Mercedes-Benz Light Truck 2002 Installation and operation manual

Service Booklet
Light Truck

PLEASE NOTE
SERVICE, REPLACEMENT, OR REPAIR OF THE
EMISSION CONTROL DEVICES AND SYSTEMS MAY BE
PERFORMED BY ANY AUTOMOTIVE REPAIR ESTAB-
LISHMENT OR INDIVIDUAL USING CERTIFIED PARTS.
THE USE OF DEFECTIVE OR NON-EQUIVALENT PARTS
MAY RESULT IN YOUR EMISSION PERFORMANCE
WARRANTY CLAIM BEING DENIED.
WE STRONGLY RECOMMEND, HOWEVER, TO HAVE
YOUR VEHICLE SERVICED BY YOUR AUTHORIZED
MERCEDES-BENZ LIGHT TRUCK CENTER WHO IS FULLY
EQUIPPED TO PROVIDE THIS SERVICE.

1
Model
Vehicle Identification No.
Date of registration
Paint No.
License Plate No.
License Plate No.
License Plate No.
License Plate No.

2
Notes:

3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Emission System Maintenance . . . . . . . . . . . . . . . . . . . 7
Emission Control System Caution . . . . . . . . . . . . . . . . 8
System Records
Pre-deli ery Inspection Confirmation . . . . . . . . . . . . . . 9
Ser ice Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Required Vehicle Service Work . . . . . . . . . . . . . . . . . .20
A-Ser ice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
B-Ser ice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Additional Work to be Performed together with
the Respecti e Ser ice . . . . . . . . . . . . . . . . . . . . . . . . . .26
Spark plug replacement inter als . . . . . . . . . . . . . . . . .28
Description of Emission System
Maintenance Jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Contents

4
Introduction
We want you to enjoy your Mercedes-Benz automobile. Vehicle
safety and operational reliability are two ery important fac-
tors and to maintain them, a certain amount of ser ice and
maintenance is necessary. The Mercedes-Benz Flexible Ser-
ice System calls for all the necessary maintenance required
for your engine.
We continuously stri e to impro e our product, and ask for
your understanding that we reser e the right to make changes
in the required periodic maintenance work which is required
for our ehicles.
The ehicle comes equipped with the Flexible Ser ice System
(FSS) which e aluates engine temperature, oil le el, ehicle
speed, engine speed, distance dri en and the time elapsed
since your last ser ice. It determines when your ehicle needs
ser ice and alerts you well in ad ance. The next necessary
FSS ser ice is indicated in the instrument cluster.
There are two types of scheduled ser ices for your ehicle, a
(“minor” =) A-ser ice, and a (“major” =) B-ser ice.
Under normal circumstances the dri en distance between ser-
ices is an a erage of approximately 12 000 miles. Under most
circumstances, A and B-ser ices will be called for by FSS alter-
nati ely, i.e. A will follow B which will be followed by an A-ser-
ice.
Exception: A B-ser ice will be followed by another B-ser ice, if
the FSS calculates an oil change inter al of 14 000 miles or
more.
Following each A or B-ser ice your Mercedes-Benz Center will
reset the FSS counter. The next ser ice is indicated in the
instrument cluster (see chapter “Flexible Ser ice System” in
your Operator’s Manual).
Required ser ice work which is not calculated by the FSS is
listed in the section “Additional Work to be Performed” (see
page 26).
Wear items such as, but not limited to, engine belts, brake
discs, brake pads, brake pad wear sensors, clutch discs and
clutch pressure plates are not co ered by the Mercedes-Benz
Maintenance Commitment.
A detailed listing of maintenance procedures performed are
contained in this booklet, starting on page 21.

5
Special Service Requirements Beyond A- and B-Service
Brake luid should be replaced e ery two years, preferably in
the spring, see page 27. We recommend that you only use
brake fluid appro ed by Mercedes-Benz.
A reminder for the next scheduled brake fluid replacement is
affixed in the engine compartment.
Coolant should be checked for the proper concentration
before the start of the winter season (or once a year in hot
regions). Ha e the coolant (water/anticorrosion/antifreeze
mixture) replaced e ery three years, see page 27.
Dust ilter should be replaced at the scheduled B-ser ice.
Under se ere dust conditions, or with the Automatic Climate
Control frequently operating in the air recirculation mode, the
dust filter should be replaced correspondingly sooner.
Tire rotations should be performed in accordance with the
tire manufacturer’s recommendations in order to maximize
the useful life of the tires. In addition, tire rotation will be per-
formed as part of the B-ser ice on an if necessary basis.
MBUSA recommends that you follow your tire manufacturer’s
schedule for tire rotation, which is specific to the tires
installed as original equipment and most likely calls for tire
rotations more frequently than the rotations performed with
the B-ser ice. Tire rotation performed at other than a B-ser ice
is not co ered by the Mercedes-Benz Maintenance Commit-
ment. Please note that the useful life of tires will also ary
depending on tire type, speed rating, road surfaces, and indi-
idual dri ing style.
The per ormance o all scheduled service work is required
to maintain your vehicle in good operating condition and
is essential to keep your warranty valid. We strongly rec-
ommend that you have scheduled maintenance service as
well as all other repairs to your vehicle per ormed at an
authorized Mercedes-Benz Light Truck Center because
they are equipped with the tools, instruments, literature,
and trained personnel necessary or the correct and
proper per ormance o these jobs.
Spare Parts/Operating Materials
We recommend only the use of Genuine Mercedes-Benz parts
for ser ice and repairs, since they meet our specifications. It is
also important to only use fuels, lubricants and anticorrosion/
antifreeze coolant meeting factory specifications. Please refer
to the Factory Appro ed Ser ice Products booklet or see your
Mercedes-Benz Light Truck Center for more information on
this subject.

6
Routine Checks
In addition to the ser ices, we recommend that you check the
following items regularly (for example, weekly or each time
you fill up) and prior to any long trip:
• Engine oil level – at regular inter als (such as e ery fuel
stop)
• Coolant level - Please refer to the Operator’s Manual for the
correct procedure to check the coolant le el.
• Fluid level o brake system - If brake fluid has to be added,
see an authorized Mercedes-Benz Light Truck Center to
determine the cause, e.g. leaks or worn brake pads.
• Windshield washing system - If the washer fluid le el
drops below 1/3, the windshield washer fluid le el warning
lamp will illuminate. Add washer fluid mixed with Mer-
cedes-Benz windshield washer sol ent/concentrate, test
function and check wiper blades.
• Exterior lamps - check for proper function
• Tire pressure – at least e ery other week.
Recommended Synthetic Motor Oil
Mercedes-Benz recommends only the use of MB appro ed syn-
thetic motor oil for all ehicles equipped with the Flexible Ser-
ice System (FSS) as of Model Year 1998.
Con entional petroleum based oils are not recommended for
ehicles equipped with the Flexible Ser ice System.
Please refer to the Factory Appro ed Ser ice Products booklet
or see your Mercedes-Benz Light Truck Center for more infor-
mation on selecting the proper motor oil for your ehicle.
MB Appro ed Synthetic Engine oil MB Sheet
Mobil 1 Tri-Synthetic Formula 15W-50
Mobil 1 Tri-Synthetic Formula 0W-40
Val oline SynPower Full Synthetic Motor Oil 5W-40
Castrol Syntec 5W-50
Castrol Syntec 10W-40
Quaker State Full Synthetic European Formula 5W-40
Pennzoil Synthetic European 5W-40
76 P u re S y n t he t i c M o to r O i l 5 W - 40
Castrol TXT Softec Plus 5W-30
Shell Helix Ultra 5W-30
Shell Helix Ultra 5W-40
229.1
229.1
229.1
229.1
229.1
229.1
229.1
229.1
229.3
229.3
229.3

7
Service Records
Your authorized Mercedes-Benz Light Truck Center will certify
in the ser ice booklet the ser ices on your ehicle which it has
carried out.
The ser ice booklet does not record or reflect any repair work
that may ha e been performed to your ehicle. Please keep
those receipts with your ehicle records.
For information concerning warranty, see your Ser ice and
Warranty Information booklet.
Your authorized Mercedes-Benz Light Truck Center will gladly
furnish additional information on the maintenance of your
ehicle.
We extend our best wishes for many miles of safe, pleasurable
dri ing.
DAIMLERCHRYSLER AG
Emission System Maintenance
The U. S. En ironmental Protection Agency and, in California,
the Air Resources Board ha e certified that the emission con-
trol system of your ehicle meets exhaust emission standards
for 2002. This ehicle also complies with the Canadian Motor
Vehicle Emission Standards.
To be certain that the emission control system functions as
designed, regular maintenance is necessary for all compo-
nents of the ehicle which affect exhaust emission composi-
tion.
The ehicle owner is responsible for the regular maintenance
of the emission control system, as well as the use of premium
unleaded gasoline with an anti-knock index of at least 91
(displayed on the pump) in all models.
Refer to your Ser ice and Warranty Information booklet and
Operator’s Manual for additional information.
Failure to properly maintain the emission system may result in
repairs not being co ered by the emission systems warranty.
Explanations of each maintenance job are gi en in numerical
order on page 29.

8
Emission Control System Caution
Your Mercedes-Benz is equipped with both a three-way cata-
lyst and a closed loop oxygen sensor system to comply with
current exhaust emission regulations. Keep your ehicle in
proper operating condition by following our recommended
maintenance instructions as outlined.
The following has to be adhered to:
a. In all models, use only premium unleaded gasoline with
an anti-knock index o at least 91 (as displayed on the
pump). Damage to the engine could occur if premium
unleaded fuel is not used. Refer to the Operator’s Manual or
Factory Appro ed Ser ice Products booklet for special pre-
cautions.
b. Leaded gasoline should not be used under any circum-
stances. Damage to the emission control components will
result.
c. The speci ied engine maintenance jobs have to be per-
ormed completely and at the required intervals.
Correct ignition timing and properly functioning spark
plugs for instance are important for the ser ice life of the
catalysts. Failure to properly perform the specified mainte-
nance jobs may ad ersely affect the emission control sys-
tem on the ehicle and reduce its ser ice life.
d. The operation o the emission control system must not
be altered in any way. Alterations are not permissible by
law. In addition, alterations may result in damage to the cat-
alysts, increased fuel consumption and impaired engine
running conditions.
e. Irregular engine running conditions should be cor-
rected immediately by an authorized Mercedes-Benz
Light Truck Center. Such irregular running conditions can
influence the proper function of the emission control sys-
tem.
“CHECK ENGINE” indicator lamp in the instrument cluster: If
the lamp comes on when the engine is running, it indicates a
possible malfunction of the engine management system or
emission control system.
We recommend that you ha e the malfunction checked as soon
as possible.