2010 Mercedes Benz Truck ML 63 AMG (164.177) V8-6.3L (156.980)
Vehicle: All Technical Service Bulletins
Electrical - Battery Symbol + Service Required Displayed
MESSAGE IN INSTRUMENT CLUSTER: BATTERY SYMBOL = SERVICE REQUIRED (IN WHITE)
Themen-Number LI54.10-P-049567
Version 1
Konstruktionsgruppe 54.10 Battery, voltage supply, voltage converter
Stand 09-15-2010
Gultigkeit Model 164 affected as of VIN ...A308430 up to ... A107073
Model 251 affected as of VIN ...A063924 up to ... A107073
Anderungsgrund
Beanstandung:
Message in instrument cluster Battery symbol + Service Required (in white) is shown in the display.
Ursache:
Fault message is displayed if the charge level is too low or the park pawl additional battery is defective.
In addition fault code FC 9061 and/or FC 9062 is stored in the front SAM.
Abhilfe:
^ Installation of a DC/DC converter to increase the charging voltage of the park pawl additional battery.
^ Replace park pawl additional battery after check.
Notes
^ Work through the test steps as described in the DAS (Body - Front SAM - General listing of guided tests - Park pawl additional battery).
^ Do not replace the SAM.
^ The installation of the DC/DC converter supersedes the measure "software update for front SAM" for the chassis number range listed under
Validity.
^ The DC/DC converter can also be installed and operated if the software update has already been performed.
^ Refer to SI54.10-P-0025A when replacing the park pawl additional battery.
There are two different procedures for model 164 and model 251.
Procedure for model 164:
^ Work through the test steps as described in the DAS (Body, Front SAM, General listing of guided tests, Park pawl additional battery).
Procedure for installation of a DC/DC converter:
^ Remove vehicle battery, see AR 54.10-P-0005GZ.
Create access to front SAM control unit.
^ Remove cover of front SAM control unit by removing the right guide rail cover from the front passenger seat and folding back the floor covering
(carpet).
Use a suitable Torx driver T 25 to remove the Torx bolt (see Figure 1 A).
Note
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2010 Mercedes Benz Truck ML 63 AMG (164.177) V8-6.3L (156.980)
Depending on the production date, the cover of the front SAM may be additionally fastened with an expansion clip beside the Torx bolt but below
the plastic cover that is visible from above.
When the front SAM cover is removed, the two (or one) plastic locating pin(s) on the cover can break off.
^ Disconnect 40 pin connector (see Figure 2, B) on SAM and unclip the contact carrier on which pin 11 (pink line, circuit 15) is located (see Figure
2, C).
^ The slot for the 40-pin connector is marked in Figure 2 (D).
^ Detach pin 11 (pink line, circuit 15) from contact carrier.
Note:
To facilitate access to the 40-pin connector, unplug the connectors in front of it.
Installation of DC/DC converter
^ Connect unpinned pink line (circuit 15, see Figure 4, J) with connector of DC/DC converter, free slot 2 (see Figures 3 and 4, F).
^ Insert pin 1 (pink line, see Figure 4, E) from connector of DC/DC converter into slot of pin 11 of contact carrier and lock in place.
Note
In order to reliably connect the pink line (circuit 15) with the connector of the DC/DC converter, the connector should be disassembled to ensure that
the pin is installed in the correct position. Ensure that it is properly locked (see Figure 5, K).
^ Cover DC/DC converter with single-sided self-adhesive foam padding (see Figure 6, L) on the three long sides.
^ The DC/DC converter is fastened/clamped on the retaining clamp (Figure 7, M) of the park pawl additional battery so that the model plate is
legible (Figure 7, L).
^ Connect flat distributor connector cables of DC/DC converter with park pawl additional battery (red cable to positive terminal (Figure 7,1), brown
cable to negative terminal (Figure 7, H)).
^ Plug connection lines of park pawl additional battery onto flat distributor connector of DC/DC converter (red connector to positive terminal, black
connector to negative terminal).
^ Connect the plug coming from the DC/DC converter with the connector and use one-sided self-adhesive foam padding (see Figure B, 0) to
fasten it onto the front SAM (see Figure 8, N).
Note
When fastening the DC/DC converter and the associated connector, make sure that the connecting cables are not under tension.
When installing the protective cover of the front SAM control unit, make sure that none of the cables of the DC/DC converter are trapped.
Check DC/ DC converter for proper operation
Use Star Diagnosis (DAS) to check voltage of park pawl additional battery. Switch on ignition (wait 60 s).
Step 1: (Control units, Body, Front SAM, Actuations, Additional battery, Test of additional battery) Start routine # Result All actual values must be
OK.
Step 2: (Control units, Body, Front SAM, Actual values, On board electrical system, Additional battery) Specified value with engine running:
Voltage of additional battery U = 13.7...14.3 V.
Note
If the voltage (U = 13.7...14.3V) is not displayed, switch on ignition for approx. 5 minutes and then repeat the measurement from the beginning,
from step 1.
Procedure for model 251:
^ Work through the test steps as described in the DAS (Body, Front SAM, General listing of guided tests, Park pawl additional battery)
Procedure for installation of a DC/DC converter:
Create access to front SAM control unit
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2010 Mercedes Benz Truck ML 63 AMG (164.177) V8-6.3L (156.980)
^ Move front passenger seat all the way back and all the way up.
^ Unclip and pull out both seat rail bars of front passenger seat.
^ Remove door sill of front passenger door.
^ Remove floor covering (carpet) in front passenger footwell.
^ Remove impact absorber from front passenger footwell.
^ Unscrew protective cover in front passenger footwell.
^ Disconnect 40-pin connector (see Figure 9, B) on SAM and unclip the contact carrier on which pin 11 (pink line, circuit 15) is located (see Figure
9, C).
^ The slot for the 40-pin connector is marked in Figure 9 (D).
^ Detach pin 11 (pink line, circuit 15) from contact carrier.
Installation of DC/DC converter
^ Connect unpinned pink line (circuit 15 see Figure 4 J) with connector of DC/DC converter free slot 2 (see Figures 3 and 4 F).
^ Insert pin 1 (pink line see Figure 4 E) from connector of DC/DC converter into slot of pin 11 of contact carrier and lock in place.
Note:
In order to reliably connect the pink line (circuit 15) with the connector of the DC/DC converter, the connector should be disassembled to ensure that
the pin is installed in the correct position Ensure that it is properly locked (see Figure 5, K).
^ Fasten DC/DC converter (see Figure 10, L) with velcro strip (see Figure 10, P) and refer to Figure 11 L, for the ex act installation position.
^ Connect flat distributor connector cables of DC/DC converter with park pawl additional battery (red cable to positive terminal (see Figure 11 I),
brown cable to negative terminal (see Figure 11 H)).
^ Plug connection lines of park pawl additional battery (see Figure 11 Q) onto flat distributor connector of DC/DC converter (red connector to
positive terminal, black connector to negative terminal).
^ Connect the plug coming from the DC/DC converter with the connector and fasten to wiring harness with a cable tie.
Note:
When fastening the DC/DC converter and the associated connector, make sure that the connecting cables are not under tension.
Check DC/ DC converter for proper operation
^ Use Star Diagnosis (DAS) to check voltage of park pawl additional battery Switch on ignition (wait 60 s)
Step 1: (Control units, Body, Front SAM, Actuations, Additional battery, Test of additional battery) Start routine # Result: All actual values must be
OK.
Step 2: (Control units, Body, Front SAM, Actual values, On board electrical system, Additional battery) Specified value with engine running:
Voltage of additional battery U = 13.7...14.3 V.
Note:
If the voltage (U = 13.7...14.3 V) is not displayed. switch on ignition for approx. 5 minutes and then repeat the measurement from the beginning,
from step 1.
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2010 Mercedes Benz Truck ML 63 AMG (164.177) V8-6.3L (156.980)
Anhange
Symptome
Steuergerat / Fehlercode
Teile
Arbeitswerte
WIS-Referenzen
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2010 Mercedes Benz Truck ML 63 AMG (164.177) V8-6.3L (156.980)
Fastening of front SAM cover
Front SAM exposed
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2010 Mercedes Benz Truck ML 63 AMG (164.177) V8-6.3L (156.980)
Illustration of DC/DC converter
Installed DC/DC converter connector
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2010 Mercedes Benz Truck ML 63 AMG (164.177) V8-6.3L (156.980)
DC/DC converter connector
DC/DC converter with foam padding
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2010 Mercedes Benz Truck ML 63 AMG (164.177) V8-6.3L (156.980)
DC/DC converter installation position
Fastening of DC/DC converter connector
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2010 Mercedes Benz Truck ML 63 AMG (164.177) V8-6.3L (156.980)
Front SAM exposed_251
DC/DC converter fastening_251
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2010 Mercedes Benz Truck ML 63 AMG (164.177) V8-6.3L (156.980)
DC/DC converter installation position_251
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