1997 MERCEDES-BENZ ML430 ignition

2
Withdraw ignition key

3
Unclip cap (1) from outer paneling (3)

4
Unscrew bolt (2) from belt end fitting (4)

*BA91.40-P-1001-01D

Torx bit set

*000589011000

5
Pull belt end fitting (4) out of front seat

6
Remove paneling on B-pillar

AR68.30-P-4700GH

7
Unscrew bolt (5) of belt height adjuster from

B-pillar


*BA91.40-P-1004-01D

8
Disconnect connector from passenger ETR

[GUS] ignition squib (R12/2)

9
Unscrew bolt (6) from automatic belt retractor

(7)


*BA91.40-P-1008-01D

Torx bit set

*000589011000

10
Detach automatic belt retractor (7)

The automatic belt retractor must not be

disassembled.

Never use oil or grease to eliminate noises.

Automatic belt retractors that have been

opened are no longer under warranty!

11
Check seat belt for signs of damage

e

Check seat belts for damage

AP91.40-P-9150GH

12
Install in the reverse order


Installation:
Pay attention to different

version (left/ right) of emergency tensioning
retractors and satisfactory seating in the

locking device.

13
Read fault memory and erase

14Carry out diagnosis
see Diagnosis Manual.


Seat belts/emergency tensioning retractors

Number

Designation
Model 163 up to

08/99
Model 163 as of

09/99

BA91.40-P-1001-01D
Screw on belt end fitting
Nm
3535

BA91.40-P-1004-01D
Bolt to belt height adjuster
Nm
2525

BA91.40-P-1008-01DScrew on front automatic belt reel
Nm
30 (+10/-0.15)30 (+10/-0.15)

Torx bit set

000 589 01 10 00

Copyright DaimlerChrysler AG 14.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 2

AR91.40-P-0681GI
Remove/install rear seat belts
16.4.99

MODEL
163.136 /154 /172 as of 1.9.99,

163.113 /128 /157 /174 /175

1
Bolt

2
Seat belt guide bracket

3
Bolt

4
Automatic belt retractor

5
Belt height adjuster

R12/7
Right rear ETR ignition squib

P91.40-2114-03


Remove/Install

Danger!

Risk of injury
when carrying out test or repair

work on airbag or emergency tensioning

retractor units
Store airbags with exit surface pointing

upward, do not expose to temperatures above

100 °C. Interrupt power supply when working

on such units.

AS91.00-Z-0001-01A

Danger!

The spring in the inertia reel can pose an

injury hazard
when the tension is released

and it uncoils.
Never disassemble inertia reels

AS91.00-Z-0002-01A


Important instructions for performing repair,

body work and welding on vehicles with

airbags or belt tensioner units
Models 129 as of 1.7.93, 163, 168, 170, 202

as of 1.7.93, 208, 210, 414, 638, 690.6, 901,

902, 903, 904, 905

Model 461 with engine 602.983

Model 463 up to 30.11.00

MODELS WD141, WD241, WD341, WD641,

WD741, XD141, XD241, XD341, XD441,

XD541, XD641, XD741, YD141, YD241,

YD341, YD441, YD541, YD641, YD741

AH91.00-P-0002-01B


Evaluation of airbags and emergency

tensioning retractors on accident vehicles
Model 129 as of 1.7.93, 163, 168, 170, 202 as

of 1.7.93, 203, 208, 209, 210,

211.004/006/016/061/065/070, 215, 220, 230,

240, 414, 463, 638, 901, 902, 903, 904, 905

Models WD141, WD241, WD341, WD641,

WD741, XD141, XD241, XD341, XD441,

XD541, XD641, XD741, YD141, YD241,

YD341, YD441, YD541, YD641, YD741

AH91.00-P-0006-01B


Legal regulations concerning the handling

and storage of airbag and emergency

tensioning retractors
Models 124, 129, 140, 163, 168, 170, 202,

203, 208, 209, 210,

211.004/006/016/061/065/070, 215, 220, 230,

240, 314, 316, 318, 414, 461, 463, 638, 668,

670, 690.6, 901, 902, 903, 904, 905, 950,

952, 953, 954, 970, 972, 974, 975, 976

Models WD141, WD241, WD341, WD641,

WD741, XD141, XD241, XD341, XD441,

XD541, XD641, XD741, YD141, YD241,

YD341, YD441, YD541, YD641, YD741

AH91.00-P-0004-01A

o

Notes on disposal of airbags and emergency

tensioning retractors
All models

OS91.00-P-0001-01A


Render emergency tensioning retractors

unusable

AR91.40-P-0611A

1
Withdraw ignition key

2
Remove paneling on C-pillar

AR68.30-P-4490GH

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d by Modification services.
Page 1

3
Unscrew bolt (1) from seat belt guide bracket

(2)
If necessary, remove belt height adjuster
(5).


*BA91.40-P-1002-01D

4
Disconnect connector from right rear ETR

[GUS] ignition squib (R12/7)

5
Unscrew bolt (3) from automatic belt retractor

(4)


*BA91.40-P-1003-01D

6
Detach automatic belt retractor (4)

The automatic belt retractor must not be

disassembled.

Never use oil or grease to eliminate noises.

7
Check seat belts for damage

e

Check seat belts for damage

AP91.40-P-9150GH

8
Install in the reverse order


Installation:
Pay attention to different

version (left/ right) of emergency tensioning
retractors and satisfactory seating in the

locking device.

9
Read fault memory and erase

10Carry out diagnosis
see Diagnosis Manual.


Seat belts/emergency tensioning retractors

Number

Designation
Model 163 up to

08/99
Model 163 as of

09/99

BA91.40-P-1002-01D
Screw in rear upper belt guide fitting
Nm
3030

BA91.40-P-1003-01D
Bolt to rear inertia reel
Nm
3030

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Page 2

AR91.40-P-1516GJ
Remove/install rear seat belt buckle
12.1.00

MODEL
163.136 /154 /172 as of 1.9.99,

163.113 /128 /157 /174 /175

60% outer rear seat

P91.40-2174-06

2
Side covers

3
Back of rear seat cover

4
Rear corner rear seat cover

5
Screw

6
Rear seat seat belt buckle


Removing, Install

1
Fold 40 % rear seat downward

See Operating Instructions

2.1
Turn ignition key to "0" position

Only with side airbag in left and right rear,

code 293. To avoid fault codes

3
Remove load area floor folding section of

60% rear seat

See Operating Instructions

4.1
Disconnect connector of electrical line of rear

seat seat belt buckle and detach from rear

seat cushion frame

Only with side airbag in the rear

(left and right), code 293.

5
Remove side covers (2)

6
Unhook rear seat cover on back (3) and rear

corner (4)

7
Unscrew bolt (5) from rear seat seat belt

buckle (6)

Lift up rear of rear seat cushion and press
forwards.


*BA91.40-P-1006-01D

8
Remove rear seat seat belt buckle (6) and
remove belt end fitting through rear seat

cushion

Do not damage rear seat cover!


Installation:
Check rear seat seat belt

buckle for damage.

9
Remove locking plate, disconnect rear seat

seat belt buckle and belt end fitting


Installation:
Replace locking plate!

10
Install in the reverse order


Seat belts/emergency tensioning retractors

Number

Designation
Model

163 as of

09/99

BA91.40-P-1006-01D
Bolt, belt buckle to rear seat
Nm
45

Copyright DaimlerChrysler AG 14.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR91.40-P-1516GK
Remove/install rear seat belt buckle
26.9.02

MODEL
163.136 /154 /172 as of 1.9.99,

163.113 /128 /157 /175 with CODE (293) Left and right rear side airbag

40% rear seat

MODEL
163.174

40% Rear seat

P91.40-2172-01 P91.18-2030-01 P91.40-2173-01

1
Bolt

2
Rear seat seat belt buckle

3
Connector
8

Adhesive tape

4
Lower cover

6
Retaining straps

7
Electrical line for rear seat seat belt

buckle


Remove/install

1
Fold down 60% rear seat

See Operating Instructions

2
Fold backrest of 40% rear seat forwards

See Operating Instructions

3
Remove side covers on rear seat seat belt

buckle

4
Unscrew bolt (1) from rear seat seat belt

buckle (2)


*BA91.40-P-1006-01D

5
Turn ignition key to "0" position

To avoid fault codes.

6
Disconnect connector (3) from electrical line

of rear seat seat belt buckle

7.1
Remove lower cover (4)

Only with 3rd seat row, code 847.

8
Remove retaining straps (6)

9
Unhook rear seat cover on reverse side and

pull out electrical line for rear seat seat belt

buckle (7) on rear seat cushion

Loosen adhesive tape (8).


Installation:
Route electrical line for rear

seat seat belt buckle (7) correctly and fasten

to rear seat cushion frame using new

adhesive tape (8).

10
Remove rear seat seat belt buckle (2)


Installation:
Check rear seat seat belt

buckle for damage.

11
Install in the reverse order


Seat belts/emergency tensioning retractors

Number

Designation
Model

163 as of

09/99

BA91.40-P-1006-01D
Bolt, belt buckle to rear seat
Nm
45

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d by Modification services.
Page 1

AR91.40-P-0683GI
Remove, replace and install rear center seat belt
4.5.99

MODELS
163.136 /154 /172 as of 1.9.99,

163.113 /128 /157 /174 /175

P91.40-2170-09


Remove/Install

Danger!

The spring in the inertia reel can pose an

injury hazard
when the tension is released

and it uncoils.
Never disassemble inertia reels

AS91.00-Z-0002-01A
1.1
Disconnect connector from electrical line of

seat belt buckle of the outer rear seat

Only with side airbag in the rear (left and

right), code 293.

Turn ignition key into position "0" in order to

avoid fault codes.

2
Unhook rear seat cover on the back of the

rear seat cushion

3
Carefully lift up rear seat cover and unscrew

bolt from belt end fitting

Do not damage rear seat cover.


Installation:
Align rear seat cushion and

rear seat cover correctly.


*BA91.40-P-1001-01D

Torx bit set

*000589011000

4
Remove belt end fitting from rear seat

5
Detach paneling (1) of belt guide (2) from rear

backrest

Lift up front paneling and remove

6
Unscrew mounting screws of belt guide and

remove belt guide (2)

7
Fold rear backrest forwards
See Operating Instructions

8
Unhook rear backrest cover (3) on the back of

the rear backrest

9
Unscrew bolts (5) of rear wall paneling (4)

10
Remove rear wall covering (4)

Pull at the upper corners of the rear wall

paneling in order to remove

body-bound rivets (10).


Installation:
Replace body-bound rivets.

11
Unscrew bolt (6) from automatic belt retractor

(7)


*BA91.40-P-1005-01D

Torx bit set

*000589011000

12
Detach automatic belt retractor (7) and guide

seat belt through the rear backrest cover of

the rear backrest


Installation:
Pay attention to catch and

correct installation position of the automatic

belt retractor. Make sure seat belt is not

twisted when installed.

Copyright DaimlerChrysler AG 14.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

SI47.10-P-0004A
Service Information: Procedure when tank is filled with incorrect fuel
19.12.00

MODEL
202 with ENGINE 611

MODEL
203 with ENGINE 611, 612, 646

MODEL
210 with ENGINE 611, 612, 613

MODEL
220 with ENGINE 613, 628, 648

MODEL
163 with ENGINE 612, 628

MODEL
168 with ENGINE 668

MODEL
209 with ENGINE 612

MODEL
211 with ENGINE 628, 646, 647, 648

MODEL
463 with ENGINE 612, 628

Modification notes

26.7.04

Engines have been added and procedure has been updated

Incorrect refueling of diesel-power vehicles with a common rail
injection system. Please be aware that if the customer fills the fuel
tank with the wrong type of fuel, this is the customer's fault and

cannot be submitted as a warranty claim.

If the diesel-powered vehicle with a common rail injection system has

been refueled with gasoline, follow the steps below:

1.
If the engine was not started after fuel tank is filled with the wrong

type of fuel, then emptying the fuel tank and cleaning the fuel low-

pressure lines should be enough to solve the problem.
2.

If the engine was started after fuel tank was filled with wrong type

of fuel:

On engines 611, 612, 613, 668:
-
On the rail, open the low pressure connection of the high
pressure pump return (plastic connection in area of pressure

regulator valve) and check connecting point in rail for chips.

On engine 646, 647, 648, 628:
-
Disconnect Y-distributor unit (return line HDP/Rail) at the output

and, with ignition ON, collect the fuel in a clean container. Check

fuel for metal shavings.

If the high pressure pump is not damaged and there are no metal

shavings in the injection system:

-
As in step 1, empty fuel as per the guidelines and clean the fuel

low-pressure lines. In addition to this, remove/install/replace the

high-pressure pump and fuel filter.

If metal shavings are found in the fuel

system or the high pressure pump drive is

damaged:

#
b

Engine runs rough, surges or does not start
ENGINE 611 in MODEL 203, 202, 210
ENGINE 612 in MODEL 163, 203, 210, 209

ENGINE 613 in MODEL 210, 220

ENGINE 628 in MODEL 163, 220, 211

ENGINE 646 in MODEL 203, 211

ENGINE 647 in MODEL 211

ENGINE 648 in MODEL 220, 211

ENGINE 668 in MODEL 168

ENGINE 612, 628 in MODEL 463

AF07.00-P-9000B

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Page 1

463
All
-----

1)
Recognition: existing "airbag Off" warning light in center

console.

2)
With HHT functions menu point 5 Coding Reboard child seat. If

only the passenger side airbag is de-activated, then program
menu point Vehicle equipment.
3)

Depending on model and version, unplug one or two

connectors at the passenger side airbag and insert the

corresponding replacement resistors.

4)
Without ACSR, with seat belt force limiter.

Immobilizing passenger side airbag certificate
Model 124, 126, 129, 140, 163 up to VIN

145263, 170, 202, 210


Have customer sign certificate after

immobilization

OF91.60-P-1000-01A

Cancel immobilization

D
To re-activate the passenger side airbag remove the ignition

resistor at the cable.

D
Fit together connector at passenger side airbag.

D
Fit together connector at passenger side ETR (on models fitted

with seat belt force limiter).
D

Use HHT or STAR Diagnosis tool (DAS) to re-program

passenger side airbag and passenger side ETR in the SRS

control module to "YES".

D
Remove sticker on passenger side airbag and render invalid in
Owner's Manual.

D
Complete re-activation on certificate after immobilization.

D
If re-activated, delete de-activation in vehicle documents.

Parts ordering notes
Part no.

Designation
Quantity

140 868 00 50
Ignition resistor (replacement resistor)
as required

140 817 15 20
Sticker (without seat belt force limiter)
2

210 817 20 20
Sticker (with seat belt force limiter)
2

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Page 2