1997 MERCEDES-BENZ ML350 length

Fig. 371: Identifying MCP 2.8 EL A Crimping Set (000 589 13 99 10)
Fig. 372: Identifying MCP 1.2 EL A Crimping Set (220 589 04 99 10)

Table of stripping lengths
1. Select crimp contact accor ding to assignment table in wiring harnes s repair kit, wiring harness repair kit
basic or wiring harness repair kit as supplement to passenger cars .
2. Push single-strand insulation (1) over cable (2) with lip at the front.
3. Strip line (2) using wire strippe r according to assignment table.
Damaged wire strands can lead to changes in the line cross-section and an impermissible strength of
the crimped connection.
4. Ali
gn single-strand insulation (1) with line (2) ensuring that dimension (b) = maximum 1 mm.
Contact familySingle-strand sealingCable cross-section
Length stripped of
insulation
All up to 1.5 mm 24 mm ± 0.3
All 1.5 up to 4 mm 25 mm ± 0.3

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:48 PMPage 265 © 2006 Mitchell Repair Information Company, LLC.

Fig. 380: Identifying Crimp Connections - Correct And Incorrect (1 Of 2)
14. Check crimped connection for correct length and distance of strands and insulation, as well as position
and condition of seal.
Correct crimped connection (A):
Insulation and wires are of the correct length in the shackles. Correct distance between the single-strand
insulation and the end of the insulation.
Incorrect crimped connections (B, C):
The single-strand insulation is damaged because the distance between seal and end of insulation is too
small.
Stripped strands are too lon
g, single-strand insulation is therefore not crimped.

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:49 PMPage 270 © 2006 Mitchell Repair Information Company, LLC.

A maximum of seven individual cables maybe inserted into each solder connection.
5. Insert the cables into the corresponding solder connections (Z) according to the total cable cross-section.
6. Ensure that solder connection (Z) is fully rotated onto cables.
Approx. 5 mm (A) of the stripped line ends should be visible.
Fig. 404: Rotating Solder Connection Onto Cables

7. Heat solder connector using a heat gun (approx. 400°C).
Start at tapered end until soldering ring has dissolved and sleeve has correctly wrapped itself around
the line.
Fig. 405: Heating Solder Connector Using Heat Gun
Selection table for solder connector
Total copper cross-
section A
tot.
Overall diameter with
insulationLength stripped of
insulationColor code
0.7 to 2.4 mm2 3.3 mm15 mmgreen
2.0 to 4.0 mm2 4.5 mm15 mmred
3.5 to 8.0 mm2 7.0 mm15 mmblue
7.5 to 12 mm 2 9.0 mm15 mmYellow

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:49 PMPage 279 © 2006 Mitchell Repair Information Company, LLC.

AH40.10-P-9411-01A
Information on tires/rims
Model 124, 129, 140, 163, 168, 169,

170, 171, 199, 201, 202, 203, 208, 209,
210, 211, 215, 219, 220, 230, 240, 414,
450, 452,
639


Tires

D
For service conversions, the tire/disc wheel specifications and

dimensions should be compared with the entries in the
registration papers.

D
When mounting tires, the tires and rims must be carefully

matched in order to guarantee the concentricity of the wheel.

Identification of matching points on:

- Tires with a colored dot on the outside of the tire,

- Sheet steel disk wheel by a colored dot or punch mark on the

outside of the wheel,

- Perform this operation at the valve stem hole on light-alloy

disk wheels

With an additional paint spot or punch mark in the rim base

for the 140 Model Series.

D
Always replace the rubber valve.

-----------------------------------------------------------------------------------------
D

Damaged and defective tires must always be replaced. The

repair methods employed in the tire trade are not approved by

Mercedes-Benz. Small nicks (<0.8mm) on the tire's sidewall do

not usually pose a cause for concern, and continued use of

such tires is approved

D When replacing just one tire, install it on the front of the vehicle.

This does not apply to vehicles with different tires of varying

specifications on the front and rear wheels.

D
Only use tires listed in the valid Service Information bulletins

and repair instructions.

D
If the permissible maximum speed of an M+S tire is below the

maximum speed of the vehicle, an appropriate adhesive plate

must be attached in the driver's field of view.

-----------------------------------------------------------------------------------------

D
Tires permissible for higher speeds may be used.

D
Always fit all rims with tires of the same design, make and

version.

-----------------------------------------------------------------------------------------
D

Run in new tires for approx. 100 km at moderate speed.

D
Handed tires must be installed according to the arrow on the

side wall of the tire.

D
Tires are subject to an aging process with negative effects on

the properties of the tire. In order to ensure optimum

effectiveness in winter, M+S tires should not be used for longer

than 3 years.

-----------------------------------------------------------------------------------------

Tire pressure

(For specified values see tire pressure table in the fuel filler flap, on

the Vaneo BM 414 see B-pillar on the passenger side).
Too low tire pressure increases the rolling resistance and increases

the flexing energy of the tire. This causes the critical temperature limit

to be exceeded (carcass detachment) and destroys the tire. Respond

to loss of tire pressure by determining the source and replacing the

tire as indicated.

Cleaning

Using a spray wand with high-pressure nozzles to clean the wheel

can lead to tire damage. Such damage occurs especially on the tire

side walls. The following should be observed when using flat jet

nozzles:

D
Maintain a minimum distance of 300 mm

D
Do not direct the water jet at a single point on the surface of the

tire for any length of time.

-----------------------------------------------------------------------------------------
Mounting in bearings

Before putting into storage, clean tires thoroughly and check for
damage and adequate tread depth. Mark the position and running

direction of the tires with chalk. Do not store tires outdoors. Under the

influence of sunlight, heat, moving air and ozone the rubber looses

elasticity and strength, ages more quickly and becomes cracked.

Storage areas should be dry, cool and dark. Avoid drafts by keeping

doors and windows closed as much as possible. Do not bring tires

into contact with gasoline, oil or other greases as they dissolve the

rubber.

Disposal

Collection, storage and disposal should be performed in accordance

with the legal requirements and the company's own regulations.

-----------------------------------------------------------------------------------------

Copyright DaimlerChrysler AG 06.07.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1

11
Oil piston pin (2) and conrod bush

12
Assemble piston (3) and conrod (4)

Install piston (3) with arrow in direction of

travel.

13
Push in piston pin (2) by hand

14
Insert circlip (1) of piston pin (2) in the groove

on piston (3)

Do not damage piston (3). Place a clean

cloth underneath.

15
Oil cleaned parts (cylinder bore, conrod

bearing journal, conrod bearing shells and

pistons)

16
Fit on tensioning strap (10) and tension

Piston ring gaps must be offset 120°.

Tensioning strap

*000589041400

17
Install piston (3) with arrow pointing in

direction of travel

Rotate crankshaft far enough so that the

connecting rod when inserting piston into

cylinder bore does not line up at the

connecting rod journal!

18
Inspect conrod bolts (6)

AR03.10-P-6111-01BV

Thread and shank length

*BE03.10-P-1001-03A

19
Install conrod bearings and fit on conrod

bearing cap (5)


The connecting rod bearing shell (7) with

oil drilling (arrow) must be mounted in the

connecting rod, otherwise the piston pin (2) is

not lubricated.

The anti-twist locks (8) of the connecting rod

bearing shells (7) must be seated in the

grooves (9) in the conrods (4) and connecting

rod bearing caps (5).
AR03.10-P-6111-06AV

The connecting rod and connecting rod

bearing cap are cracked (broken) (arrow).

They must not be installed the wrong side

round!

20
Tighten conrod bolts (6)

AR03.10-P-6111-02BV


*BA03.10-P-1001-01E

21
Rotate crankshaft

To inspect ease of operation.

22
Install oil pump
-
Ensure oil return flow check valve is

correctly located.

-
Clean strainer of oil pump.

-
Fill oil pump with engine oil before

installing so that it pumps oil when first

started.

All except models 203, 209, 211.061/065/070,

220 without 4MATIC, 230.474 /475

AR18.10-P-6020B

Model 203 without 4MATIC, 209,

211.061/065/070

AR18.10-P-6020PV

Model 203 with 4MATIC, model 220 with

4MATIC

AR18.10-P-6020PW

Model 230.474/475

AR18.10-P-6020R

23
Fit on cylinder head
Models 463.206/ 209/ 232/ 233/ 240/ 241/

243/ 244/ 245/ 246/ 247/ 248/ 249/ 250/ 254

AR01.30-P-5800GV

Engine 112 in model 129 and engine 113 in

models 129, 202, 208, 210

AR01.30-P-5800B

Engine 112 in models 170, 202, 208, 210,

220 and engine 113 in models 220,

230.474 /475

AR01.30-P-5800BA

Model 163

AR01.30-P-5800MV

Models 203, 209 with engines 112, 113

Models 211.061/065/070

AR01.30-P-5800PV

24
Fit on top part of oil pan
Model 463

AR01.45-P-7500FG

Model 230.474/475

AR01.45-P-7500R

Model 220 without 4MATIC

AR01.45-P-7500I

Model 220 with 4MATIC

AR01.45-P-7500IW

Model 210 with 4MATIC

AR01.45-P-7500FA

Model 210 without 4MATIC

AR01.45-P-7500F

Models 202, 208

AR01.45-P-7500FC

Model 203 without 4MATIC, 209 with engines

112,113

AR01.45-P-7500PV

Model 203 with 4MATIC

AR01.45-P-7500PW

Model 211.061/065/070

AR01.45-P-7500TV

Model 170

AR01.45-P-7500SV

Model 163

AR01.45-P-7500FB

Model 129

AR01.45-P-7500FD

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 3

25.1
Fit on automatic transmission
Models 463.206/ 209/ 232/ 233/ 240/ 241

AR27.10-P-0500BD

Models 463.243/ 244/ 245/ 246/ 247/ 248/

249/ 250/ 254

AR27.10-P-0500GA

Model 230.475

AR27.10-P-0500R

Model 230.474

Model 220 without 4MATIC

AR27.10-P-0500I

Model 220 with 4MATIC

AR27.10-P-0500IW

Models 210, 208, 202,170. 129

AR27.10-P-0500B

Model 203 without 4MATIC, 209 with engines

112,113

AR27.10-P-0500P

Model 203 with 4MATIC

AR27.10-P-0500PW

Models 211.061/065/070

AR27.10-P-0500T

Model 163

AR27.10-P-0500GH

25.2
Fit on manual transmission
Models 210, 202, 129

AR26.10-P-0020A

Models 203, 209 with engine 112

AR26.10-P-0020P

Model 211.061

AR26.10-P-0020T

Model 208 with transmissions 716.662/622

AR26.10-P-0020E

Model 170,

Model 208 with transmission 716.663

AR26.10-P-0020D

26
Install engine
Models 463.243/ 244/ 245/ 246/ 247/ 248/

249/ 250/ 254

AR01.10-P-2400CC

Model 230.475

AR01.10-P-2400R

Model 230.474

AR01.10-P-2400RVK

Model 220 without 4MATIC

AR01.10-P-2400AB

Model 220 with 4MATIC

AR01.10-P-2400IW

Model 210 with 4MATIC

AR01.10-P-2400C

Model 210 without 4MATIC, 208, 202, 129

AR01.10-P-2400CB

Model 203 without 4MATIC, 209 with engine

112

AR01.10-P-2400PV

Model 203 with 4MATIC

AR01.10-P-2400PW

Model 209 with engine 113

AR01.10-P-2400Q

Models 211.061/065/070

AR01.10-P-2400TC

Model 170

AR01.10-P-2400SV

Model 163

AR01.10-P-2400CA

Inspection data of conrod bolts

Number

Designation
Engine

112 except

112.951,

113.94/96/980/

981/982/984/986
Engine

113.992

BE03.10-P-1001-03A
Conrod bolts
Thread
4M8B18B1

Shank length
when new
mm
4742

max.
mm
47.642.6

Part no.
--

Designation
Engines

112 except

112.951,

113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/980/
981/982/984/
986/987/988/
990/991/992/

993

BA03.10-P-1001-01E
Connecting rod bolt
Stage 1
Nm
5

2nd stage
Nm
25

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 4

GF54.30-P-3017A
Quartz, location/task/function
8.7.99

MODEL
129, 140 as of 1.6.96,

163, 168, 170,

202 as of 1.8.96,

208,

210 as of 1.6.96,

215, 220

P54.30-0519-01

Piezo-electric effect:

A thin quartz plate (c) is coated on two opposing sides with a conductive material (a), (b) (see

illustration). If a tensile or compressive load is applied to the array, an electrical voltage "U" i
s

produced between the points (d) and (e). The polarity of the generated voltage depends on the

direction of load (compression/tension).

Reversed piezo-electric effect:

If, however, a voltage is applied to the points (d) and (e), the quartz plate increases or decreases


in length.

Task:

Mechanical vibrations can be converted into electrical oscillations using the piezo-electric effect.


For example, for microphones, knock sensors, pressure sensors.

Electrical oscillations can be converted into mechanical vibrations or motion using the reversed

piezo-electric effect: piezo-electric speakers, actuators.

Both effects are combined in the quartz resonator: If an AC voltage whose frequency is roughly

equal to the mechanical resonant frequency (fundamental or harmonic component) of the quartz

plate is applied to the points (d) and (e), the quartz is stimulated to generate resonant vibrations


which stabilize the frequency of the electrical oscillations. For this reason, quartz resonators are


often used where a high degree of frequency stability is required (e.g. in clock generators

(oscillators) for electronic clocks and microprocessors).

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

Test values for shock absorber
the projection length (a) of
the piston rod.
Push in piston rod as
far as it will go. Then hold
vertically so that piston
rod points down, and
measure projection length
(a) of piston rod.
Shock absorber in new
condition:
Shock absorber in used
condition:
Model 129, 170, 202, 208,
210, 211, 230*BE32.25-P-1002-02A
Model 129, 170, 202, 208,
210, 211, 230
If shock absorber exceeds
specified value, dispose of
it:
By workshop: ?*BE32.25-P-1001-02A
Disposing of shock
absorberModel 129, 170, 202, 208,
210OS32.25-P-0121-01A
Model 211OS32.25-P-0121-01TX
Model 230
Disposal by scrap
dealer: ?
Notes on scrapping gas-
filled hydraulic
componentsOS00.00-P-1000-01A
4.1Check rubber mount in
housing eye, replace if
necessary Only on shock
absorbers with rubber
mount in housing eye and
only if the shock absorber
is not replaced.
The rubber mounts
must be seated securely in
the body eye and must not
be cracked or damaged.
If fitted, damaged rubber
mounts can cause
knocking noises.
NumberDesignationModel 129Model 170Model 202
BE32.25-P-1001- Oil reserve check mm0+20+20+2

2001 Mercedes-Benz ML320
1998-2005 SUSPENSION Suspension - 163 Chassis
me
Saturday, October 02, 2010 3:37:36 PMPage 20 © 2006 Mitchell Repair Information Company, LLC.