Mercedes-Benz ML320. 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.

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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.

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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.

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163 589 01 07 00

Claw-type wrench

Pliers

163 589 00 37 00

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

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