition
cable from
the front end
of the
radiator
Only required on right-hand drive vehicles
with ENGINES 111 /112/113.
4Release coolant overflow from
battery shield
5Disconnect upper coolant hose
from the electric coolant pump Detach hose clamp from the upper
coolant hose.
6Unscrew nuts from expansion
reservoir at firewall
7Remove expansion reservoir from
the firewall and lay aside
8Disconnect coolant delivery/return
hoses for heat exchanger (17) Detach hose clamps from coolant
delivery/ return hoses for heat exchanger.
9Discharge air conditioning system
Installation: Evacuate air
conditioning, refill and check for proper
operation and leaktightness.AR83.30-
P-1760GH
10Unscrew self-locking nut (16) at
the expansion valve (15) Replace self-locking nut.
*BA83.30-
P-1003-01B
11
Detach low-pressure refrigerant
line (13) and high-pressure
refrigerant line (14) from expansion
valve (15)
Installation: Install new sealing rings
and moisten with compressor oil.
12Remove instrument panel carrier
(4) AR68.10-
P-1111GH
2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 197 © 2006 Mitchell Repair Information Company, LLC.
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
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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
Page 3482 of 4133
GF54.30-P-3003A
Indicator/warning messages triggered via CAN data buses, 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
Indicator and warning displays triggered via CAN
Low brake fluid level/parking brake indicator lamp (A1e7)
The parking brake signal comes from the traction system
control module.
The brake fluid signal comes directly from the switch (S11)
(except model 163).
Brake pad wear indicator lamp (A1e6)
The parking brake signal comes from the traction system
control module (N47)
Low engine oil level indicator lamp (A1e12)
The oil level signal comes from the injection system control
module (N3).
For vehicles with ASSYST, also refer to document: ASSYST
engine oil monitoring.
Preglow indicator lamp (A1e16)
The signal comes directly from the injection system control
module (N3).
Coolant level and temperature warning lamp (A1e11) model 168
only as of 9.99
The coolant temperature signal comes from the injection
system control module (N3)
-----------------------------------------------------------------------------------------
ABS MIL (A1e17)
The parking brake signal comes from the traction system
control module (N47).
"CHECK ENGINE" MIL (A1e26),
I
only
The signal comes from the injection system control module (N3)
ETS (A1e35) or ASR (A1e22) or ESP (A1e42) MIL
Lamp illuminated if there is a fault in the respective system.
The signal comes from the traction system control module
(N47).
ETS (A1e36) or ASR (A1e21) or ESP (A1e41) warning lamp
The lamp indicates that the respective system is active.
The signal comes from the traction system control module
(N47).
-----------------------------------------------------------------------------------------
Severe leak warning (
I
as of 97 only)
The fuel reserve indicator lamp (A1e4) flashes. The signal
comes from the injection system control module (N3).
The warning takes place at the earliest 30 minutes after cold
start with the engine idling and the vehicle stationary.
Also refer to document: Purge system with leak test, function
Fog lamps indicator lamp (A1e57), model 163 only except
I
)
The signal comes from the All-activity module (AAM, N10)
"LOW RANGE" indicator lamp (A1e53), model 163 only
The signal comes from the transfer case control module (N78)
Active service system (ASSYST)
Engines 112, 113, 611 (engines with oil
sensor)
GF00.20-P-2009A
Engine oil monitoring, function
Model 210 as of 01.03.97 with engine M111,
OM602, OM604, OM605 and OM606
As of 06.97 models 129, 140, 170, 202 except
engines 112, 113, 611
(Valid for engines with low oil level switch).
GF00.20-P-2009B
Displaying coolant temperature, function
Model 168 as of 9.99
GF54.30-P-3020GC
Purge system with leak test, function
GF47.30-P-3016L
Bus systems, overall function
GF54.00-P-0004A
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 3483 of 4133
GF54.30-P-3002A
Indicator and warning signals triggered over direct lines, 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
Indicator and warning signals
Indicator lamps for left turn signal (A1e1) and right turn signal
(A1e2)
The signal in models 129, 140, 170, 202 comes from the
combination relay (turn signals with trailer coupling, rear
window defroster, wiper motor, anti-theft alarm system)
(N10/2), and in model 210 from the multifunction control
module (N10-1) or the driver's side signal acquisition and
actuation module (SAM) (N10/1).
In model 168 the entire turn signal control is located in the
instrument cluster (A1).
Brake fluid / parking brake warning lamp (A1e7)
The signal for the brake fluid comes direct from the brake fluid level switch (S11) (except model 163).
(The signal for the parking brake comes over CAN.)
Low windshield washer fluid level warning lamp (A1e13) except
models 163 and 168
See
document: Coolant/washer fluid level voltage coding, task /
function
-----------------------------------------------------------------------------------------
Low windshield washer fluid level warning lamp (A1e13) as of
01.09.01 for model 163
See document: Displaying washer fluid level, function
Low engine coolant level warning lamp (A1e11) except models
163 and 168
See
document: Coolant/washer fluid level voltage coding, task /
function
Low engine coolant level warning lamp (A1e11) model 163 as of
3.99
See
document: Displaying coolant level, function
Coolant level and temperature warning lamp (A1e11) model 168
as of 9.99
See
document: Displaying coolant level, function
Fuel reserve warning lamp (A1e4)
When the reserve fuel level is reached, this lamp lights up and
goes out again only after refueling is detected. If the vehicle is
refueled with the ignition ON, refueling is detected only if at
least 7 liters of fuel are added.
-----------------------------------------------------------------------------------------
AIRBAG OFF indicator lamp (A1e56), only model 163 except
I
The signal comes from the emergency tensioning retractor
(ETR) control module with airbag (AB, N2/2)
Generator charge indicator/warning lamp (A1e5)
See document: Terminal 61 and terminal 61e, charge indicator
lamp, exterior lamp failure, function
Seatbelt/backrest lock warning lamp (A1e9)
The seat belt warning lamp is only used in a few national
versions, and is actuated direct by a seat belt buckle switch
(normally closed contact). After engine start, the lamp flashes
for a short time (approx. 6 seconds).
In model 129 if this lamp fails to go out after flashing briefly, but
continues to shine constantly, then the seat backrest is not
locked.
Exterior lamp failure indicator lamp (A1e14)
The signal comes from the lamp failure monitor
See document: Terminal 61 and terminal 61e, charge indicator
lamp, exterior lamp failure, function
Hydraulic fluid level warning lamp (A1e37)
The signal comes direct from the ADS level control oil level
switch (S44).
ADS warning lamp, suspension (A1e27) The signal comes from the ADS control module, suspension
(N51).
SRS airbag malfunction indicator lamp (A1e15)
The signal comes from the emergency tensioning retractor
(ETR) control module with airbag (AB, N2/2)
Voltage coding of coolant / windshield washer
fluid level, function
Except models 163 and 168
GF54.30-P-3006A
Displaying coolant level, function
Model 163 as of 3.99
GF54.30-P-3028GH
Model 168 as of 9.99
GF54.30-P-3028GC
Terminal 61 and terminal 61e, charge
indicator lamp, exterior lamp failure, function
GF54.30-P-3007A
Copyright DaimlerChrysler AG 04.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1
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 3496 of 4133
AD54.30-P-5000GH
Instrument cluster (IC) diagnosis troubleshooting
10.4.97
MODEL
163
Connection and use of test equipment
AD00.00-P-1000AZ
Instrument cluster diagnosis, previous
knowledge
AD54.30-P-2000GH
Explanatory notes on diagnosis
troubleshooting chart IC
AD54.30-P-5000-01GH
Display instruments controlled via CAN
troubleshooting chart IC
AD54.30-P-5000-02A
Display instruments controlled directly,
troubleshooting chart IC
AD54.30-P-5000-03A
Troubleshooting
Complaint
Possible cause
Notes
Remedy/Test step
Instrument cluster (A1) completely inoperative
Voltage supply, instrument cluster (A1)
AD54.30-P-6000-01GH
Malfunction indicator lamps or indicator lamps
inoperative
Voltage supply, instrument cluster (A1)
AD54.30-P-6000-01GH
HHT and instrument cluster cannot
communicate
Cables, instrument cluster (A1)
AD54.30-P-6000-02GH
Low brake fluid level/parking brake indicator
lamp, brake pad wear indicator lamp, ABS
MIL, malfunction indicator lamp (ETS, ASR,
ESP) come on together and speedometer
remains on lower stop.
Traction system control module (N47)
AD42.35-P-1001BZ
RPM counter, engine coolant gauge remain
on the lower stop and the low engine oil level
indicator lamp comes on.
Injection system control module (N3)
AD07.61-P-1000AZ
Low brake fluid level/parking brake indicator
lamp, brake pad wear indicator lamp, low
engine oil level indicator lamp, ABS MIL,
malfunction indicator lamp (ETS, ASR, ESP)
come on together and RPM counter, engine
coolant gauge and speedometer remain on
lower stop.
CAN faulty
AD54.30-P-6000-04GH
AD54.30-P-6000-05GH
Steering lock warning lamp (A1e40) is
continuously illuminated or is inoperative.
Cables,
steering lock switch (S97/1)
AD54.30-P-6000-06GH
Coolant level indicator disrupted
Cables,
Coolant level indicator electronic switch (S41)
Model 163 as of 3.98
AD54.30-P-6000-42GH
Copyright DaimlerChrysler AG 05.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1
Page 3499 of 4133
AR68.10-P-1040GH
Remove/install bottom section of instrument panel
13.3.97
MODELS
163.113 /128 /136 /154 /157 /172 /174 /175
P68.10-2226-09
1
Instrument panel
2
Instrument cluster cover frame
3
Combination switch with paneling
4
Bottom section of instrument panel
5
Screws in left footwell
6
Screws in right footwell
7
Bolts
15
Paneling
16
Bolt
17
Entrance lamps
A
Spreading clips
B
Guide tongues
8
Bolts
9
Bolts
10
Heater/ventilation switch
11
Instrument panel center section
12
Glove compartment
13
Parking brake release handle
14
Parking brake control cable
Remove/install
1
Shift transmission selection lever to position" 1"
Secure vehicle to prevent it moving away.
2
Disconnect ground cable of battery
AR54.10-P-0003A
3
Remove combination switch with paneling (3)
AR54.25-P-2800GH
4
Remove cover frame of instrument cluster (2)
5
Unscrew the screws (7).
3 screws up to 08/99. 1 screw as of 09/99.
6
Unscrew screws in left footwell (5) on the
lower part of the instrument panel (4)
7
Remove center section of instrument panel
(11)
AR68.10-P-1030GH
8
Remove switch unit for heater / ventilation (10)
Up to 31.08.01.
AR83.20-P-1835GH
As of 01.09.01.
AR83.40-P-6500GH
9
Unscrew screws (8, 9)
10
Remover glove compartment (12)
Up to 31.08.99.
AR68.10-P-1400GH
As of 01.09.99.
AR68.10-P-1400GI
11
Unscrew screws in the right footwell (6) on
the lower part of the instrument panel (4)
12.1
Unclip entrance lamps (17) and disconnect
electrical connectors
As of 09/99.
13.1
Remove paneling (15) and unscrew screws
(16)
As of 09/99.
14
Unclip lower part of instrument panel (4) at
the four expanding clips (A) on the instrument
panel (1)
Installation: Ensure that guide lugs (B) are
properly seated in the mounts on the
instrument panel.
15
Unhook the Bowden cable of the parking
brake (14) at the release handle of the
parking brake (13)
16
Remove bottom section of instrument panel (4)
Do not damage instrument panel when
removing and installing.
17
Install in the reverse order
18
Read diagnostic trouble code memory and
erase
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