1997 MERCEDES-BENZ ML500 oil

AR91.40-P-0630GH
Remove/install seat belt with emergency tensioning retractor
26.3.97

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

P91.40-0374-09

1
Cap

2
Bolt

3
Outer paneling
7

Automatic belt retractor

R12/2
Passenger ETR [GUS] ignition

squib

4

Belt end fitting

5
Screw

6
Screw


Remove/Install

Danger!

Risk of injury
when carrying out test or repair

work on airbag or emergency tensioning

retractor units
Store airbag unit with expulsion area on top,

do not subject 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
Move front seat forwards to the full extent, tilt

front seat backrest forwards

See owner's manual.

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

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
d by Modification services.
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

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

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

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

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

SI18.00-P-0010A
Service Information: oil sludge
26.3.01

ENGINE
111 in MODELS 124, 163, 170, 202, 203, 208, 210

ENGINE
112 in MODELS 129, 163, 170, 202, 203, 208, 210, 220

ENGINE
112, 113 in MODEL 463

ENGINE
113 in MODELS 129, 163, 202, 208, 210, 215, 220

ENGINE
137 in MODEL 215, 220

ENGINE
166 in MODEL 168

Oil sludging in gasoline engines with ASSYST maintenance

system

Recently we have determined that time and time again oil

sludging occurs in gasoline engines with an ASSYST maintenance

system.

Oil sludging can lead to the following complaints:
D
engine oil consumption

D
engine smoke (white/blue)

D
influencing of oil level indicator

D
clogged oil filter, engine oil thickened like jelly

D
Check engine lamp illuminated

D
oil sludge visible during assembly job, e.g. in oil filter, in cylinder

head covers, condensation sludging
(engine 166) etc.

-----------------------------------------------------------------------------------------
The following list of causes may lead individually or as a combination
to engine oil sludging:

D
Crankcase ventilation inoperable, function orifices, bores,

passages in cylinder head cover, cylinder head, crankcase etc.

are mechanically sealed. A nonfunctioning crankcase

ventilation boosts loads on the engine oil through organic

nitrates. The risk of oil sludging increases.

The mechanical condition of the engine is always to be

checked, i.e. all engine oil drain orifices on the cylinder head

and crankcase and all crankcase ventilation ducts must be free

of obstacles. Crankcase breather lines may not be kinked.
Check the ventilation bores in the cylinder head covers.

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

D
The engine oil used does not comply with the specifications in

Sheet 229.1 or 229.3 of the Specifications for Service Products.

The additive process, e.g. dirt-carrying capability, neutralization

capability and oxidation resistance as well as the quality of the

base stock influence sludging time.

Use of engine oils with best possible resistance to formation of

sludge, i.e. use only tested and approved engine oils (from

Sheet 229.1 or 229.3). The best protection is afforded by the

engine oils on Sheet 229.3, which fulfill more stringent

specifications with regard to preventing sludge and deposits
(see Sheet 221.0, page 11). These oils have a distinctly better

anti-sludge characteristic than other engine oils.

D
Sludging after adding a fuel or engine oil special additive.

Do not use fuel or engine oil special additives. More information

hereto is available on Sheet 219.0 of the Specifications for

Service products. Reference to customer not to use special

additives.

D
Engine oil change not performed according to ASSYST

specifications. At driven distances

exceeding > approx. 3000 km, engine oil sludging may occur.

-----------------------------------------------------------------------------------------
Comply with engine oil and filter change as under ASSYST

specifications. Observe remaining distance.

D
Fuel grade lies outside standard (regionally contingent). If

contaminated, deficient fuel is used, then engine oil sludging

may occur even where approved engine oil is used.

Operation with fuel, e.g. as under DIN EN 228. Clarify refueling

behavior of customer. If engine operation regional, is

temporarily possible with deficient oil only, then the startup

distance has to be individually reduced, i.e. the oil change

temporarily performed at an interval of, e.g. 10,000 km.

D
Radiator antifreeze penetration into engine oil, e.g. through an

internal engine leak (cylinder head gasket, casting porosity).

The engine oil sludges within a short period. The crankcase

ventilation clogs up and stops functioning. Condensation

sludging clogs up the oil separator cells

(engine 166).
Rectify coolant leakage. Clean all sludged engine parts, in

particular the crankcase ventilation parts. If the occurrence

repeats, and casting porosity is suspected, e.g. replace

crankcase.

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

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

Measures for slightly sludged engine:

Oil and filter change. Purge engine, i.e. normal engine operation

in neutral, or while driving, using oil from Sheet 229.3, 228.3, or

228.5. Drain off scavenging oil after purging process (approx. 1

hour). Repeat purging process if necessary. Refill using engine oil

from Sheet 229.3, or 229.1. The first oil change after clearing the

sludge should be performed after approx. 10,000 km or beforehand;

when doing so use engine oil from Sheet 229.3.

Measures for severely sludged engine:

Engines with severe oil sludging and caking onto engine parts

and into bores have to be dismantled and mechanically cleaned.

Tough sludge residue must not enter the clean side of the oil circuit,

as otherwise, e.g. the piston oil spray and the hydraulic

compensation elements may have their functionality impaired. Refill

using engine oil from Sheet 229.3, or 229.1.

The first oil change after sludging should be performed after approx.

10,000 km; when doing so use engine oil from

Sheet 229.3.
Warranty/goodwill regulations

If in combination with engine oil sludging a warranty/goodwill claim is

submitted, then a regular documentation of maintenance must be

presented. The ASSYST printout is to be filed carefully for further

reference.

Oil sludging in combination with an exceeded oil change interval, or

because of special additives in the fuel/engine oil are costs to be

borne by the customer.

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

Fig. 22: Identifying Engine Control System Lubricate Joints
THROTTLE CONTROL - CHECK CONTROL CABLE FOR SMOOTH OPERATION - AP30.10-P-3024GH
ENGINE 612.963 in MODEL 163.113
ENGINE 628.963 in MODEL 163.128
ENGINE 111.977 in MODEL 163.136
ENGINE 112.942 in MODEL 163.154
ENGINE 112.970 in MODEL 163.157
ENGINE 113.942 in MODEL 163.172
ENGINE 113.981 in MODEL 163.174
ENGINE 113.965 in MODEL 163.175
Inspect
1Oil joint areas of throttle control, inspect for
ease of operation and wear Engine oil conforming to Specifications for
Operating Fluids sheet 226.0-228.3
(all except ) and 236.6/7/9 ( )

Inspect
1Slowly depress accelerator with your foot as
far as the stop and release again Pay attention to freedom of
movement. If any jolting is noticeable: ?
Replace accelerator control cable

Remove/install throttle control cable
Model 163.136 with Engine 111.977AR30.10-P-
3400GA
Model 163.113 with Engine
612.963,
Model 163.128 with Engine 628.963,

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY CAB Throttle Control, Speed Control Systems - 163 Chassis
me
Saturday, October 02, 2010 3:36:28 PMPage 37 © 2006 Mitchell Repair Information Company, LLC.