1997 MERCEDES-BENZ ML350 check oil

Notes on handling refrigerant
R134aAll models fitted with air conditioning
AH83.30-
N-0003-
01A
1.1
Remove
additional
fan (M4)

Models 163.136 /154/157 /172 with air
conditioning or for USA Tempmatic, code
580.AR83.30-
P-5600GH
2.1Remove intercooler Only models 163.113/ 128.
Model 163.113AR09.41-P-
6817MM
Model 163.128AR09.41-P-
6817CD
3Discharge air conditioning system
Installation: Evacuate, refill air
conditioning system and check for proper
operation and tightness.AR83.30-
P-1760GH
4.1Detach lower engine compartment
panelingModel 163.172/174/175AR61.20-
P-1105GH
4.2Remove noise encapsulation Removal: Only remove front part.
Model 163.113/128AR94.30-P-
5400GH
5.1Remove air guide Only if present Located at front
crossmember, in center behind front bumper.
6Unscrew bolts at bottom of
electric fan or fan shroud. Also remove sheet metal nuts.
7Remove attachment parts (20) and
rubber shock absorber(21) Removal: Lower attaching parts and
damper rubber.
Installation: Replace attaching parts.

8Unscrew screw (2) for refrigerant
line at fluid reservoir
*BA83.30-
P-1001-
01B
9Detach refrigerant line from fluid
reservoir Installation: Replace sealing rings and
moisten with compressor oil.
10Unscrew screw (6) for refrigerant
line at condenser(5)
*BA83.30-
P-1002-
01B
11Detach refrigerant line from
condenser (5) Installation: Replace sealing rings and
moisten with compressor oil.
12Detach rubber seal (4) from
radiator (7)
13Remove screws (3)
14.1Remove attachment parts (20) and
rubber shock absorber(21)Model 163.113/128
Upper attaching parts and damper rubber.
Installation: Replace attaching parts.


2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 215 © 2006 Mitchell Repair Information Company, LLC.

Remove/install

Risk of injury to skin and eyes
suffering scalding from contact with
hot coolant spray. Risk of poisoning
from swallowing coolant.
Do not open cooling system unless coolant
temperature is below 90°C. Open cap slowly
and release the pressure. Do not pour
coolant into beverage bottles.
Wear protective gloves, protective clothing
and eye protection.
AS20.00-Z-
0001-01A

Risk of explosion from welding or
soldering work on closed air
conditioning system. Risk of
poisoning. Inhaling overheated
refrigerant vapors may be toxic. Risk
of injury from skin and eye contact
with liquid refrigerant.Do not carry out any welding work on the
closed air conditioning system or in the
surrounding area. No smoking or open
flames. Wear eye protection and protective
gloves. Work only in well ventilated areas.
Carry out repair work on the air
conditioning system circuit only after the
system has been discharged.
AS83.00-Z-
0001-01A
Procedures if air conditioning system
is damaged or leakingAll models
AH83.30-
N-0004-
01A

Protect air conditioning circuit and
components from moisture when
carrying out repair work
All models fitted with air conditioning
AH83.30-
N-0005-
01A
Notes on handling refrigerant R134aAll models fitted with air conditioning
AH83.30-
N-0003-
01A
1Drain coolant J Engine 112, 113.AR20.00-P-
1142HA
Engine 111.AR20.00-P-
1142HG
Engine 612.963.AR20.00-P-
1142M
2Unscrew coolant compensating
reservoir (1) on firewall Lay compensating reservoir to one side.
3Disconnect coolant delivery/return
hoses for heat exchanger (2) Remove hose clamps from coolant hoses.
4Discharge air conditioning system
Installation: Evacuate air conditioning,
refill and check for proper operation and
leaktightness.AR83.30-P-
1760GH
5Remove cover on expansion valve
(4)
6Remove nut (3) on expansion valve
(4) Replace self-locking nut.
*BA83.30-
P-1003-01B
7Disconnect refrigerant lines from
expansion valve Installation: Install new sealing rings
and moisten with compressor oil.

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:19 PMPage 220 © 2006 Mitchell Repair Information Company, LLC.

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

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AH40.10-P-9411-01A
Information on tires/rims
Model 124, 129, 140, 163, 168, 169,

170, 171, 199, 201, 202, 203, 208, 209,
210, 211, 215, 219, 220, 230, 240, 414,
450, 452,
639


Tires

D
For service conversions, the tire/disc wheel specifications and

dimensions should be compared with the entries in the
registration papers.

D
When mounting tires, the tires and rims must be carefully

matched in order to guarantee the concentricity of the wheel.

Identification of matching points on:

- Tires with a colored dot on the outside of the tire,

- Sheet steel disk wheel by a colored dot or punch mark on the

outside of the wheel,

- Perform this operation at the valve stem hole on light-alloy

disk wheels

With an additional paint spot or punch mark in the rim base

for the 140 Model Series.

D
Always replace the rubber valve.

-----------------------------------------------------------------------------------------
D

Damaged and defective tires must always be replaced. The

repair methods employed in the tire trade are not approved by

Mercedes-Benz. Small nicks (<0.8mm) on the tire's sidewall do

not usually pose a cause for concern, and continued use of

such tires is approved

D When replacing just one tire, install it on the front of the vehicle.

This does not apply to vehicles with different tires of varying

specifications on the front and rear wheels.

D
Only use tires listed in the valid Service Information bulletins

and repair instructions.

D
If the permissible maximum speed of an M+S tire is below the

maximum speed of the vehicle, an appropriate adhesive plate

must be attached in the driver's field of view.

-----------------------------------------------------------------------------------------

D
Tires permissible for higher speeds may be used.

D
Always fit all rims with tires of the same design, make and

version.

-----------------------------------------------------------------------------------------
D

Run in new tires for approx. 100 km at moderate speed.

D
Handed tires must be installed according to the arrow on the

side wall of the tire.

D
Tires are subject to an aging process with negative effects on

the properties of the tire. In order to ensure optimum

effectiveness in winter, M+S tires should not be used for longer

than 3 years.

-----------------------------------------------------------------------------------------

Tire pressure

(For specified values see tire pressure table in the fuel filler flap, on

the Vaneo BM 414 see B-pillar on the passenger side).
Too low tire pressure increases the rolling resistance and increases

the flexing energy of the tire. This causes the critical temperature limit

to be exceeded (carcass detachment) and destroys the tire. Respond

to loss of tire pressure by determining the source and replacing the

tire as indicated.

Cleaning

Using a spray wand with high-pressure nozzles to clean the wheel

can lead to tire damage. Such damage occurs especially on the tire

side walls. The following should be observed when using flat jet

nozzles:

D
Maintain a minimum distance of 300 mm

D
Do not direct the water jet at a single point on the surface of the

tire for any length of time.

-----------------------------------------------------------------------------------------
Mounting in bearings

Before putting into storage, clean tires thoroughly and check for
damage and adequate tread depth. Mark the position and running

direction of the tires with chalk. Do not store tires outdoors. Under the

influence of sunlight, heat, moving air and ozone the rubber looses

elasticity and strength, ages more quickly and becomes cracked.

Storage areas should be dry, cool and dark. Avoid drafts by keeping

doors and windows closed as much as possible. Do not bring tires

into contact with gasoline, oil or other greases as they dissolve the

rubber.

Disposal

Collection, storage and disposal should be performed in accordance

with the legal requirements and the company's own regulations.

-----------------------------------------------------------------------------------------

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

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
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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
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Page 1

BT27.10-P-0006-01W
Oil pan and overflow tube modified

k

TRANSMISSION
722.901

P27.10-2139-06

To improve fluid supply to the transmission,

the transmission oil pan and the overflow tube

have been redesigned.

The characteristic sloped surface (arrow) can

be used to identify the new oil pan (1). This oil

pan configuration should be installed only

together with the white overflow tube (2).

The fluid temperatures used as references for

checking and refilling are different with the

new components.

Whenever a transmission is removed for repairs, the earlier oil pan (3) with the black overflow

tube (4) should be replaced by the new sloped-surface version (1) with the white overflow tube
(2).

P27.10-2140-03

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Page 1

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.

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Page 1