1997 MERCEDES-BENZ ML320 steering

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
d by Modification services.
Page 1

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

AR54.25-P-2800GH
Removing and installing combination switch
21.1.97

MODEL
163.113 /128 /136 /154 /157 /172 /174 /175

P54.25-0325-06

1
Bolt

2
Lower steering column cover

3
Upper steering column cover

12
Cover

P54.25-0333-06

4
Bolt

5
Bolt

6
Retaining web

7
Steering shaft

8
Bolt

9
Connector

S4
Combination switch

S40
CC switch


Remove/install

1
Disconnect ground cable of battery


To protect against unwanted contact

between the disconnected ground line and

the ground (right major assemblies

compartment, common ground W16/4,

insulate cable lug of ground line.

AR54.10-P-0003A

2
Remove steering wheel

Caution when handling airbag

unitImproper handling can lead to damage to

the airbag unit.

AR46.10-P-0100GH

3
Remove clock spring contact

AR46.10-P-0200GH

4
Unscrew screws (1) and remove lower

steering column molding (2)

5
Remove upper steering column molding (3)

6
Remove covers (12) on left and right

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

AR68.10-P-1111GH
Remove/install instrument panel carrier
17.3.97

MODEL
163.113 /128 /136 /154 /157 /172 /174 /175

P68.10-0612-09

1
Caps on A-pillar

2
Bolts

3
Instrument panel

4
Bolt

5
Bolts

6
Heater housing

7
Front passenger airbag unit

8
Nuts, self-locking
17

Cover below instrument panel on right

18
Connector on MB immobilizer switch

19
Connector at steering/ignition lock

20
Steering column adjustment switch

connector

10

Steering column

11
Bolts

12
Nuts

13
Instrument panel

14
Bottom section of instrument panel

15
Wiring harness

16
Cover below instrument panel on left


Remove/install

1
Remove instrument panel (13) and the lower

part of instrument panel (14)

AR68.10-P-1000GH

2
Remove passenger airbag (7)

AR91.60-P-0680GH

3
Remove cover below instrument panel on

right (17)
Up to chassis number A145272, X708318.

AR68.10-P-1520GH

As of chassis number A145273, X708319.

AR68.10-P-1520GI

4
Unscrew screws (5) from instrument panel

carrier (3) on heater housing (6)

5
Remove cover below instrument panel on left

(16)

AR68.10-P-1500GH

6
Remove insulating mat between steering
column (10) and carrier for instrument panel (3)

7
Unscrew screws (11) for steering column (10)

from instrument panel carrier (3)


*BA46.10-P-1006-03C

8
Remove nuts (12) for steering column (10)

from instrument panel carrier (3)


*BA46.10-P-1007-03C

9
Unscrew screws (4) for instrument panel

carrier (3) from middle tunnel

10
Disconnect connector from steering column

height adjustment switch (20)

11
Disconnect connector from MB immobilizer

switching unit (18)

12
Disconnect connector from steering/ignition

switch (19)

13
Disconnect wiring harness (15) from

instrument panel carrier

Installation:
Ensure that wiring harness

is routed correctly on instrument panel carrier.

14
Remove wiper system

AR82.30-P-6400GH

15
Unscrew nuts for instrument panel carrier (3)

on firewall


Installation:
Install new self-locking nuts.

16
Remove caps on A-pillar (1)

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

Fig. 16: Identifying Instrument Panel Carrier Components

Remove/install
1Remove instrument panel (13) and the
lower part of instrument panel (14) AR68.10-P-
1000GH
2Remove passenger airbag (7) AR91.60-P-
0680GH
3Remove cover below instrument panel on
right (17)Up to chassis number A145272,
X708318.AR68.10-P-
1520GH
As of chassis number A145273,
X708319.AR68.10-P-
1520GI
4Unscrew screws (5) from instrument panel
carrier (3) on heater housing (6)
5Remove cover below instrument panel on
left (16) AR68.10-P-
1500GH
6Remove insulating mat between steering
column (10) and carrier for instrument

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Interior Equipment - 163 Chassis
me
Saturday, October 02, 2010 3:35:21 PMPage 23 © 2006 Mitchell Repair Information Company, LLC.

Jacket tube
REMOVING AND INSTALLING CENTER AIR NOZZLE - AR68.10-P-1150GH
MODEL 163.113 /128 /136 /154 /157 /172 /174 /175
panel (3)
7Unscrew screws (11) for steering column
(10) from instrument panel carrier (3) *BA46.10-P-
1006-03C
8Remove nuts (12) for steering column (10)
from instrument panel carrier (3) *BA46.10-P-
1007-03C
9Unscrew screws (4) for instrument panel
carrier (3) from middle tunnel
10Disconnect connector from steering column
height adjustment switch (20)
11Disconnect connector from MB
immobilizer switching unit (18)
12Disconnect connector from steering/ignition
switch (19)
13Disconnect wiring harness (15) from
instrument panel carrier Installation:Ensure that wiring
harness is routed correctly on
instrument panel carrier.

14Remove wiper system AR82.30-P-
6400GH
15Unscrew nuts for instrument panel carrier
(3) on firewall Installation: Install new self-
locking nuts.
16Remove caps on A-pillar (1)
17Unscrew screws (2) for instrument panel
carrier (3) from A-pillar
18
Remove instrument panel carrier (3) and
take out of passenger compartment to side
through passenger doorBe careful not to damage center
console when removing and
installing.

19Install in the reverse order
NumberDesignationMODEL Series
163
BA46.10-P-1006-
03CScrew for jacket tube on upper instrument panel carrierNm20
BA46.10-P-1007-
03CJacket tube collar nut on instrument panel carrier at
bottomNm18

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Interior Equipment - 163 Chassis
me
Saturday, October 02, 2010 3:35:21 PMPage 24 © 2006 Mitchell Repair Information Company, LLC.

MODEL all
CLEAN INSTRUMENT CLUSTER, STEERING WHEEL AND GEARSHIFT LEVER (STANDARD VERSION) - AP68.10-P-
1000-01A
all
Work procedure
Wipe off with moist, lent-free rag.

Do not use scouring agent to prevent scratching surfaces.
Do not bring Plexiglas cover on instrument cluster and Mercedes Star in steering wheel into contact with
solvent or cleaning agents containing solvents (danger of tension cracking).
Do not apply liquids to Plexiglas cover on instrument cluster.
Repair materials
Cleaning vehicle headliners of textile material (prefabricated headliners), floor
coverings, rear shelf coverings, and other textiles AP68.00-P-
1000-01A
Cleaning synthetic leather vehicle headliners (tensioned headliners) AP68.00-P-
1000-02A
Cleaning seat belts AP91.40-P-
1000-01A
Cleaning instrument cluster, steering wheel and gearshift lever (standard version) AP68.10-P-
1000-01A
Cleaning leather upholstery, leather steering wheel, and leather gearshift lever AP91.18-P-
1000-01A
Cleaning plastic covering parts AP68.30-P-
1000-01A
Cleaning MB Tex upholstery AP91.18-P-
1000-02A
Cleaning fabric upholstery AP91.18-P-
1000-03A
Cleaning velours upholstery AP91.18-P-
1000-04A
Cleaning amaretta upholstery AP91.18-P-
1000-05A
NumberDesignationOrder number
BR00.45-Z-1002-04ACar shampooA 001 986 41 71

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Interior Equipment - 163 Chassis
me
Saturday, October 02, 2010 3:35:22 PMPage 76 © 2006 Mitchell Repair Information Company, LLC.

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