1997 MERCEDES-BENZ ML320 engine

2
The fresh air openings, the windshield and the
front fenders must be generously masked off
before cleaning and preserving.
be determined by each workshop itself.
Masking is necessary in order to ensure that
no materials whatsoever, e.g. cold cleaning
solvent, wax or similar, penetrate inside the
car (difficult to clean).

3
The screw joint holding the brake fluid
reservoir must be masked off with adhesive
tape, which is to be removed again after
preservation of the engine compartment.

4
Mask off the ventilation hole for the
diaphragm chamber in the pressure control
valve in the cylinder head cover.
Engines 601, 602, 603
AP01.00-
P-8503-
01A
5
Cleaning is to be performed when the engine
is no hotter than hand-hot (at the exhaust)
using a demulsifying cold cleaning solvent
(short action time) and a high-pressure hot-
water cleaner, depending on how dirty the
engine is.
"Demulsifying" means that a mixture of oils
and greases in water separated in the oil
separator pipe.

6
When cleaning the component compartment
behind the engine compartment: Spray only as
much water as necessary under very low
pressure.Electronic control modul es must be covered
beforehand; any that become wet must be
dried afterwards.

7After washing/preserving the engineLubricate throttle cont rol linkage and check
for ease of movement and wear.
8
Preservation is to be performed only when the
engine compartment is dry and using properly
functioning commercially available
equipment.Only use approved wax preservation agents.
Airless devices produce the least
contamination.

9Do not spray the follow ing with preservation
wax:Electrical and electroni c components, belt
drive (belts and pulleys), exhaust pipe and
muffler in component compartment.


2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 153 © 2006 Mitchell Repair Information Company, LLC.

AR54.21-P-1200GH
Remove/install Extended-Activity-Module (EAM)
11.7.00

MODEL
163.136 /154 /172 #A as of 145273,

163.136 /154 /172 #X as of 708319,

163.113 /128 /157 /174 /175

P54.21-2098-06

1
Lock

2
Extended-Activity-Module (EAM)


Remove/install

1.1
Read out coding of Extended-Activity-Module

(EAM)

Only

when replacing the EAM and if it can

still be read out using STAR DIAGNOSIS.

2
Remove cover under the instrument panel (left)

AR68.10-P-1500GH

3
Loosen the lock (1) which secures the EAM in

the bracket

4
Remove the Extended-Activity-Module (EAM)

(2) downwards out of the bracket

5
Disconnect connectors

6
Remove drive authorization module

AR54.21-P-1300GH

7
Install in the reverse order

8.1
Code the EAM

Only

when installing a new EAM.

AR54.21-P-1200-01GH

9
Turn ignition key into position 1 and wait for

40 seconds before first starting the engine.

Copyright DaimlerChrysler AG 05.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AP18.00-P-0101-02Z
Extract engine oil

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e. g.)
Order number

WH58.30-Z-1007-16A
Engine oil extractor
Deutsche Tecalemit

Am Metallwerk 11

33659 Bielefeld

1.386950.2

P18.00-0019-01

Shown on Engine 104

1
Extract engine oil through the dipstick guide tube.

Perform only when engine is at normal operating temperature.

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR68.30-P-4010GHRemove/install paneling in footwell
9.4.97

MODELS
163.113 /128 /136 /154 /157 /172 /174 /175

P68.30-2266-01

1
Door sill molding cover

2
Door seal

3
Driver-side paneling

4
Passenger side paneling

5
Bolt

6
Engine hood release lever

7
Arresting mechanism

8
Fuse and relay box cover

9
Nut

P68.30-2267-01


Remove/install

1
Remove front door sill molding cover (1)

2
Unscrew screws from door sill molding on

rocker panel

Only two front screws.

3
Pull off door seal (2) in the area of driver's

side paneling (3) or front passenger's side

paneling (4)

4
Unscrew screw (5) for engine hood release

lever (6) on A-pillar

Driver's side only.

5
Unhook engine hood cable and remove

engine hood release lever (6)

Driver's side only.

6.1
Rotate locks (7) on the cover of the fuse and

relay box (8) 1/4 revolution counterclockwise

into the vertical position

As of 09.99. Passenger side only.

7.1
Pull back cover of fuse and relay box (8)

(arrow) and remove

As of 09.99. Passenger side only.

8.1
Unscrew nut (9)

As of 09.99. Passenger side only.

9
Unclip driver's side paneling (3) and front

passenger's side paneling (4) and remove

Lift door sill molding slightly to allow

removal.

10
Install in the reverse order

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

1998-2005 DRIVELINE/AXLES
Front Axle - 163 Chassis
TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: FRONT AXLE - AR33.00-Z-9163AA
MODEL 163
ATTACH ENGINE SUPPORT BRACKET AND RAISE ENGINE - AR33.10-P-0100-01BV
Workshop equipment
Removing and installing front axleMODELS
163.113 /128 /136 /154 /157 /172 /174 /175AR33.10-P-
0100GH
Remove/install rubber bushes of front
axle transmission mountingMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.10-P-
0120GH
Remove/install front axle halfMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.10-P-
0200GH
Remove/install front axle shaft flange
and double-row angular ball bearingMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0315GH
Checking follower joint of steering
knuckle mount (installed)MODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0426GH
Replace supporting jointMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0440GH
Removing and installing upper
wishboneMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0500GH
Remove/install lower wishboneMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0510GH
Replace front bearing of lower
wishboneMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0526GH
Removing and installing steering
knuckleMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.25-P-
0400GH
Remove/install front axle gearMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.30-P-
0525GH
Replace shaft seal on drive pinionMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.30-P-
0530GH
Remove/install radial shaft seal at front
axle gear of front axle shaftMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.30-P-
0545GH
Remove/install front axle shaftsMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.30-P-
0620GH
Replace rubber boots on front axle shaftMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.30-P-
0660GH
WE58.40-Z-1007-11AEngine lifting fixture

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:21 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.
me
Saturday, October 02, 2010 3:38:25 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.

The engine support bracket (1) is positioned with its support surfaces resting on the left and right-side
fenders' inside seams (arrows).
During installation it is important to proceed with caution to avoid damage to the vehicle paintwork.
1. Lift engine by the front suspension hook.
Shown on model 163 with engine 112.942
Fig. 1: Identifying Engine Support Bracket
- Shown On Model 163 With Engine 112.942
SUPPORTING FRONT AXLE CARRIER WITH INSPECTION PIT OR ASSEMBLY LIFT - AR33.10-P-0100-03GH
Workshop equipment
1. Support front axle with axle removal device (070) and inspection pit or assembly lift. Ensure that the
guide pin (arrow) is inserted in the front axle carrier.
Lower the front axle carefull
y; ensure that no cables and lines are trapped in between.
WE58.40-Z-1019-11ARemoval fixture for axles

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:21 PMPage 2 © 2006 Mitchell Repair Information Company, LLC.

brake hoses *BA42.10-P-1001-04A
Ring wrench socketFig. 5
5Unbolt propeller shaft at
flange on front axle
transmission *BA41.20-P-1001-01A
6Remove left and right
front springs AR32.20-P-0200GH
7.1Remove lower engine
compartment panelingModel
163.157 /172 /174 /175AR61.20-P-1105GH
Model 163.113/ 128AR94.30-P-5400GH
8Detach torsion bar (28) at
vehicle frame *BA32.20-P-1001-02G
9Detach upper transverse
control arm (6) from
vehicle frame Installation: Tighten
new nuts slightly. Tighten
bolt fully only when
vehicle is on its wheels and
ready to drive.
*BA33.20-P-1006-01D
10Detach bracket for oil
lines from transmission to
oil cooler on front axle
carrier
11Unclip brake line at rear
of front-axle
crossmember
12.1Remove vehicle level
controller connecting rod
(95b) at lower transverse
control arm on right Vehicles with xenon
headlamps.
13Extract fluid from power
steering pump reservoir Hand pumpFig. 6
14Turn steering wheel to
center position (front
wheels in straight-ahead
position) and secureThe steering wheel must
not be turned when the
steering coupling has been
removed. This will damage
the fanfare horns and airbag
clock spring contact
beyond repair.
Remove ignition key
and turn steering wheel so
that it locks.
15.1Detach plug-in connector
for speed-sensitive power
steering to timing case Vehicles with speed-
sensitive power steering
only.

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:21 PMPage 5 © 2006 Mitchell Repair Information Company, LLC.

Front axle carrier
Wheel control, hub
Front axle torsion strut
Propeller shaft of front axle gear
Use original bolts
only.
Do not position bolts
at an angle when
screwing in.
Do not use an impact
wrench.
Observe the
tightening torque.
*BA33.10-P-1001-01C
21Lower front axle carrier
(1), pushing all hoses to
one side Installation: Contact
surfaces of front axle
carrier to longitudinal
member must be cleaned
and flat.
Insert the locating pins of
the front axle carrier into
the holes in the side
member.
22Check front axle carrier
(1) for damage
23Install in the reverse order
24Fill power steering pump
and bleedEngine 112, 113AR46.30-P-0010B
Engine 111, 612AR46.30-P-0010P
25Bleed brake system AR42.10-P-0010GH
26Perform chassis
alignment AR40.20-P-0200GH
NumberDesignationModel Series 163
BA33.10-P-1001-01CBolt of front axle carrier to frameNm200
NumberDesignationModel Series 163
BA33.20-P-1006-01DBolt, upper transverse control arm to frameNm120
NumberDesignationModel Series 163
BA32.20-P-1001-02GBolt, retaining bracket to frameNm100
NumberDesignationModel Series 163

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:21 PMPage 7 © 2006 Mitchell Repair Information Company, LLC.