1997 MERCEDES-BENZ ML320 brake

21
Detach rear brake cables

Unclip at underfloor of vehicle and

unscrew brake cable holder on right and left

at frame.

22.1
Unbolt check strap of rear axle carrier from

underfloor of vehicle

As of VIN A145273, X708319.

23
Remove left rear stone shield

24
Remove lower tensioning straps (80/2) and

loosen the upper tensioning straps

Tensioning straps are color-coded and

cannot be mixed up.

Support fuel tank using assembly jack.


*BA47.10-P-1001-01D

25
Remove longitudinal strut for tensioning

straps (80/18)


*BA47.10-P-1002-01D

26.1
Unscrew linkage for headlamp range

adjustment
at the top

If installed.

27
Unscrew nuts on bottom of the shock
absorbers at the transverse control arm


Installation:
Install new self-locking nuts.


*BA32.25-P-1001-03D

28
Unscrew rear axle carrier from floor of vehicle

and lower as far as possible

Support rear axle carrier.


Installation:
Install new self-locking bolts.


*BA35.10-P-1001-01C

29
Lower fuel tank

Support fuel tank.

30
Remove upper tensioning strap
at the rear
The tensioning strap at the top at the front.

31.1
Unclip lines from side of fuel tank

As of VIN A289565, X754620.


Installation:
The lines must not be

damaged.

32
Disconnect fuel pump electrical plug

connection

33
Disconnect fuel feed line (90/12) and fuel

return line (90/11)

Fuel lines must not be bent.

Pliers

*163589003700

34
Remove fuel tank (80)


Installation:
Ensure that the sealing

rubbers (5) seat correctly in the body floor to

prevent water entry.

Do not damage fuel lines at filler neck.

Guide filler neck with its chamfered side

(arrow) through between frame and body.

Filler neck and fuel tank cannot be separated

from each other.

35
Install in the reverse order

36.1
Dispose of fuel tank

Ony when replacing the fuel tank.

o

Disposal of fuel tanks

OS47.10-P-0001-01A


Rear axle carrier

Number

Designation
Model

Series 163

BA35.10-P-1001-01C
Self-locking bolt, rear axle carrier at front and rear

to frame floor
Nm
200


Propeller shaft

Number

Designation
Model

Series 163

BA41.10-P-1002-01C
Self-locking bolt, rear propsharft

at rear axle center section
Nm
50

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 3

GENERAL NOTES: PASSENGER CARS - AH00.01-Z-0998AZ
MODEL all
Notes on TowingMODEL 461, 463AH00.60-P-0100-
02GA
Overall vehicle
Overall vehicleFG00AH00.00-Z-9999AZ
Engine
Complete engine,
crankcase ventilation,
cylinder head, crankcaseFG01AH01.00-Z-9999AZ
Crank assemblyFG03AH03.00-Z-9999AZ
Engine timingFG05AH05.00-Z-9999AZ
Mixture formationFG07AH07.00-Z-9999AZ
Air intake, superchargingFG09AH09.00-Z-9999AZ
Electrical system - engineFG15AH15.00-Z-9999AZ
Engine lubrication,
engine oil coolingFG18AH18.00-Z-9999AZ
Engine cooling systemFG20AH20.00-Z-9999AZ
Engine suspensionFG22AH22.00-Z-9999AZ
Throttle control, cruise
control systemFG30AH30.00-Z-9999AZ
Fuel systemFG47AH47.00-Z-9999AZ
Exhaust systemFG49AH49.00-Z-9999AZ
Chassis
Manual transmissionFG26AH26.00-Z-9999AZ
Automatic transmissionFG27AH27.00-Z-9999AZ
Frame, trailer operationFG31AH31.00-Z-9999AZ
SuspensionFG32AH32.00-Z-9999AZ
Rear axleFG35AH35.00-Z-9999AZ
Wheels, chassis
alignment checkFG40AH40.00-Z-9999AZ
Brakes - hydraulic and
mechanical systemsFG42AH42.00-Z-9999AZ
Brakes - pneumatic
system and auxiliary
brakesFG43AH43.00-Z-9999AZ
SteeringFG46AH46.00-Z-9999AZ
Electrical system,
equipment and
instrumentsFG54AH54.00-Z-9999AZ

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 10 © 2006 Mitchell Repair Information Company, LLC.

CONVERSION MEASURES RESULTING IN ALTERATION TO VEHICLE MODEL - AH00.10-P-1000-01A
Model 100, 107, 108, 109, 111, 112, 113, 114, 115, 116, 123, 124, 126, 129, 140, 163, 168, 170, 201, 202, 208,
210
We disapprove of all vehicle conversions resulting in an alteration to the model. A standard production vehicle
is a design entity which, upon installation of parts alien to the model, usually changes in a detrimental way.
Changes to important components influence the homogeneity of the vehicle in its entirety. For this reason we
have not investigated the details to be observed when performing such conversions. Such conversions can also
lead to changes on the vehicle which require new proof that the vehicle complies with legal requirements.
The main reasons for our disapproval are:
1. Subsequent installation of a component such as a more powerful engine may overload the remaining
components such as the transmission, brakes, axles, etc.
Body
Body - generalFG60AH60.00-Z-9999AZ
Front end and fire wallFG62AH62.00-Z-9999AZ
Side wallFG63AH63.00-Z-9999AZ
Rear wall and rear endFG64AH64.00-Z-9999AZ
RoofFG65AH65.00-Z-9999AZ
WindowsFG67AH67.00-Z-9999AZ
Interior equipmentFG68AH68.00-Z-9999AZ
DoorsFG72AH72.00-Z-9999AZ
Sliding roof, soft top, top
attachmentsFG77AH77.00-Z-9999AZ
Central locking,
convenience feature,
drive authorization
systemFG80AH80.00-Z-9999AZ
Electrical system bodyFG82AH82.00-Z-9999AZ
Climate controlFG83AH83.00-Z-9999AZ
Emergency equipment,
sanitary equipment,
galleyFG86AH86.00-Z-9999AZ
Detachable body
components, exterior
flapsFG88AH88.00-Z-9999AZ
Seats, bunks, restraint
systemsFG91AH91.00-Z-9999AZ
Body sealing, corrosion
protectionFG97AH97.00-Z-9999AZ
PaintworkFG98AH98.00-Z-9999AZ

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 11 © 2006 Mitchell Repair Information Company, LLC.

Overview of authorized reworking on wiring harnesses
into the body
Lines get pinched in clamps
or trim parts
Fatigue Lines routed or secured
incorrectly
Excessive stress
Open circuit in wiring
Corrosion Due to contact with acids or
aggressive fluids (e.g. brake
fluid, antiseize, coolant
additives, fuels, lubricants),
water penetration due to
defective seals, use of high
pressure cleaner
Wiring harness covered in
paint after paint repair
Hardening of insulation due
to contact with an
incompatible agent (e.g.
solvent)
Line open circuit, contact
pairing not longer conductive
(transition resistances)
Insulation and wires
damaged
Lines or connections to
contacts
High line resistance
Components with sharp
edges
Corrosion
Assembly fault Use of incorrect tools, e.g.
wrong crimper or wrong
release tool
Damaged contacts or lines
through use of unsuitable test
tools (e.g. probes)
Lines pinched or screwed in
Loose contacts in plug
connections
Wrong contacts crimped
Undesirable transition
resistances
Open circuit in wiring, short-
circuit
Insulation damaged
Type of faultRemedial action
Faulty contact part
Contact part
missing
wrong part
deformed
Install new contact part
Contact part not engaged properlyLatch contact part, then check, and replace if
necessary
Not all individual wires are crimpedCut off contact part and install new part
Insulation also crimpedCut off contact part and install new part
Conductor not far enough in contact partCut off contact part and install new part

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 22 © 2006 Mitchell Repair Information Company, LLC.

Risk of accident
from vehicle starting off during starting operation (e.g. when testing compression pressure) as a result of gear
engaged or when engine running, or vehicles with automatic transmission as a result of selector lever position
"P" or "N" not engaged (exception: some vehicles do not have a selector lever position "P" ).
Injury hazard
Severe injuries may be caused by unshielded rotating parts in the area of the running engine.
The heat produced by the running engine can result in severe burns if contact is made with individual,
unshielded parts.
Procedural guidelines and safety precautions
As a general rule, carry out work on the running engine only if this is absolutely necessary.
Before starting the engine, apply parking brake .
On models with manual transmission move gearshift lever into Neutral position .
On vehicles with automatic transmission move selector lever into position "P" or "N" (exception:
some vehicles do not have a selector lever position "P" ).
On models which do not have selector lever position "P", secure selector lever to prevent it from
being operated unintentionally .
Wear closed and close-fitting work clothes.
All items of jewelry like chains or rings must be taken off.
Restrain long hair by wearing an appropriate head cover.
Before commencing any work on the running engine, familiarize yourself with the location of potentially
hot parts.
When carrying out work when starting the engine or when engine is running do not touch any hot and
rotating parts .
First aid measures in the event of burns
Do not rub the skin areas affected; flush with plenty of cold water and cover skin with sterile bandages.
Consult a doctor without delay.
RISK OF INJURY CAUSED BY DRILLING GAS-FILLED ASSEMBLIES OR COMPONENTS (NONCOMBUSTIBLE GASES)
- AS00.00-Z-0006-01A
Wear safety glasses and a face mask.
Risk of injury when drilling
There is an increased risk of injury to the skin and eyes when drilling gas-filled assemblies due to shavings
being thrown out. The shavings are picked up by the escaping gases and accelerated to a greater or lesser extent
depending on the pressure. The extent of injuries increases as the pressure increases. The pressures involved

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:47 PMPage 219 © 2006 Mitchell Repair Information Company, LLC.

ASSIGNMENT OF DATA LINK CONNECTOR - AD00.00-P-2000-02C
Hazardous
voltage Short-circuit to
positive
Multimeter direct
voltage type of
measurement
Brake lining
wear indicator Plug Socket
DescriptionLogoDescriptionLogoDescriptionLogo
Program heating
(1st cut-in time) Air up and down Air Drying
Program heating
(2nd cut-in time) Standard setting Cooling mode
(standard setting)
Cut-in time Economy setting Air conditioning
Off
Time of day
display Air to center and
side outlet Air conditioning
On/Off (USA
only)
Instant heat Minimum air
volume Off (no air
supply)
Return flow Maximum air
volume ° Celsius
Supply Automatic blower
control ° Fahrenheit
Air upwards Defrosting Residual heat
Air upwards,
downwards,
doors Automatic mode
Air downwards Recirculated air

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 239 © 2006 Mitchell Repair Information Company, LLC.

SPECIAL SERVICE PROCEDURES - AP00.20-P-0000-06B
Have the brake fluid replaced if more than 2 years have elapsed since the last change; this is best done in the
spring.
The coolant should be inspected for correct anticorrosion/ antifreeze concentration before the beginning of, and
during the cold season of the year. Depending on the model series, the coolant has to be replaced every 3 years
or 15 years (or after 250,000 km).
Refer to the particular valid service sheet for further additional operations based on kilometers or years.
SERVICE DATE REMINDER - AP00.20-P-0000-07B
The confirmation in the service booklet must be filled out completely and signed for every service (A or B).
Confirmation in the service booklet
Fig. 643: Identifying Service Date Reminder

SERVICE CARD FOR UNITS - AP00.20-P-0000-08A
Mercedes-Benz
Service card - major assembly
Maintenance
During the first service after exchanging a Mercedes-Benz genuine major assembly the operations listed in the
maintenance sheet or maintenance manual are to be carried out and confirmed.
Running-in:
The first 1 500 km
WARNING:When vehicles without service display are inspected, the assembly will be
serviced within the scope of the following care and/or maintenance
service.

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:52 PMPage 402 © 2006 Mitchell Repair Information Company, LLC.

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

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:52 PMPage 403 © 2006 Mitchell Repair Information Company, LLC.