1997 MERCEDES-BENZ ML320 Complete Repair Manual

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Page 2129 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual This document was created with Win2PDF available at
http://www.daneprairie.com.
The unregistered version of Win2PDF is for evaluation or non-commercial use only.

Page 2130 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
AR68.30-P-4100GI
Remove/install door sill molding
20.4.01

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

Door sill molding in cargo space

P68.30-2393-11

1
Caps

2
Door sill molding

Remov

Page 2131 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
AR63.20-P-2010GH
Remove/install D-pillar paneling
26.1.99

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

P63.20-3336-11

1
D-pillar paneling

2
Bonding material

Remove

1
Remove D-pillar pa

AR63.20-P-2010GH
Remove/install D-pillar paneling
26.1.99

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

P63.20-3336-11

1
D-pillar paneling

2
Bonding material

Remove

1
Remove D-pillar paneling (1)

Separate glue bead with cutting wire.

Additional pull handle for cutting wire

*WH58.30-Z-1017-02A

2
Remove any residual bonding material on the

D-pillar flange

Not more than 2 mm of glue must remain.

Install

3
Clean D-pillar paneling

In order to ensure a good adhesion.

4
Apply primer to damaged paint areas on D-

pillar flange

Use 2K primer
. Allow primer to air for at

least 5 minutes.

5
Prepare D-pillar flange

If the remaining glue (cut glue bead) is

older than 24 hours, also apply
primer
for

paint to body to obtain optimum glued joint.

*BR00.45-Z-1059-02A

If the
body
has been damaged or if there

is no bonding material then apply the
primer

to the bonding first. Allow the primer to flash

off for at least 10 minutes, but not for longer

than 15 minutes.

6
Prepare D-pillar paneling (1)

Apply primer to bonding. Allow the primer

to flash off for at least 10 minutes, but not for

longer than 15 minutes.

*BR00.45-Z-1059-02A

7
Prepare glue cartridge

AR67.10-P-1000-07P

Betapower II (2-component electric

cartridge gun)

*WH58.30-Z-1015-20A

2-component glue kit

*BR00.45-Z-1055-02A

8
Apply glue (2) as glue bead to D-pillar

paneling (1)

The paneling must be put on within 5

minutes, otherwise the adhesion quality of the

bonding material will be impaired.

Height of adhesive bead approx. 13 mm

Use reference points on inside of D-pillar

paneling.

Betapower II (2-component electric

cartridge gun)

*WH58.30-Z-1015-20A

9
Align D-pillar paneling (1)

10
Install D-pillar paneling (1)

Firmly press D-pillar paneling to D-pillar

flange.

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e. g.)
Order number

WH58.30-Z-1017-02A
Additional handle for cutting wire
Stahlwille

Eduard Wille GmbH &

Co.Lindenallee 27

D-42331 Wuppertal

10351/1

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 2132 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
WH58.30-Z-1015-20A
Betapower II (2-component electric cartridge gun)
DOW Automotive

(Deutschland) GmbH

Am Güterbahnhof

D-35683 Dillenburg

Tel.: +49 (0)

39484/8714-0

995.182

Repair produc

Page 2133 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
AR47.10-P-4000GH
Empty fuel tank if fuel pump is faulty
28.10.97

MODEL
163.113 with ENGINE 612.963

MODEL
163.128 with ENGINE 628.963

MODEL
163.136 with ENGINE 111.977

MODEL
163.154 with E

Page 2134 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
1.1
Unscrew bolts at rear of 2/3 seat bench and

raise rear of seat bench

Up to VIN A145272, X708318.

1.2
Remove covers at seat frame of 60% bench

seat

As of VIN A145273, X708319.

AR91.12-P

1.1
Unscrew bolts at rear of 2/3 seat bench and

raise rear of seat bench

Up to VIN A145272, X708318.

1.2
Remove covers at seat frame of 60% bench

seat

As of VIN A145273, X708319.

AR91.12-P-1100GH

Only remove the covers which are
identified in the document with A, D and E.

2.1
Fold 60% bench seat forward into footwell

As of VIN A145273, X708319. See

operator's manual.

3.1
Pull floor covering below rear seat mounting

bracket (1) of 60% seat forward

Carefully pull floor covering forward under

the seat console to prevent it from tearing.

As of VIN A145273, X708319.

4.1
Pull the floor covering forward under the front

corner of the left C-pillar cover (2)

Carefully pull the floor covering forward

under the cover to prevent it from tearing.

As of VIN A145273, X708319.

5
Cut into floor covering directly behind seat

retaining cable (3)

Ensure that the wiring harness (4) is not

damaged when cutting the floor covering.

As of VIN A145273, X708319. Broken

line marks the cut.

6
Fold floor mat back

Do not crease floor mat!

Fold floor mat back far enough to provide

access to cap (84) between body and fuel

pump.

7
Remove end cover (84) of body

Installation:
Replace cap and insert with

new sealing compound.

Cap (84) is sealed in with body sealer.

Heat with hot air blower to make it easier to

remove.

8
Seal fuel return line (90/11)

Pliers

*163589003700

9
Connect extraction hose (90/14) with adapter
hose to connection for fuel return line (90/11)

Extraction hose

*168589009000

Adapter hose

*163589009100

10
Connect ground cable (90/10) of extraction

pump ground terminal vehicle battery

Pumping out

11
Pump fuel out into safety container using

extraction pump

*BF47.10-P-1001-01A

*WH58.30-Z-1001-16A

12
Install in the reverse order

Fuel tank

Number

Designation
Models

163.113/
136/154/

172 up to

31.08.01
Models

163.113/
136/154/

172 as of

01.09.01

Models

163.157/

175
Model

163.128
Model

163.174

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liter
72838393

Reserve capacity
Liter
10121212

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 2135 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
163 589 00 91 00

Extraction hose

Adapter hose

Pliers

163 589 00 37 00 168 589 00 90 00

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e.g.)
Order num

Page 2136 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
AR40.10-P-1080A
Draining TIREFIT sealant out of tires
18.6.96

MODEL
163.174

MODEL
168, 170, 171, 203, 209, 211, 230, 240

P40.10-0309-02

1
Tire sealant container

2
Hose

3
Tire sealant

Dra

AR40.10-P-1080A
Draining TIREFIT sealant out of tires
18.6.96

MODEL
163.174

MODEL
168, 170, 171, 203, 209, 211, 230, 240

P40.10-0309-02

1
Tire sealant container

2
Hose

3
Tire sealant

Draining

Danger!
Risk of death
cased by vehicle slipping or

toppling off of the lifting platform.
Align vehicle between the columns of the

hydraulic hoist and position the four support

plates below the hoist support points specified

by the vehicle manufacturer.

AS00.00-Z-0010-01A

1
Remove wheel.

e

Remove/install wheels, rotate if necessary
Model 163.174

AP40.10-P-4050GH
Model 168, 170, 203, 209, 211, 230, 240

AP40.10-P-4050Z

Type 171

AP40.10-P-4050V

2
Position road wheel upright with valve

pointing downwards for

approx. 10 minutes.

Raise wheel approx. 200 mm to allow tire

sealant (3) to run out.

3
Unscrew valve element from the valve and

allow pressure to escape from the tire

4
Pull valve out of rim.

Press remains of valve remaining in valve

bore of disk wheel into inside of tire.

5
Attach hose (2) to tire sealant container (1).

Replace original hose of tire sealant

container (1) with a hose (2) approx.

400 mm long.

6
Press tire sealant container (1) together and

immerse hose (2) through the valve hole in

the disk wheel, as low as possible into the tire

repair kit (3)

7
Reduce pressure on tire sealant container (1),

the tire sealant (3) is extracted.

This method can be used to remove

approx. 90% of the tire sealant (3).

If the tire sealant container (1) is not

available, drill the tire tread with a twist drill (

4

10mm) and allow the tire repair kit (3) to flow

into a suitable container.

TIREFIT tire sealant
Model 163.174, 168, 170, 171, 203, 209, 211,

230, 240

AH40.10-P-0001-01A

8
Replace tire

Remove the remaining tire repair kit (3)
from the rim using a damp cloth.

AR40.10-P-1030A

9
Place new TIREFIT tire repair kit in the vehicle
See
#
e

TIREFIT tire sealant - check expiration date.

AP40.10-P-4054R

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