Mercedes-Benz ML320. Service manual - part 491

 

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Mercedes-Benz ML320. Service manual - part 491

 

 

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 recorded by Modification services.

Page 1

AR47.10-P-7000GI

Remove/install fuel level sensor

21.2.01

MODEL 

163.113 with ENGINE 612.963

MODEL 

163.128 with ENGINE 628.963

P47.10-2128-06

1

Rear seat console

2

Left C-pillar cover

4

Wiring harness

5

Seat retaining cable

P47.10-2083-09

3

Housing

84

Closing cover

89 

Union nut

6

Seal

90/10

Fuel intake line

90/11

Fuel-return line

90/12

Fuel feed line

90/13

Stationary heater connection

B4

Fuel level gage sensor

  

Remove, Install

 Danger!

Risk of explosion from fuel igniting, risk of 
poisoning
 from inhaling and swallowing fuel 
as well as risk of injury to eyes and skin 
from contact with fuel.

Fire, sparks, naked flame and smoking 
prohibited.
Pour fuels only into suitable and appropriately 
marked containers

Wear protective clothing when handling fuel

AS47.00-Z-0001-01A

1

Drain fuel

 Fuel tank must not be filled to more than 

3/4. If fuel tank is full, drain at least 
23 liters of fuel.

AR47.10-P-4000GH

 Pay attention to filling capacity of fuel tank. *BF47.10-P-1001-01A

Copyright DaimlerChrysler AG  28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services.

Page 1

2

Remove covers at seat frame of 60% bench 
seat

 As of VIN A145273, X708319.

AR91.12-P-1100GH

 Only remove the covers which are 

identified in the document with A, D and E.

3

Fold 60% bench seat forward into footwell

 As of VIN A145273, X708319. See 

operator's manual.

4

Pull floor covering below rear seat mounting 
bracket (1) of 60% seat forward

 Ensure that the floor covering is not torn 

when pulled forward.

 As of VIN A145273, X708319.

5

Pull floor covering below front corner of trim 
panel of C-pillar (2) forward

 Ensure that the floor covering is not torn 

when pulled forward.

 As of VIN A145273, X708319.

6

Cut into floor covering directly behind seat 
retaining cable (5)

 Ensure that the wiring harness (4) is not 

damaged when cutting into floor covering.

 As of VIN A145273, X708319. broken line 

marks cut-in.

7

Turn back floor covering to gain access to 
cap (84) 

 

Do not kink floor covering.

8

Remove cap (84)

 

Cap (84) is sealed in with body sealer. 

Heat with hot air blower to make it easier to 
remove.

 

Installation: Replace cap and install with 

new sealing compound.

9

Detach fuel feed line (90/12) and fuel return 
line (90/11) and, if fitted, the fuel line at 
connection (90/13)

 

Do not kink the fuel lines.

 

If no stationary heater is fitted to vehicle, 

do not remove connection (90/13) otherwise 
housing will be damaged.

*163589003700

10

Remove nut (89)

*163589010700

 

*BA47.20-P-1006-01B

11

Remove housing (3)

 Fuel lever sensor and housing are a 

single part and cannot be removed separately.

 

Installation: Re-install nut (89) together 

with seal (89/2).
Apply a thin film of oil to seal.

12

Install in the reverse order

 

Fuel pump

Number

Designation

Engine 612 Engine 628

BA47.20-P-1006-01B

Union nut for fuel tank sensor on fuel 
tank

Nm

65

65

 

Fuel tank

Number

Designation

Models 
163.113/
136/154/
172 up to 
31.08.01

Model 
163.113/
136/154/
172 as of 
01.09.01 
Model 
163.157/
175

Model 
163.128

BF47.10-P-1001-01A

Fuel tank capacity Total capacity

Liter

72

83

83

Reserve capacity

Liter

10

12

12

Copyright DaimlerChrysler AG  28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services.

Page 2

163 589 01 07 00

Claw-type wrench

Pliers

163 589 00 37 00

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Page 3

 

 

 

 

 

 

 

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