1997 MERCEDES-BENZ ML320 engine

the side jacking points.
Fig. 639: Identifyin g Lifting At Rear

RAISING, JACKING UP VEHICLE - AR00.60-P-1000GH
MODEL 163
Fig. 640: Raising, Jacking Up Vehicle

Fig. item, etc.Work instructions
Lethal injuries are
possible if vehicle slips
off of lifting platformAlign vehicle between the
four lifting platform pillars
and position the four
support plates at the hoist
mounting points specified
by the vehicle
manufacturer.AS00.00-Z-0010-01A
Danger of accident
through self-acting
movement of the vehicle
when jacked up Risk of
injury through intrusion
into engine compartment
or driveline where rotating
parts pose a serious
hazard.Make sure that the jack
stands are securely
positioned. Authorized
person should occupy
driver's seat. Wear closed
and close-fitting work
clothes. Do not grasp hot
or rotating parts.AS00.00-Z-0008-01A

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These instructions are to be read carefully and complied with in full In order to rule out any risk of personal
injury, to avoid impairing the reliability and safety of the vehicle, and to prevent damage to the vehicle as a
result of work improperly carried out.
It is therefore not possible for DaimlerChrysler AG to evaluate in the last consequence every situation which
might present a risk of injury for the operative. It is therefore an urgent necessity that everyone who carries out
repair work on Mercedes-Benz passenger cars by applying his professional knowledge satisfies himself that his
own safety is not at risk and that the vehicle will not suffer any negative effects, in particular of a safety
engineering nature, as a result of the repair procedure adopted.
It is therefore expressly pointed out that all work for the operations described must be carried out in compliance
with valid directives and instructions from the responsible local authorities and those relating to health, work
safety and environmental protection.
ADDITIONAL DESIGNATION FOR MODELS AND COMPONENTS - AP00.20-P-0000-03A
Models and components, in addition to their 3 to 6-figure designation (e.g. 124 or 124.028), may have different
versions, dates and work procedures. These differences are indicated b
y the following additional designations:

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For these vehicles the service sheet for the Active Service System (ASSYST) and the maintenance manual
volume 4 apply.
With the ASSYST service sheet the previous distinction between care service and maintenance service no
longer applies. Instead, the service category A (minor service) and service category B (major service) have been
introduced.
The service scopes for each model series can be seen in the respective valid service sheet.
The order no. is stated on the particular SERVICE SHEET.
On manual transmissions, automatic transmissions, transfer cases, front axles and rear axles the service item
"Check fluid level" has been replaced by an inspection of all visible parts for leaks.
In view of the fact that these components are not oil consumers, as is the case for the engine, a loss of oil can
occur only to the outside.
If any leaks are present, the procedure, as before, is to determine the cause and to rectify it subject to a separate
repair order.
The service operations carried out should be documented in the boxes in front of the operation titles. It is
essential to ensure that the specified service operations are carried out in full.
An indication is given in the boxes after the operation titles of which service operations should be carried out
for service category A (minor service) or service category B (major service). Enter a cross behind these boxes to
identify any items which are not in proper order when the vehicle is received.
Additional operations should be defined by the service adviser in agreement with the customer and an indication
should be made on the service sheet whether these additional operations are to be carried out.
Fig. 642: Service Intervals/Work Sheets


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Run in gently, but briskly.
Avoid high load, high rpm and high speed.
Automatic transmissions: do not use kick-down and do not brake the vehicle by shifting down manually.
After 1 500 km
Gradually bring the vehicle up to its full road and engine speeds.
MAINTENANCE - AP00.20-P-0000D
MODEL 210 as of 1.3.97, 129,140,170, 202 as of 1.6.97, 163, 168, 203, 208, 209, 215, 220, 230, 414 ASSYST
Preface AP00.20-P-0000-01C
Safety notes/warning
notes AP00.20-P-0000-02A
Additional designation
for models and
components AP00.20-P-0000-03A
Service intervals/work
sheets general
information AP00.20-P-0000-04C
Special service
procedures AP00.20-P-0000-06B
Service date reminder AP00.20-P-0000-07B
Service card for units AP00.20-P-0000-08A
Service Information:
Engine oil changeModels 129, 163, 168, 170,
203, 208, 209, 210, 215,
220, 230SI 18.00-P-0011A
SERVICE SHEET for
Active Service System
(ASSYST)Model 129 as of 1.6.97AP00.20-P-0001D
Model 140 as of 1.6.97AP00.20-P-0001E
Model 163AP00.20-P-0001A
Model 168AP00.20-P-0001B
Model 170 as of 1.6.97AP00.20-P-0001C
Model 202 as of 1.6.97AP00.20-P-0001F
Model 203AP00.20-P-0001K
Model 208AP00.20-P-0001G
Model 209AP00.20-P-0001M
Model 210 as of 1.3.97AP00.20-P-0001H
Model 215AP00.20-P-0001J
Model 220 except code
Z04/Z07AP00.20-P-0001I
Model 220.175/176/178 AP00.20-P-0001IG

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CHECK ALL VISIBLE PARTS FOR SIGNS OF LEAKS AND DAMAGE - AP00.20-P-0053GH
MODEL 163.113 /128 /136 /154 /157 /172 /174 /175
INSPECTING CHASSIS AND LOAD-BEARING BODY PARTS FOR DAMAGE AND CORROSION - AP00.20-P-0090GH
MODEL 163
with Code Z04/Z07
Model 230AP00.20-P-0001L
Model 414AP00.20-L-0001A
Taxi serviceModels 202, 210AP00.20-P-0007A
Model 203AP00.20-P-0007C
Remove
Detach lower engine
compartment panelingModels 163.172/174/175AR61.20-P-1105GH
Remove noise
encapsulationModel 163.113/128AR94.30-P-5400GH
Check

2If traces of fluid are noted
(e.g. oil), then determine
and correct the cause (on a
separate work order).
Check for leaksEngine:
Transmission
Transfer case
Front axle
Rear axle
Pressure oil pump
3Check for leaks and fixingShock absorbers,
suspension struts
4Inspect for leaks and
conditionRubber boots of front axle
shafts
5Inspect lines and hoses for
leaks and condition, pay
attention to chafing points
and routingRadiator
Fuel system
Exhaust system
Clutch actuation
Automatic transmission
Power steering
Brake system
Install
Install lower engine
compartment paneling.Models 163.172/174/175AR61.20-P-1105GH
Install noise encapsulationModel 163.113/128AR94.30-P-5400GH
1Visual inspectionControl arm mountings and
control arms of front axle

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RENDER NEW VEHICLES, WHICH WERE IMMOBILIZED OPERATIONAL - AP00.70-P-1001ZZ
MODEL 129, 140, 163, 168, 170, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240
MODEL 461.302 /332 /342 /345
MODEL
463.200 /204 /206 /207 /208 /209 /220 /221 /224/225 /227 /228 /230 /231 /232 /233 /240 /241 /243 /244 /245 /2
4
servicerecommend that the
vehicle fuel tank is
completely filled. Then
allow gasoline engines to
run warm for 2-3 minutes.
Notes on paintwork,
decorative and detachable
components AH98.00-P-9019-01Z
if necessary, corrosion
protection after painting
(Section D) AP98.00-P-0641A
1Perform delivery
inspection
2Check battery AR54.10-P-1129-01A
3
+Vent stationary heater and
top up coolantModel 163, 168, 170, 202,
203, 208, 209, 210, 211,
215, 220, 230, 240, 461,
463
Models 129, 140 with
stationary heater, code 228ra83001291165x
4Check fluid level of
engine cooling system,
correct if necessary and
check corrosion protection
as well as antifreeze and
correct if necessaryModel 129, 140, 163, 168,
170, 202, 203, 208, 209,
210, 211, 215, 220, 230,
240
Model 463 with engine
112, 113AP20.00-P-2010GA
Models 461, 463 with
engines 102, 103, 104,
117, 602, 603, 606, 612,
628AP20.00-P-2010G
Risk of accident caused
by vehicle starting off by
itself when engine is
running. Risk of injury
caused by contusions and
burns during starting Secure vehicle to prevent
it from moving. Wear
closed and snug-fitting
work clothes. Do not grasp
hot or rotating parts.AS00.00-Z-0005-01A

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procedure or when
working near engine
5Start engine Allow to run at idle
speed until oil pressure is
displayed.
6Check refrigerant level of
air conditioning systemModel 129 up to 31.5.96
with automatic air
conditioning, code 581a,AP83.30-P-8312DA
Model 140 up to 31.5.95
with automatic air
conditioning, code 581a
with rear air conditioner,
code 582,
Model 202 up to 30.9.95
with automatic air
conditioning, code 581a,
Models 129, 170, 202,
208, 210, 220 with air
conditioning (or
Tempmatic for USA),
code 580
Models 461, 463 with air
conditioning, code H02AP83.30-P-8312G
7Move the pull switch of
the hydropneumatic
suspension into position N
and allow the engine to
run at increased idle speed
until the vehicle has
reached its normal levelOnly for Hydropneumatic
suspension with automatic
level lowering device and
controlled damping, code
215c, All-round
hydropneumatic
suspension, code 487
8Brake testing on test standModel 129, 140, 170, 202,
203, 208, 209, 210, 215,
220AP42.00-P-4290BA
Models 461, 463AP42.00-P-4290G
9Check brake disks for
signs of corrosion. For vehicles which
were parked for more than
6 months.
10Replace brake fluid For vehicles which
were parked for more than
6 months.
Model 140 as of 1.7.93
except code 471AP42.00-P-4280BA
Model 170 except code
471
Model 202 up to 31.5.94
except code 471

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Repair materials
RETROFITTING & CONVERSION
TABLE OF CONTENTS FOR RETROFITTING AND CONVERTING SPECIAL EQUIPMENT - AN00.10-P-1000NZ
MODEL 163
cleaning agents.
Only for Activated
charcoal filter, code 306:
Cover inside of air inlet
grille on engine hood.
Cleaner
14Treat paintwork using
polishing paste and buffer If films still on
paintwork.
Polish*BR00.45-Z-1015-04A
15Perform treatment using
polish and gloss
preservation.Polish*BR00.45-Z-1013-04A
Gloss preserver*BR00.45-Z-1014-04A
NumberDesignationOrder number
BR00.45-Z-1017-04ACleanerA 001 986 13 71
BR00.45-Z-1014-04AGloss preserverA 000 986 44 74
BR00.45-Z-1015-04APolishA 000 986 43 74
BR00.45-Z-1013-04APolishA 000 986 45 74
AN31.10-P-8080AA Retrofit trailer
couplingModel 163.113 /136 /154 /172 #A as
of 145273,
Model 163.113 /136 /154 /172 #X as
of 708319,
Model 163.128 /175 except styling
package, code U49AN31.10-P-8080AA
AN31.10-P-8080AB Retrofit trailer
couplingModel 163.113 /136 /154 /172 #A as
of 145273,
Model 163.113/136 /154 /172 #X as
of 708319,
Model 163.128 /175 with styling
package, code U49
Model 163.174AN31.10-P-8080AB
AN31.10-P-8080AC Retrofit trailer
couplingModel 163.136 /154 /172 #A up to
145272,
Model 163.136 /154 /172 #X up to
708318AN31.10-P-8080AC
AN91.12-P-0001A Retrofit third seat rowModel
163.113 /128 /136/154 /157 /172 /175AN91.12-P-0001A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:52 PMPage 409 © 2006 Mitchell Repair Information Company, LLC.