1997 MERCEDES-BENZ ML320 engine

Risk of explosion
Spray cans (engine compartment preservative, paints, etc.) are pressurized and can explode when heated up to
above 50°C.
Safety instructions/precautions
Protect cans from direct sunlight and temperatures above 50°C. Do not drill or burn the can after use.
Only use in well ventilated areas, wear respiratory protection if necessary.
RISK OF POISONING & RISK OF INJURY - AS00.00-Z-0016-01A
Wear respiratory protection, protective gloves and safety glasses. Only pour glue into suitable and
appropriately marked containers.
Potential risks
Risk of poisoning
When glue vapors are inhaled , the respiratory system could be damaged because even small amounts of the
substances contained in some types of glues can attack the mucous membranes.
Swallowing glue can cause poisoning symptoms such as headaches, dizziness, cramps, stomach aches,
vomiting, respiratory paralysis and unconsciousness. Moreover, irritation may occur to the respiratory paths and
eyes.
Risk of injury
Most adhesives can glue limbs and eyelids as well as cause severe irritation to skin and eyes.
Safety precautions/instructions
Before applying adhesives, ensure that you have complied with all use and safety instructions; obtain the
safety data sheet from the manufacturer if required.
Perform gluing work only in well ventilated rooms.
No fire, sparks, open flames or smoking.
Wear protective gloves and eye protection, if necessary respiratory protection and protective clothing.
Do not fill glue into beverage cups
Store glue where it is not accessible for unauthorized persons.
First aid measures
Eye contact
Immediately rinse eyes thoroughly with running, lukewarm water and contact a physician.

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 226 © 2006 Mitchell Repair Information Company, LLC.

Skin contact
Remove moistened clothing.
Immediately wash affected skin areas with warm water and soap.
Swallowed glue
Rinse out mouth Drink large quantity of water.
Contact physician or medical service.
INJURY HAZARD OF CUTTING OR SCRAPING ON SHARP VEHICLE PARTS - AS00.00-Z-0017-01A
When working on or in the area of sharp vehicle parts with burrs always wear protective gloves. Deburr
repair panels.
Injury hazard
When working on body, superstructure, assembly and chassis parts which cannot be or are not yet deburred due
to the production procedure or processing stage, injuries are possible from cutting, scratching or scraping
against the burr.
Rules of behavior/protective measures
Wear protective gloves.
Deburr repair panels and processed cut edges.
RISK OF DEATH CAUSED BY BODY PARTS BEING PULLED IN BY ROTATING VEHICLE WHEELS AND ROLLER
DYNAMOMETER ROLLERS - AS00.00-Z-0019-01A
Do not insert your hand into rotating parts. Wear closed and snug-fitting work clothes. Safeguard areas
with rotating vehicle parts and dynamometer rollers against unauthorized access. Safeguard roller
dynamometer from unauthorized access.
Risk of death
Rotating parts in and around the running engine and the drive train as well as rotating dynamometer rollers and
vehicle wheels can cause serious injury .
When performing operations on the roller dynamometer, appropriate shielding (barriers, safety guards) must be
used to protect blind hazard zones from unauthorized access.
Safety instructions/precautions
Always observe the general safety rules for roller dynamometer operation.
Wear closed and close-fitting work clothes.
Remove all items of jewelry (chains, rings, etc.).

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 227 © 2006 Mitchell Repair Information Company, LLC.

coming into contact with
components of a 220 V
system
Risk of death caused by
work performed on
liquefied gas systemsMODEL allAS00.00-Z-0022-01A
Risk of injury. Skin or eye
injuries may result when
handling hot or glowing
objects.MODEL allAS00.00-Z-0002-01A
Risk of injury when
handling liquid nitrogen or
from touching extremely
cool objects. Risk of
asphyxiation from inhaling
nitrogen gas.MODEL allAS00.00-Z-0003-01A
Risk of death. Death may
occur if body parts are
drawn into rotating vehicle
parts.MODEL allAS00.00-Z-0004-01A
Risk of accident as vehicle
may start off by itself with
the engine running. Risk of
injury as working around
the engine during start-up or
while running may result in
contusions and burnsMODEL allAS00.00-Z-0005-01A
Risk of injury caused by
drilling gas-filled
assemblies or components
(noncombustible gases)MODEL allAS00.00-Z-0006-01A
The high voltage used for
arc welding presents a lethal
hazard. Explosion hazard
when welding in the area of
highly combustible
materials. Risk of injury
from weld splatter and UV
light when welding. Risk of
poisoning when inhaling
welding vapors.MODEL allAS00.00-Z-0007-01A
Risk of accident caused by
vehicle starting off on its
own when jacked up. Risk
of injury caused by rotating
parts when working on MODEL 906, 613, 671,
171, 203, 209, 164, 169,
219, 245, 251AS00.00-Z-0008-01A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 232 © 2006 Mitchell Repair Information Company, LLC.

running engine or drive
train.
Risk of injury. Moving parts
can pinch, crush or, in
extreme cases even sever
extremities.MODEL allAS00.00-Z-0009-01A
Risk of injury caused by
fingers being jammed or
pinched when removing,
installing or aligning hoods,
doors, trunk lid/rear-end
door or sliding roof.MODEL allAS00.00-Z-0011-01A
Risk of injury from fingers
being pinched or jammed
when working on gas struts
under pressureMODEL allAS00.00-Z-0012-01A
Risk of injury to skin or
eyes from hydraulic fluid
spraying out under pressure.
Risk of poisoning from
swallowing hydraulic fluid.MODEL allAS00.00-Z-0013-01A
Risk of injury. Rubber
mounts and bearing parts
can suddenly come loose
during installation/ removal
and shoot wildly through
the air.MODEL allAS00.00-Z-0014-01A
Risk of explosion from
pressurized spray cansMODEL 100, 107, 108,
109, 111, 112, 113, 114,
115, 116, 123, 124, 126,
129, 140, 163, 168, 170,
201, 202, 208, 210, 215,
216, 220, 221, 251 ...AS00.00-Z-0015-01A
Risk of poisoning caused by
inhaling vapors or
swallowing adhesive. Risk
of injury caused by glue
coming into contact with
skin and eyesMODEL 163, 169, 199,
204, 209, 211, 215, 216,
219, 221, 240, 245, 397,
461, 463, 613, 638, 639,
671, 684, 901, 902, 903,
904 ...AS00.00-Z-0016-01A
Injury hazard of cutting or
scraping on sharp vehicle
partsMODEL allAS00.00-Z-0017-01A
Risk of explosion caused by
escaping natural gas or an
overheated compressed-gas
tanks when working on MODEL 901, 902, 903,
904, 957.AS00.00-Z-0018-01A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 233 © 2006 Mitchell Repair Information Company, LLC.

natural gas powered
vehicles. Risk of frostbite to
body parts caused by
escaping natural gas or
contact with components
near the valves when
draining compressed-gas
tanks. Risk of poisoning or
suffocation caused by
inhaling natural gas. 6/07
G/02/07. This WIS printout
will not be recorded by the
updateservice.
Risk of explosion caused by
liquefied petroleum gas
escaping or pressurized gas
reservoirs overheating when
working on vehicles
operated with liquefied
petroleum gas. Risk of
frostbite to body parts
caused by liquefied
petroleum gas exiting under
pressure. Risk of poisoning
or risk of suffocation caused
by inhaling liquefied
petroleum gas.ENGINE 111.984 For
Fluid Gas ConcernAS00.00-Z-0023-01A
Risk of injury caused by
burns to skin and eyes. Risk
of poisoning caused by
inhaling fumes when
working with heat-
shrinkable tubing.MODEL 124, 126, 129,
140, 163, 164, 168, 169,
170, 171, 199, 202, 203,
204, 208, 209, 210, 211,
215, 216, 219, 220, 221,
230, 240, 245, 251, 374,
375, 414, 450, 454, 461,
463, 638, 690, 901, 902,
903, 904, 905, 930, 932,
933, 934, 940, 942, 943,
944, 950, 952, 953, 954,
957, 958, 970, 972, 974,
975, 976 ...AS00.19-Z-0001-01A
Risk of injury caused by
burns to skin and eyes, risk
of poisoning caused by
inhaling fumes during
soldering.MODEL 124, 126, 129,
140, 163, 164, 168, 169,
170, 171, 199, 202, 203,
208, 209, 210, 211, 215,
216, 219, 220, 221, 230,
240, 245, 251, 414, 461,
463...AS00.19-Z-0002-01A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 234 © 2006 Mitchell Repair Information Company, LLC.

211, 215, 216, 219, 220, 221,
230, 240, 245, 251, 414, 461
as of 1.4.94, 463
Assessment of damage
in wiring harnessesModel 124, 126, 129, 140,
163, 164, 168, 169, 170, 171,
199, 202, 203, 208, 209, 210,
211, 215, 216, 219, 220, 221,
230, 240, 245, 251, 414, 461,
463AH00.19-P-1000-05A
Assessment of airbag
and belt tensioner units
in accident vehiclesModel 129, 202 up to 30.6.93
Model 124, 126, 140AH91.00-P-0006-01A
Assessment of airbag
and belt tensioner units
in accident vehiclesModel 129 as of 1.7.93, 163,
164, 168, 169, 170, 171, 199,
202 as of 1.7.93, 203, 208,
209, 210, 211, 215, 216, 219,
220, 221, 230, 240, 245, 251,
414, 461 as of 1.4.94, 463,
638, 901, 902, 903, 904, 905,
906, WD1, WD2, WD3, WD6,
WD7, XD1, XD2, XD3, XD4,
XD5, XD6, XD7, YD1, YD2,
YD3, YD4, YD5, YD6, YD7AH91.00-P-0006-01B
Notes regarding plug
connections AH00.19-P-1000-06A
Advantages of repairing
wiring harnesses AH00.19-P-1000-03A
Repair methods for
wiring harnesses AH00.19-P-1000-04A
Repair supplemental
restraint system (SRS)
squib wiring harnessModel 124, 129, 140, 163,
164, 168, 169, 170, 171, 202,
203, 208, 209, 210, 211, 215,
216, 219, 220, 221, 230, 240,
245, 251, 414, 461 as of
1.4.94, 463
Model 126 with code 291
Airbag for driver and front
passenger (for front passenger
only if driver airbag standard)
Model 126 with code 442
Airbag in steering wheelAR54.18-P-0600A
Repairing wiring
harnessModel 168.031 ## up to
180747 with engine 166.940
Engine wiring harness at body
side
Model 168.033 ## up to AR54.18-P-0100GF

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 247 © 2006 Mitchell Repair Information Company, LLC.

180747 with engine 166.960
Engine wiring harness at body
side
Repairing wiring
harnessModel 168.007 with engine
668.941
Engine wiring harness at body
side
Model 168.008 with engine
668.940
Engine wiring harness at body
sideAR54.18-P-0100GD
Repairing wiring
harnessModel 168.007 with engine
668.941
Engine wiring harness
Model 168.008 with engine
668.940
Engine wiring harnessAR54.18-P-0100GC
Install left front repair
wiring harnessModel
168.007/008/031/032/033
Only vehicles with one-piece
wiring harnessAR54.18-P-0700GC
Install right front repair
wiring harnessModel
168.007/008/031/032/033
Only vehicles with one-piece
wiring harnessAR54.18-P-0701GC
Install left rear repair
wiring harnessModel
168.007/008/031/032/033
Only vehicles with one-piece
wiring harnessAR54.18-P-0702GC
Install right rear repair
wiring harnessModel
168.007/008/031/032/033
Only vehicles with one-piece
wiring harnessAR54.18-P-0703GC
General repair method
for wiring harness. AR00.19-P-0100A
Checking wiring harness AR54.18-P-0600-01A

Electrical connection setFig. 336
126-pin socket boxFig. 337

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 248 © 2006 Mitchell Repair Information Company, LLC.

Fig. 394: Wrapping Insulating Tape Around Corrugated Hose At Both Ends
PROTECT REPAIR AREA AFTER CABLE REPAIRS - AR00.19-P-0100-08C
Protect repair area by wrapping fabric tape around it.
1. Wrap fabric tape around repair area as per original condition.
Fabric tape restores the appearan ce of the repair area and provides pr otection from chafing. In parts of
vehicle subject to high levels of st ress (e.g. engine compartment) fabric tape should only be used together
with other (watertight) protective measures.
REPAIRING WIRING HARN ESS USING SOLDER CONNECTORS - AR00.19-P-0100-09A
Fig. 395: Identifying New Passe nger Vehicle Wiring Harness Repair Kit (220 589 04 99 00)
Fig. 396: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:49 PMPage 276 © 2006 Mitchell Repair Information Company, LLC.