Page 2577 of 4133
Fig. 101: Identifying Oute r Joint And Locking Ring
REPLACE RUBBER BOOTS ON FRONT AXLE SHAFT - AR33.30-P-0660GH
MODEL 163.113 /128 /136 /154 /157 /172 /174 /175
Fig. 102: Identifying Fron t Axle Shaft Components
Removing
1Remove front axle shaft (37) AR33.30-P-
0620GH
Disassemble/assemble
2
Detach inner rubber boot (37l) or
outer rubber boot (37m) from ball
joint
AR33.30-P-
0660-01GH
Inner ball joint: ?
*BF33.30-P-
1001-02C
2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
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Page 2578 of 4133

Front axle shaft
MAINTENANCE
FRONT AXLE CARRIER - RETIGHTENING BOLTS - AP33.10-P-3373GH
MODEL 4JG163.### ## up to 221505, WDC163.### ## up to 734087
Outer joint: ?
*BF33.30-P-
1002-02C
3Drive out outer joint (37b) AR33.30-P-
0660-02GH
4
Pull inner rubber boot (37l) or outer
rubber boot (37m) off front axle
shaft (37)
Removal:
Left-hand front axle shaft:
The inner rubber boot (37l) can only be
removed when the outer joint (37b) is
driven out.
Right-hand front axle shaft:
The inner rubber boot (37l) cannot be
replaced as the shaft has a reinforcement in
the center.
If necessary, replace front axle shaft
Installation: To push on the rubber
boots, place suitable assembly sleeve on
the splined shaft profile of the rear axle
shaft.
5Replace circlips (37o, 37p)
6Assemble in the reverse order
Install
7Install front axle shaft (37) AR33.30-P-
0620GH
NumberDesignationModel 163
BF33.30-P-1001-02CFilling capacityInner joint rubber bootg155
Inner joint inner chamberg110
BF33.30-P-1002-02CFilling capacityOuter joint rubber bootg155
Outer joint inner chamberg65
2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:22 PMPage 59 © 2006 Mitchell Repair Information Company, LLC.
Page 2579 of 4133
Fig. 103: Identifying Front Axle Carrier - Retightening Bolts
Front axle carrier
INSPECT FRONT AXLE JOINT FOR PLAY, INSPECT RUBBER BOOTS - AP33.20-P-3353GH
MODEL 163.113 /128 /136 /154 /157 /172 /174 /175
Tightening
Lethal injuries are
possible if vehicle slips off
of lifting platformAlign vehicle between lifting platform columns and
position the four hoisting plates beneath the lifting
platform mounting points specified by the vehicle
manufacturer.
AS00.00-Z-
0010-01A
1Place vehicle on lift
2Torque axle carrier bolts
(1) *BA33.10-P-
1001-01C
NumberDesignationModel 163 up to 31/08/00
BA33.10-P-1001-01CBolt, front axle carrier to frameNm200
2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:22 PMPage 60 © 2006 Mitchell Repair Information Company, LLC.
Page 2580 of 4133

Fig. 104: Identifying Supporting Joint, Bottom Track Control Arm And Rubber Boots
Fig. 105: Identifying Supporting Joint, Transverse Control Arm And Dial Gage Holder
Remove
Risk of death. Death may result if
vehicle slips or topples from the
lifting platform.Align vehicle between columns of lifting
platform and position the four support plates
below support points specified by vehicle
manufacturer.
AS00.00-Z-
0010-01A
1Remove front wheels AP40.10-P-
4050GH
Inspect
2Check rubber boot (7f) on
supporting joint for leakage and
condition Visual inspection, if rubber boot is leaking
(e.g. grease flowing out): ?
Replace supporting jointAR33.20-P-
0440GH
3Check rubber boot (8f) on follower
joint for leakage and condition.
Visual inspection, if rubber boot is leaking
(e.g. grease flowing out): ?
Replace upper transverse control armAR33.20-P-
0500GH
4
Mount dial gage (022) with gage
stand (015) on the underside of the
transverse control arm (4) and pre-
tension The feeler must be set firmly up against the
face of the supporting joint dome cap (7) with
an indicating pretightening of 3mm.
5
Steering angle must not be altered while
measuring.
Determine the amount of play in the
supporting joint (7) through vertical pulling
2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
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Page 2581 of 4133
Fig. 106: Identifying Dial Indicator Holder (363 589 02 20 00)
Fig. 107: Identifying Dial Indicator (001 589 53 21 00)
Determine the play in the supporting
joint (7)
and pushing of the wheel hub. If measurement yields a play > or = 0,4 mm
the supporting joint (7) must be replaced, refer
to: ?
Replace supporting jointAR33.20-P-
0440GH
6Repeat the operation on the other
side of the vehicle
Install
7Remove dial gage and gage stand
8Fit front wheels AP40.10-P-
4050GH
2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:22 PMPage 62 © 2006 Mitchell Repair Information Company, LLC.
Page 2582 of 4133

AR82.62-P-7850GH
Remove/install front door speakers in mirror triangle
17.5.01
MODELS
163.113 #A as of 289565,
163.113 #X as of 754620,
163.154 /174 #A as of 289565,
163.128 /157 /175
P82.62-2232-11
1
Mirror triangle
2
Retaining clamps
3
Bracket
H4/23
Left front door speaker, mirror triangle
H4/23x1
Left front door speaker connector, mirror triangle
H4/24
Right front door speaker, mirror triangle
H4/24x1
Right front door speaker connector, mirror triangle
Remove/install
1
Unclip mirror triangle (1) from door
Assembly wedge
*110589035900
2
Disconnect left front door speaker connector,
mirror triangle (H4/23x1) or right front door
speaker connector, mirror triangle (H4/24x1)
from left front door speaker, mirror triangle
(H4/23) or right front door speaker, mirror
triangle (H4/24)
3
Remove retaining clips (2)
4
Remove speaker from mirror triangle
Disconnect plug from bracket (3).
5
Install in the reverse order
Assembly wedge
110 589 03 59 00
Copyright DaimlerChrysler AG 04.08.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1
Page 2583 of 4133

AR07.16-P-1100MM
Remove, install fuel cooler
5.11.99
ENGINE
612.963 in MODELS 163.113
P47.00-2042-12
1
Fuel feed hose
2
Fuel drain hose
3
Coolant feed hose
4
Coolant return flow hose
5
Fuel cooler
7
Bolts of fuel cooler
Operation no. of operation texts or standard texts and flat rates
Category
Op. no.
Operation text
P
075890
REMOVING AND INSTALLING FUEL COOLER
P
075895
REPLACE FUEL COOLER
Remove, Install
Danger!
Risk of injury
to
fingers being jammed or
squeezed
when removing and installing or
aligning hoods, doors, tailgate/tailgate and
sliding roof.
When moving components ensure that no
body parts or limbs are in the area of motion.
AS00.00-Z-0011-01A
Danger!
Risk of injury
to skin and eyes suffering
scalding from contact with hot coolant spray.
Risk of poisoning
from swallowing coolant.
Do not open cooling system unless coolant
temperature is below 90 °C. Open cap slowly
and release the pressure. Do not pour coolant
into beverage bottles.
Wear protective gloves, protective clothing
and eye protection.
AS20.00-Z-0001-01A
Danger!
Risk of explosion
from fuel igniting,
risk of
poisoning
from inhaling and swallowing fuel
as well as
risk of injury
to eyes and skin
from contact with fuel.
No fire, sparks, naked flames or smoking.
Pour fuels only into suitable and appropriately
marked containers.
Wear protective clothing when handling fuel.
AS47.00-Z-0001-01A
1
Open engine hood and raise to vertical position
Have second person secure hood.
AR88.40-P-1000GI
2
Remove trim panel of cylinder head cover
AR01.20-P-5014-02B
*BA01.20-P-1002-01A
*BA01.20-P-1003-01A
3
Drain coolant
At radiator.
AR20.00-P-1142M
4
Close fuel feed hose (1) at the fuel cooler (5)
Set of plugs
*129589009100
*WH58.30-Z-1001-06A
*WH58.30-Z-1002-06A
5
Detach fuel outlet hose (2)
Clamp
*000589543700
Set of plugs
*129589009100
*WH58.30-Z-1001-06A
*WH58.30-Z-1002-06A
6
Disconnect coolant return flow hose (4) to
thermostat housing
Hose clamp pliers (length 210 mm;
adjustment range 80 mm)
*WH58.30-Z-1026-02A
7
Unscrew bolts (7) at fuel cooler
Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1
Page 2584 of 4133

8
Disconnect coolant feed hose (3) to fuel cooler
Raise fuel cooler.
Hose clamp pliers (length 210 mm;
adjustment range 80 mm)
*WH58.30-Z-1026-02A
9
Install in the reverse order
Danger!
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
burns
Secure vehicle to prevent it from moving off
by itself.
Wear closed and tight-fitting work clothes.
Do not grasp hot or rotating parts.
AS00.00-Z-0005-01A
10
Pour in coolant
*BF20.00-P-1001-02E
Switch heater to maximum and warm up
engine at moderate revs. Top up coolant
constantly at coolant expansion reservoir.
Close coolant expansion reservoir once
coolant temperature is 60-70 °C.
Note on coolant level
Models 124, 129, 140, 168, 170, 202, 208,
210, 220, 463
AH20.00-P-1142-01A
11
Inspect cooling system for leaks
AR20.00-P-1010HA
12
Run engine and inspect fuel system for leaks
Crankcase ventilation, cylinder head cover
Number
Designation
Engine
612.963
BA01.20-P-1002-01A
Screw of trim panel of cylinder head cover
to cylinder head cover
NM
10
BA01.20-P-1003-01A
Screw attaching cover panel to charge air
distribution pipe
NM
10
Cooling system
Number
Designation
Engine
612.963
BF20.00-P-1001-02E
Cooling system
Total capacity
Liter
Y
11,0
Capacity of anticorrosion/
antifreeze agent down to -37 °C
Liter
Y
5,5
Capacity of anticorrosion/
antifreeze agent down to -45 °C
Liter
Y
6,25
Specifications for Service
Products
SheetBB00.40-P-0310-01A
SheetBB00.40-P-0325-02A
129 589 00 91 00
Set of closure plugs
Circuit
000 589 54 37 00
Commercially available tools
(see Workshop Equipment Manual)
Number
Designation
Make (e.g.) g.)
Order number
Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2