Microsoft Word 1511 1638 02 01 E 164 DOC Cars complete vehicle M Class (164 model series) AKUBIS Initial training Cars • complete vehicle M Class (164 model series) AKUBIS Initial training r As at 05.
Trang 1Cars complete vehicle M-Class (164
model series) AKUBIS Initial training
Cars • complete vehicle
M-Class (164 model series)
AKUBIS
Initial training
Trang 2
This document is for training purposes only and is not subject to ongoing revision
Printed in Germany
© 2005 Copyright DaimlerChrysler AG
Publisher: Global Training
This document, including all its parts, is protected under the laws of copyright Any further processing or use
requires the previous written consent of DaimlerChrysler AG This applies in particular to reproduction, distribution,
alteration, translation, microfilming and storage and/or processing in electronic systems, including databases and
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Content I 1
Content 24.05.2005 Title Page Dimensional drawings 1
Model plates 3
Equipment packages 4
Seats 8
Fuse plan 11
Battery arrangement 14
Overall network: location of control units 16
Instrument cluster 21
Drive authorization system (DAS) 23
Central locking (ZV) 24
Anti-theft alarm system (ATA) 26
Vehicle climate control 27
Improved verification of repairs (VRV) 32
Engines 36
Walkaround 54
Wheels and tires 60
Brake system 61
Tire pressure monitoring system (TPM) 63
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Content I 2
Steering 66
Suspension 67
All-wheel drive system 76
Telematics 84
Vehicle shell 92
Supplemental restraint systems 97
NECK-PRO (special equipment) 106
Power liftgate 108
Removing and installing the instrument cluster 112
Emergency operation 113
Automatic transmissions with DIRECT SELECT 116
AKUBIS online 122
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P00.10-2724-00
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Permissible towing capacity, braked kg 3500 3500 3500 3500
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The vehicle identification number is located:
∗ on the crossmember under the right rear seat
bench In case of repairs, the vehicle
identification number must be stamped in
using the special stamping guide tool
∗ on the model plate on the lower left of the
B-pillar If it becomes damaged due to an
accident, it can be re-ordered
P60.00-2638-06
The model plates on the engine hood and the rear
right longitudinal member can not be re-ordered if
they are damaged in an accident
GT00_01_0042_C71 GT00_01_0043_C71
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Offroad styling package
∗ Complete underride guard in stainless steel,
front and rear
∗ Radiator grille with three radiator slats in
silver/chrome
GT88_20_0024_C71 GT88_20_0023_C71
Chrome package (standard for ML 500)
∗ Radiator grille painted black, features three
chrome-trim radiator slats
∗ Four trim strips on the doors with a light matt
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Sport package (exterior)
∗ Door handle in vehicle color and with a chrome
∗ Taillamps with a dark sport design
∗ Chrome-plated stainless steel tailpipe,
rectangular
∗ Scratch protection on rear bumper in chrome,
ribbed design
∗ 5-spoke 19" light alloy sport wheels
∗ All windows with heat-insulating blue glass
GT88_00_0022_C71 GT88_00_0023_C71
Sport package (interior)
∗ Lower half of the center console features a
high-gloss black aluminum overlay
∗ Upper half of the center console in high-gloss
black
∗ Sport pedals
∗ Electrically adjustable front sport seats
Upholstery features Alcantara/ARTICO
leather* and contrast stitching
∗ Sport instrument cluster
∗ Interior light package
GT68_00_0061_C71 GT68_00_0062_C71
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Interior equipment package
∗ 4 trim strips on upper door panels in burred
walnut veneer wood trim
∗ Lower half of the center console has a burred
walnut veneer wood trim
∗ Center console paneling in burred walnut trim
with chrome elements
∗ Leather upholstery
∗ Interior light package
∗ Electrically adjustable front seats
∗ Stowage compartment with cover
Trim parts package
"Fineline" bird's-eye maple paneling
∗ 4 trim strips on upper door panel
∗ lower half of the center console
∗ center console trim
GT68_00_0064_C71 GT68_00_0065_C71
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Interior light package
(only in combination with the Interior equipment and Sport packages)
∗ Illuminated and door handle recess in the front and rear
∗ Right liftgate marking lamp
∗ Ambient lamp in the liftgate
∗ Illuminated stowage compartment at the front of the center console
∗ Illuminated cupholder at the front of the center console
∗ Rear footwell illumination
AIRmatic package
∗ Front and rear air suspension with level control (+50 mm to –30 mm)
∗ Adaptive damping system (ADS)
Offroad Pro technical package
∗ Off-road reduction (Low Range) with shift on the move (can be selected while driving) and a gear ratio of 2.93:1
∗ Multiple disk limited-slip center differential with up to 100% locking capability
∗ Multiple disk limited-slip rear axle differential with up to 100% locking capability
∗ Mode selection (using the switch on the center console):
1 Automatic mode for center and rear axle differential locks
2 Manually lock center differential
3 Manually lock rear axle differential
∗ Underride guard
∗ Compass
∗ Front axle differential can be locked when brakes are activated by ETS
∗ Air suspension with a wider setting range (+30 mm compared to the AIRmatic package)
∗ Transmission control: automatic standard transmission mode "S" and manual transmission mode "M" (can be selected using the button)
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Electric front seats
∗ Electric front seats are standard equipment
and come with manual steering column
adjustment
Note: Power is supplied to the seat adjustment
once the driver door is opened
∗ Electric seats are also available as special
equipment with electric steering column
adjustment and memory
Note: Power is supplied to the seat adjustment
once the door is opened
∗ Move the seat backrest switch up or down to
adjust both head restraints
GT91_10_0051_C71 GT91_10_0052_C71
Electric seats with memory
∗ Each front seat has its own control unit (left N32/1, right N32/2)
∗ Each front seat has 3 seat position memories (set manually and saved by the user)
∗ The most recent seat position is also stored when the key is removed
∗ Easy entry and exit, as in other Mercedes-Benz model series
∗ The driver seat control module also stores the values of actuator motors for the steering column and
outside mirrors (controls the actuator motor on the steering column adjustment)
∗ The seat actuator motors must be normalized to use the seat position memory function
GT91_10_0050_C71
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Seat normalization
∗ To return to normal positions, move the seat into the following final position until the mechanical stop has been reached Then engage the switch a further
250 ms for:
− fore-and-aft adjustment: front stop
− inclination adjustment: down stop
− height adjustment: down stop
− backrest adjustment: front stop
− head restraint adjustment: down stop
∗ If the seat is used after normalization, the seat control unit shuts off the drive motor before the mechanical stop is reached
Note:
If a Hall sensor is malfunctioning, the seat control unit cancels the attempted adjustment function after 2 seconds The motor can only run in the respective direction once the switch has been released for a period longer than 2 seconds The motor is immediately fully functional in the opposite direction
Heated front seats
∗ Standard equipment in the ML500 (otherwise special equipment)
∗ Front seat switches are read in via the upper control panel (N72/1)
∗ Switch position message for the front signal acquisition and actuation module (N10) is sent via
CAN B
∗ Heated seat elements are supplied via the front signal acquisition and actuation module (N10)
depending on the switch position and/or time
Heat level / LED Heat output Duty cycle in (%) Operating time
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Front seat ventilation & heated rear seats
∗ Heating package available for model year 2007 as an equipment option
∗ Controlled by the heated seats control unit (N25/5)
∗ The upper (N72/1) and rear control panels (N72/2) read in the switch position and provides a
message for N25/5 to CAN B
∗ N25/5 supplies the rear seat heater elements with current and sends the control signals of the
electronic blower for front seat ventilation
Installation location: beneath the left rear seat
GT91_10_0049_C71
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at market launch all fuses to circuit 30
∗ Luggage compartment fuse and relay box (F4)
∗ Prefuse box (F32)
up to 5 prefuses (bolted version)
∗ Prefuse box (F33)
contains bolted and plugged prefuses
Note: Bolted prefuses must not be replaced
individually
∗ Engine compartment fuse and relay box (F58)
Fuse and relay assignment diagram located
beneath the folding wheel chock
P54.15-2726-09
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Prefuse plan
A32n1 Blower motor
A80 Intelligent servo module (ISM)
F3 Instrument panel fuse box
F4 Rear fuse and relay box
F32 Front prefuse box
F33 Battery compartment prefuse box
F58 Engine compartment fuse and relay box
G2 Alternator
M1 Starter
N2/7 ARCADE airbag control unit
N2/11 Weight sensing system (WSS)
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Jump starting, charging the battery
∗ The jump-starting/battery charging point is located in the engine compartment (red plastic cover)
∗ When charging the main battery at the workshop, the charger can be connected directly to the
jump-starting point
∗ To test the main battery, the Midtronics Tester MCR 717 must be connected directly to it (this
prevents inaccurate measurements caused by line resistance)
∗ The (charging) status of the additional battery G1/7 is monitored by the front SAM (N10) Discharged
additional batteries are recognized by the front SAM (N10) and shown on the instrument cluster's
multifunction display via CAN B
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The M-Class features a two-battery arrangement
∗ Installed underneath the front passenger seat:
− Main battery (G1) 12 V 95 Ah AGM battery
− Additional battery (G1/7) 12V 1.2 Ah
∗ The main battery is responsible for supplying the entire vehicle with
voltage (including starter power supply)
∗ Only one plastic cover needs to be removed to disconnect the batteries
∗ Also remove the ground plug for the additional battery at the main
negative terminal
GT54_10_0047_C81
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Additional battery (G1/7)
∗ If the main battery does not supply enough
voltage, the additional battery provides an
emergency supply for the intelligent servo
module ISM (A80)
∗ This ensures that the parking position is
engaged and that the drive authorization is
immobilized Drive authorization (shift
mechanism) can only be enabled using the
main battery
∗ The charging and the status of the additional
battery G1/7 is regulated by the front SAM
(N10)
∗ The instrument cluster displays an error
message for faulty or disconnected additional
battery
∗ When disconnecting the main battery, also
remove the ground plug for the additional
battery at the main negative terminal
GT54_10_0045_C71 GT54_10_0046_C71
∗ The N10 voltage supply to the G1/7 ensures
that:
− the battery status is checked
− the additional battery's charging status is
displayed
− the battery is charged
∗ The electronic ignition switch supplies voltage
to the ISM (A80m2) when:
− the main battery G1 fails to supply voltage
and the electronic ignition key is removed or
− the ignition is turned off and the driver door
is opened (only with Keyless Go)
G1/7 Additional battery A80 Intelligent servo module (ISM)
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Overall network: location of control units 16
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Overall network: location of control units 17
CAN bus Class B
1 Instrument cluster (IC)
2 Electronic ignition switch (EIS)
8 Automatic air conditioning operating unit (C-AAC))
9 Weight Sensing System (WSS)
10 Driver seat adjustment with memory (SCU-D)
11 Passenger seat adjustment with memory (SCU-FR)
12 Parktronic System (PTS)
13 Driver-side front door control unit (DCU-D)
14 Passenger-side front door control unit (DCU-FR)
15 Overhead control panel (OCP)
16 Upper control panel (UCP)
17 Liftgate remote locking (HFS)
18 Tire pressure monitoring system (TPM)
19 COMAND
20 Rear control panel (RCP)
LIN bus
8 Automatic air conditioning operating unit (C-AAC)
13 Driver-side front door control unit (DCU-D)
15 Overhead control panel (OCP)
16 Upper control panel (UCP)
18 Tire pressure monitoring system (TPM)
21 Steering column module (SCM)
CAN bus Class C
1 Instrument cluster (IC)
2 Electronic ignition switch (EIS)
4 Central gateway (CGW)
21 Steering column switch module (MRSM)
22 ARCADE airbag
23 Motor electronics (gasoline)
24 Motor electronics (diesel)
25 Intelligent servo module (ISM)
26 Air spring with adaptive damping system (ADS)
27 Electronic transmission control (NAG2)
28 Electronic stability program (ESP)
29 Headlamp range adjustment (HRA)
30 Left front reversible emergency tensioning retractor
31 Right front reversible emergency tensioning retractor
CAN bus Class D
35 Satellite Digital Audio Radio System (SDARS), USA only
36 Universal portable CTEL interface (UPCI)
37 Sound amplifier
DYNAMICS CAN
28 Electronic stability program (ESP)
38 Yaw rate sensor, ax and ay sensors
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Overall network: location of control units 18
Signal acquisition and actuation module (SAM)
The front and rear SAM control units take on multiple electric functions They are not directly connected to the fuse and relay modules, but are installed
separately, just like other control units
Main functions of the front SAM (N10)
∗ Front windshield wipers
∗ Front exterior lights (lights master)
∗ Front/rear windshield wiper pump (dual pump)
∗ Headlamp cleaning system
∗ Footwell lighting
∗ Spray nozzle heating
∗ Heated front seats (with timer control)
∗ Power windows on right and left rear doors
∗ Central locking system for the left rear door
∗ Monitoring and charging the additional battery G1/7
∗ Reading in switches and sensors
∗ Diagnosis and coding
GT54_21_0056_C81
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Overall network: location of control units 19
Main functions of the rear SAM (N10/8)
∗ Heated rear window
∗ Anti-theft alarm system
∗ Turn signal indicator (master)
∗ Central locking system for the left rear door and the fuel filler flap
(CLS master)
∗ Liftgate central locking and power closing
∗ Trailer recognition
∗ Trailer illumination (ECE/USA)
∗ Rear window wiper
∗ Right rear entrance illumination
∗ Rear-end door and load compartment illumination
∗ Right and left vent windows (X164)
∗ Electric load compartment floor (X164)
∗ Diagnosis and coding
P46.15-2188-01
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Overall network: location of control units 20
Overview
Compared to its predecessor, the W163, the W164 makes use of a variety of communication networks, most of them already familiar from other Mercedes-Benz passenger car models
The entire communication network in the W164 consists of:
∗ CAN C (CAN engine)
∗ CAN B (CAN interior compartment)
∗ CAN D (CAN diagnosis)
∗ CAN S (Sensor CAN or Dynamic CAN) (Yaw sensor/Lateral acceleration sensor)
∗ MOST bus
∗ Local Interconnect Network (LIN bus)
∗ Private bus (e.g headlamp range adjustment)
Central gateway (N93)
Installation location: beneath the left front seat
Tasks:
∗ CAN B master
∗ Vehicle variant codings
∗ Gateway between CAN C and CAN B
∗ CAN status diagnosis (system diagnosis)
∗ Interface between CAN C and CAN D
∗ Interface between CAN B and CAN D
P00.19-3294-04
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∗ Fuel level indicator
As in many other passenger model series, several
functions and displays can be regulated and
accessed by pressing the buttons on the
multifunction steering wheel and display
GT54_30_0101_C75
Maintenance system
The instrument cluster displays the Assyst Plus data stored in the central gateway, i.e the instrument cluster displays the customer service codes "A-G"
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Menu navigation
Pressing the buttons on the multifunction steering
wheel allows maintenance data to be selected,
read out to the display, and confirmed or reset if
so desired
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Function
No mechanical gearshift linkages have been installed on the W164 Instead, the “Intelligent Servo Module” (A80) was installed and takes over gear selection (“Shift by Wire”)
The new ISM (A80) component of the drive authorization replaces the manual steering wheel lock of the predecessor, the 163
The ISM (A80) enables the standard shifting operations of P-R-D and N as well as engaging the parking position (towing protection) if the electronic ignition key
is removed or the front door is opened using Keyless Go
The electronically generated code is first recognized by the electronic ignition switch (DAS master) and is then relayed to the:
∗ engine control unit
∗ electronic transmission control module
∗ intelligent servo module
∗ Linked to CAN-B and CAN-C
∗ Supplementary battery connection to
the intelligent servo module (ISM)
(key function ‘P’)
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Arrangement of components
P80.20—275509
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Features
∗ Electronic transmitter key with radio and infrared function (DAS3, RoW 433 MHz)
∗ RF antenna integrated into the antenna module
∗ Electric actuator motors in every door, the liftgate, and the fuel filler flap
∗ Can be set for global or selected unlocking
∗ Automatic locking set to vehicle speed:
∗ Locks at 15 km/h
∗ Liftgate cannot be opened at speeds faster than 3 km/h
∗ Relocking after ∼ 40 seconds (when door/doors is/are not opened after being unlocked)
∗ Emergency unlocking via SRS after airbags and/or emergency tensioning retractors have been deployed
∗ Liftgate opens and closes using an electronic key (if the vehicle is equipped with an automatic liftgate)
∗ Turn signal indicator indicates locked or unlocked status: ± = 3 flashes ² = 1 flash
Operation
Only the driver door has an infrared receiver
(A26/1) and a mechanical lock cylinder for
emergency unlocking
Each front door has a lock-unlock button in front
of the inside door release The switch is read by
the respective door control unit The subsequent
message is forwarded to CAN-B
If the vehicle is equipped with Keyless Go and an
automatic liftgate, an additional locking button is
located on the underside of the liftgate (S62/26)
The switch is read out by the automatic liftgate
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The anti-theft alarm system (ATA) (code 551) monitors the status of the alarm inputs and evaluates them
The following are monitored:
∗ Doors, the engine hood, and the liftgate
∗ Interior and
∗ Vehicle position
A change in the vehicle's parking state activates a country-specific visual and acoustic alarm
Special equipment for interior protection (code 882)
via the ultrasonic sensor in the overhead control panel (OCP [DBE]) The following are monitored:
∗ Left rear window glass breakage sensor (B39), side window
∗ Right rear window glass breakage sensor, (B39/1), side window
∗ Rear window glass breakage sensor (B39/4), rear window
∗ Ultrasonic sensors CDBE
Alarm triggering
Alarm types and lengths differ greatly from country to country Using STAR Diagnosis, the alarms can be
coded from options provided for the rear SAM and the central gateway
ATA activation
The anti-theft alarm system (ATA) is activated and deactivated by locking or unlocking the vehicle using
the transmitter key (A8/1) (radio/infrared hand transmitter or Keyless Go)
Once the ATA has been activated, the LED in the UCP control unit (N72/1) will flash intermittently
Activation takes 10 seconds Activation of the interior protection takes an additional 30 seconds
GT80_50_0014_C03
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Thermatic air conditioning
(standard)
Dual-zone air conditioning
without a rear booster blower
GT83_30_0003_C01 GT83_30_0004_C01
Comfort Thermotronic air
conditioning
(code 581)
Tri-zone air conditioning with
a rear booster blower
GT83_30_0005_C01 GT83_30_0006_C01
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Dust and combination filter
The dust or combination filters are located behind
the glove box
∗ The glove box must be removed in order to
exchange the filters
∗ Push aside and remove the filter cover
∗ To exchange the filter, remove the first
element, then shift the second one over and
likewise remove it
∗ To avoid whistling sounds and reduce the
speed of outlet air, make sure the filter cover
is properly seated once the filters have been
exchanged
P83.00-2161-05
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Interior air outlet temperature sensor
∗ NTC sensor type
∗ Connected directly to the climate control
control and operating unit
∗ Located as close as possible to the outlet to
ensure precise temperature measurement of
outlet air
B10/31 Left side temperature sensor
B10/32 Right side temperature sensor
B10/33 Center left temperature sensor
B10/34 Center right temperature sensor
B10/35 Left footwell temperature sensor
B10/36 Right footwell temperature sensor
P83.30-4147-09
∗ The interior temperature sensor (N22/b1) is located on the climate control control and operating
unit (1), below the left temperature dial buttons
∗ The control module regulates the temperature according to the Energy Requirement Level-System
(ERL)
∗ As a rule, temperature is regulated according to a programmed performance map
∗ The interior temperature sensor provides various inputs, e.g the interior temperature when the
vehicle is started, during driving, and during the first 30 minutes after shut down It even recognizes
heat radiation through the sunroof
∗ This provides the automatic air conditioning (AAC) control unit with a starting point to regulate the
temperature Sensors on the vent outlet check if the outlet temperature meets the requirements of
the control unit
GT83_30_0002_C01
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The sun sensor (B32) or the dual sun sensor
(B32/3, Thermotronic only) is located on the
centerfill loudspeaker trim
P83.57-2087-04
The pollutant sensor (air quality) (B31) is located
on the fresh air intake duct below the right side of
the engine hood (Thermotronic only)
GT83_30_0007_C01
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Dew point sensor (B11/12)
∗ Measures the moisture of incoming air and
calculates the dew point
∗ Installed between the blower motor and the
heater housing
∗ Connected to the climate control control and
operating unit via LIN bus
∗ The dew point is used to regulate the air
conditioning compressor It is shared with the
door control units via CAN B to regulate
mirror heating
P83.30-4152-04
Rear air conditioner housing
If the vehicle is equipped with Thermatic, the housing has only one actuator motor for the rear air
distribution flap
Vehicles equipped with Thermotronic also have the following integrated components:
1 Actuator motor for rear air distribution flap
B10/7 Rear air temperature sensor
N29/2 Rear booster blower regulator
M2/1 Rear booster blower
GT83_50_0011_C71
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Improved verification of repairs (VRV) 32
VRV: overview and background
A new project was launched in light of the rising costs of repairs under
warranty and repeated visits for the same complaint The project aims to
uncover causes and provide concrete solutions
Target:
Increase customer satisfaction
Reduce warranty costs
This project is known as “Fixed First Visit”
One of the solutions which emerged from the project concerned improving
STAR Diagnosis (DAS) These improvements are implemented parallel to
the W164 introduction
In many cases, these changes will appear for the first time during
diagnosis of the newly developed or modified control units installed in the
It is still possible to select fault codes which then provide guided tests, actuations, or specific conditions to the code to be checked
If these test conditions are met and all faults have been remedied, the fault code either converts to a stored event or disappears from the displayed DAS list
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Improved verification of repairs (VRV) 33
Quick test with function view
This extended DAS feature makes troubleshooting more efficient by:
∗ displaying malfunctions after evaluating all of the control unit fault codes
(Cross references to customer complaints can be inserted here.)
∗ accessing conducted tests directly
∗ providing any existing links to service information (SI) or updated
troubleshooting documents (AF)
∗ displaying control units affected by malfunctions
Deleting faults
These extended DAS features allow faults to be deleted only after:
∗ performing DAS troubleshooting
∗ carrying out required steps
∗ and their DAS confirmation
If a fault has produced more than one fault code, remedying the specific fault
allows all of its resulting fault codes to be deleted When working on a vehicle,
∗ The creation of new faults should be prevented
∗ The processing of the fault should always be completed
GT00_00_0433_C11
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Improved verification of repairs (VRV) 34
VRV-enabled control units
In conjuction with the DAS release in March 2005, the following control
units will be VRV-enabled for the W164 launch:
∗ OCP Overhead control panel
∗ EIS Electronic ignition switch
∗ IC Instrument cluster
∗ AAC, C-AAC Automatic air conditioning
∗ DCU LF Left front door control unit
∗ DCU RF Right front door control unit
∗ CM Compass module
∗ RCP Rear control panel
∗ KG Keyless Go control unit
∗ TPM Tire pressure monitor
∗ Sound system
∗ ESA-RF Right front electric seat adjustment
∗ ESA-LF Left front electric seat adjustment
Notes on replacing the instrument cluster
Replacing the instrument cluster requires comprehensive coding
Codings must be carried out according to the SCN coding principle
SCN online coding was developed to increase process reliability during this
comprehensive coding The W164 ist the first model to use SCN online
coding
Control unit flashing
Software in an increasing number of control units can be updated by flashing This substantially reduces repair costs The following control units can be flashed:
∗ Instrument cluster (A1)
∗ Front SAM (N10)
∗ Rear SAM (N10/8)
∗ Climate control control and operating unit (N22)
∗ ESP control unit (N47/5)
∗ COMAND (A40/3)
∗ Electronic engine control unit (N3/10)
∗ Central gateway (N93)
∗ New Automatic Transmission 2 control unit (N15/11)
∗ Dual-mode TELEAID (N123/4) (USA only)
∗ Sound amplifier control unit (N40/3)
Note:
Flashing with STAR Diagnosis no longer requires a flash CD
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Improved verification of repairs (VRV) 35
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