1997 MERCEDES-BENZ ML500 instrument cluster

Z36/1In rear bumper harness, near X35/28.
Z36/2In rear bumper harness, near X35/28.
Z36/3In front bumper harness, between breakouts to left
inner sensor & right inner sensor.
Z36/4In front bumper harness, between breakouts to left
inner sensor & right inner sensor.
Z42In passenger harness, near breakout to X18.
Z50/1In dash harness, behind instrument cluster, near
breakout to instrument cluster connector.
Z50/2In dash harness, center, near breakout to A/C
control module.
Z50/3In dash harness, near breakout to passenger harness
to dash harness connector.
Z50/4In dash harness, near breakout to icing sensor.
Z50/5In dash harness, behind instrument cluster, between
breakouts to parking brake switch & stoplight
switch.
Z50/6In dash harness, behind instrument cluster, near
breakout to instrument cluster connector.
Z50/8In dash harness, in breakout to starter switch.
Z50/9In dash harness, behind instrument cluster, between
breakouts to parking brake switch & stoplight
switch.
Z50/11In dash harness, behind instrument cluster, near
breakout to instrument cluster connector.
Z50/12In dash harness, behind instrument cluster, between
breakouts to parking brake switch & stoplight
switch.
Z50/13In dash harness, in breakout to starter switch.
Z50/14In dash harness, near breakout to parking brake
switch.
Z50/17In dash harness, near entrance to E-box.
Z50/18In dash harness, in breakout to data link connector.
Z50/20In dash harness, in E-box.
Z50/21In dash harness, near breakout to PTC heater relays.
Z50/22In dash harness, near breakout to PTC heater relays.
Z50/24In dash harness, near breakout to PTC heater.
Z50/26In dash harness, in breakout to combination switch.
Z50/27In dash harness, in breakout to combination switch.
Z50/28In dash harness, in E-box.
Z50/29In dash harness, near breakout to A/C control
module.
Z50/30In dash harness, near breakout to A/C control

2001 Mercedes-Benz ML320
2001 MERCEDES-BENZ ML320 & ML430
me
Saturday, October 02, 2010 3:21:17 PMPage 9 © 2006 Mitchell Repair Information Company, LLC.

module.
Z50/31In dash harness, in E-box.
Z50/32In dash harness, near breakout for center nozzle air
stream temperature sensor.
Z50/33In dash harness, in breakout to combination switch.
Z50/34In dash harness, behind instrument cluster, between
breakouts to parking brake switch & stoplight
switch.
Z51/1In passenger harness, in breakout to dash connector
X18.
Z51/2In passenger harness, in breakout to dash connector
X18.
Z51/3In passenger harness, in E-box.
Z51/4In passenger harness, in E-box.
Z51/5In passenger harness, near breakout for radio & SRS
control module.
Z51/6In passenger harness, in breakout to electronic
selector lever module control module.
Z51/7In passenger harness, in breakout to electronic
selector lever module control module.
Z51/8In passenger harness, under right side of dash.
Z51/9In passenger harness, near breakout to W18.
Z51/11In passenger harness, near breakout to radio & SRS
control module.
Z51/12In passenger harness, in breakout to radio.
Z51/13In passenger harness in engine compartment, in
breakout to engine control module connector C4.
Z51/14In passenger harness, in E-box.
Z51/15In passenger harness, near breakout to radio.
Z51/16In passenger harness, in breakout to X18.
Z52/1In passenger harness, near breakout to trailer
connector X52.
Z52/4In passenger harness, in main harness breakout for
left side of vehicle.
Z52/5In passenger harness, near breakout to tailgate
harness.
Z52/6In passenger harness, near breakout to tailgate
harness.
Z52/8In passenger harness, in main harness breakout for
left side of vehicle.
Z52/9In passenger harness, in main harness breakout for
right side of vehicle.
Z52/10In passenger harness, in breakout to dash connector

2001 Mercedes-Benz ML320
2001 MERCEDES-BENZ ML320 & ML430
me
Saturday, October 02, 2010 3:21:17 PMPage 10 © 2006 Mitchell Repair Information Company, LLC.

Test values for generator charge indicator lamp
CHECKING REGULATION VOLTAGE OF ALTERNATOR - AR15.40-P-5010GH
ENGINES 111.977, 112.942/970, 113.942/965/981, 612.963, 628.963 in MODEL 163
to vertical position As of A145273, X708319.AR88.40-P-1000GI
Testing
2Check electrical line
terminal 30 to the following
items for firm seat and
flawless conditionBattery (G1) (+)
Generator (G2)(B+)

3Check electric cable for
circuit 31 at the following
positions for correct seat
and conditionBattery (G1) (-)
Right major assemblies
compartment ground,
Common ground
(W16/4)
Engine ground
strap/body

4Inspect tension of poly V-
belt
5Inspect operation of charge
indicator in instrument
cluster *BE54.30-P-1001-01A
6Install in the reverse order
NumberDesignationModel 129, 163, 168,
170, 202, 203, 208, 210
BE54.30-P-1001-01APosition of ignition / glow
start switchCharge indicator lamp
Of
f
0/1
Charge indicator lamp On2

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 53 © 2006 Mitchell Repair Information Company, LLC.

GF00.20-P-2009A
Engine oil monitor function
24.10.96

MODEL
129 with ENGINE 112, 113

MODEL
163 with ENGINE 112, 113, 612

MODEL
168 with ENGINE 166, 668

MODEL
202 with ENGINE 112, 611

MODEL
208 up to 31.7.99 with ENGINE 112, 113

MODEL
210 up to 30.6.99 with ENGINE 112, 113, 611

General

The oil level is constantly monitored by the oil sensor, and the

appropriate data transmitted to the processor by the ASSYST.

Oil replenishments are detected automatically and result in a bonus,

which extends the service interval accordingly.

An excess oil level or insufficient oil level appears in the display

together with the oil can symbol.

Display of low oil level at maximum:
D
at driver request

Display of warnings: D
automatically, at the earliest 60 s after engine start and oil

temperature greater than 60°C:

D
if oil level too high: the oil can symbol appears together

with the readout "OIL LEVEL ABOVE MAX". In addition, a

brief warning signal sounds. (On models not fitted with

multifunction displaly, "HI" appears flashing.)

D
if oil level too low: the oil can symbol appears together with

the readout "OIL LEVEL BELOW MIN". In addition, a brief

warning signal sounds. (On models not fitted with multifunction

display, the oil level warning lamp (A1e12) comes on and the

readout "-2L" appears flashing.)

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

if oil at minimum: the oil can symbol appears together with

the readout "OIL LEVEL MINIMUM". In addition, a brief

warning signal sounds. (On models not fitted with multifunction

display, the oil level warning lamp (A1e12) comes on.)

D
automatically 13 s after ignition ON:

D
if
no oil
is in engine: the oil can symbol appears together

with the readout "OIL LEVEL BELOW MIN". In addition, a

warning signal sounds. (On models not fitted with multifunction

display, the oil level warning lamp (A1e12) comes on and the

readout "-2L"appears flashing. In addition a brief warning

signal sounds.)

The missing oil quantity displayed no longer changes during the

display. In other words, any change in oil level cannot be observed

directly at the display. The new oil level is only displayed once the

conditions described below exist.

Display of oil quantity at driver request

The text "DISPLAY OIL LEVEL?" appears 10 s after the start switch

has been turned into position "2" (on models not fitted with

multifunction display, the oil can and the clock symbol are displayed).

If the reset button of the trip counter is pressed twice within one sec.

during this readout, for example, "add 1.0L oil" (or "-1.0L")

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

appears in the display if oil level too low. The readout appears only

after the elapse of a waiting time after engine OFF. The waiting time

depends on the engine oil temperature.

It is

D
up to 20°C
30 minutes

D
from 60°C
1 minute

D
The waiting time is between these two limits at other engine oil

temperatures.

Possible readouts are (text in parenthesis relates to models not fitted

with multifunction display.):
D
"OIL LEVEL OKAY" ("o.k."),

D
1.0L, 1.5L, 2L,

D
"Overfilling" ("HI"),

D
"OBSERVE WAITING TIME" (clock symbol flashing and oil can

symbol),

D
"DISPLAY OIL LEVEL" (clock and oil can symbols.)

If there is a fault at the oil sensor (oil level/temperature/quality, B40)

the oil can symbol and the text "OIL LEVEL SENSOR FAULTY"

appears only 30 s after the fault has occurred.

(On models not fitted with multifunction display, the oil level warning

lamp (A1e12) comes on accordingly.)

For diagnosis, read also the injection system control module (N3)

with the HHT. (The instrument cluster (A1) receives the sensor data

through the CAN from the injection system control module (N3)).

-----------------------------------------------------------------------------------------
Oil change

The ASSYST has to be reset each time the oil is changed. Resetting

ASSYST also resets the remaining time and the remaining distance.

Resetting can be performed at the instrument cluster or using the

HHT.

The following data are stored when the system is reset:

D
current kilometer reading rounded off to 100,

D
total oil replenishments in the last interval,

D
remaining distance,

D
remaining time,

D
product of the quality factors,

D
the data of the last 5 resettings in 5 data sets

These data can only be read with the HHT!

If the specified quantity of oil is not replenished when the oil is

changed, the (internal) start distance is reduced.

Detecting oil replenishments
D
With the
HHT
it is possible to retrieve the last 10 oil

replenishments and the corresponding kilometer readings of

the current interval.

D
In the normal case, detection of an oil replenishment is

displayed by the remaining distance in the instrument cluster

being extended

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

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Page 1

Oil replenishments are always only detected once the following

conditions are met:

D
the replenished quantity is
at least 1 l

D
after replenishing the oil, the car must be driven a distance of
at

least 5 km
under
normal driving conditions
at an
oil

temperature of at least 60 °C
.

There are instances, however, in which the readout of the remaining

distance nevertheless appears implausible after replenishing oil;

according to the display, no bonus or only a small bonus has been

issued. This is caused by the fact that the remaining distance is

always only displayed within a range from 15 000 km up to 30 000

km (or 20 000 km up to 40 000 km in the case of engine 668), but

internally the system calculates with the actual values which may also

be beyond this range. These internal values can only be displayed

with the HHT.
In the charts overleaf, a number of examples of this are presented.
The horizontal (x) axis represents the service interval and the vertical

(y) axis is the remaining distance in each case in km.

The readout of ASSYST in the instrument cluster always moves

within the light range.

The remaining distance calculated internally may also, however, be

within the two dark ranges. These internal values can only be

displayed with the HHT.

All examples relate to gasoline engines fitted with an oil sensor.

P00.20-0201-06

Example 1 :

Sufficient oil was added during the oil change.

This means that the starting distance is 15

000 km.

After 10 000 km oil is topped up under normal

driving conditions (a). The bonus (B1) is

issued and displayed. What this means is that

when the remaining distance is retrieved, a

greater remaining distance is displayed.

(Provided the aforementioned conditions for

detecting the oil replenishment are met.)

Oil is topped up again after a further

5 000 km (b). In this case also a bonus (B2) is

issued and displayed.

If, after this, no further oil is topped up and

the car continues to be driven in the same

manner, a service interval of about

24 000 km is thus achieved.

In this example, the curve moves at all points

within the light range of the chart;

consequently, all the oil replenishments are

displayed by increasing the remaining

distance.

P00.20-0204-06

Example 2:

The specified quantity of oil was added when

the oil was changed.

The car is driven under very favorable

conditions and oil is topped up after

10 000 km (a). Internally, the bonus B1 is

issued, the service interval is extended

accordingly by enlarging the remaining

distance. However, as the curve is sometimes

within the shaded area, only the part of B1

which is within the light area, is at first

displayed as an extension of the remaining

distance. (Provided the aforementioned

conditions for detecting oil replenishment are

met.)

Oil is topped up once again at 18 000 km (b).

In view of the fact that the maximum service

interval of 30 000 km was exceeded, the

bonus B2 is not initially displayed as an

extension. The entire service interval in this

case is 30 000 km.

If, from point b, the car continues to be driven

under less favorable conditions, it may still

also be possible now to achieve the maximum

service interval of 30 000 km because of the

internal bonus B2.

Copyright DaimlerChrysler AG 05.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 2

P00.20-0202-06

Example 3:

When the oil was changed, the quantity

added was less than the specified quantity.

Consequently, the start distance is less than

15 000 km.

If oil is now topped up after 5 000 km (a), the

remaining distance displayed is not extended

as the curve is within the shaded area. The

bonus B1 is nevertheless added internally

and results in an extension of the service

interval to slightly more than

15 000 km - provided the driving conditions

remain the same or are more favorable.

(The service interval of 15 000 km is always

reached, however, even if the internal value

were less.)

P00.20-0203-06

Example 4:

Oil has been topped up after 5 000 km under

unfavorable driving conditions (a) and the oil

replenishment (bonus B1) detected internally.

We now have two cases to consider:

D
If the car continues to be driven under

the same conditions (unbroken line), the

remaining distance displayed is not

extended as the curve is within the

shaded area.

The service interval in this case is

nevertheless 15 000 km although the

internal value is less. (The remaining

distance displayed can always only be

within the light area.)

D
If the car continues to be operated

under more favorable conditions

(broken line), the value of the internal

remaining distance slowly moves into

the light area. Consequently, the service

interval may be greater than

15 000 km.


Active service system survey of display

facilities

GF00.20-P-0003-04A


Active service system technology/ influencing

variables

GF00.20-P-0003-05A


Active service system survey

model/engine/sensor/instrument cluster

GF00.20-P-0003-06A


Active service system (ASSYST) operating

instructions, resetting

GF00.20-P-0003-01A

Oil sensor position/task/function
Oil sensor position, task, function

GF18.40-P-4111A

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Page 3

AF80.57-P-6406A
Engine sometimes fails to start and fault message "Start Error" appear in the

instrument cluster
13.8.04

MODEL
163.136 /154 /172 #A as of 145273,

163.136 /154 /172 #X as of 708319,

163.113 /128 /157 /174 /175

Operation no. of operation texts or standard texts and flat rates

Category

Op. no.
Operation text

Time
Acc. no.
Code

P
541011
Perform quick test
004 WU
------

P
805030
Replace drive authorization system (DAS [FBS]) control unit

(after check)
006 WU
------

Damage code
Cause
Remedy

82 801 90

When the ignition is switched on (circuit

15), the engine control unit sends a start

enable request to the DAS [FBS] control unit.

If during this request circuit 15 is switched off

or interrupted before the DAS [FBS] control

unit could respond, the variable code sent the

first time is used again the next time circuit 15

is switched on, since the original request is

saved by the DAS [FBS] control.

1
Replace the DAS [FBS] control unit.

AR54.21-P-1300GH


The fault message "Start Error" appears

in instrument cluster.

When ordering a new control unit, please

specify the chassis number.

Parts ordering notes

Part no.

Designation
Quantity

163 545 07 16
FBS control unit
1

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Page 1

AF54.30-P-2064A
Fuel gauge not registering correctly after refueling vehicle
4.2.03

MODEL
163.### #A as of 221506 up to 364039,

163.### #X as of 734088 up to 777100

Operation no. of operation texts or standard texts and flat rates

Sector

Op. no.
Operation text

Time
Acc. no.
Code

P
023803
RECODE INSTRUMENT CLUSTER
003 WU/0.3 h
54 208 50
---

Damage Code
Cause
Remedy

Refuel recognition software may not

recognize incremental refueling (< 7 L).

In case of complaint
#

The fuel gauge operation defaults to back-

up mode, and continuously decreases last

stored sensor value based on consumption

data supplied via engine management. This

continues until either refuel recognition or

instrument cluster (A1) reset occurs (via

STAR Diagnosis or power disconnect).
Vehicles with 83 L fuel tank (as of MY2002)
are more susceptible to this condition.

This applies only to instrument clusters

(A1) with diagnostic version 3/05, 3/06,

and 3/07.
1
Connect STAR Diagnosis.

2
Under "Control module adaptations" in

"ICM" menu, set "Fuel tank characteristic

curve" from "Normal" to "Direct sensor

value".

DO NOT replace the instrument cluster

(A1) or fuel pump assembly (M3) for this

condition.

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1