1997 MERCEDES-BENZ ML350 Complete Repair Manual

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Page 3201 of 4133

MERCEDES-BENZ ML350 1997 Complete Repair Manual
Danger!

Risk of explosion
from explosive gas.
Risk

of poisoning and caustic burns from

swallowing battery electrolyte.
Risk of injury

through burns to skin and eyes from battery

aci

Danger!

Risk of explosion
from explosive gas.
Risk

of poisoning and caustic burns from

swallowing battery electrolyte.
Risk of injury

through burns to skin and eyes from battery

acid or when handling damaged lead-acid

batteries
No fire, sparks, naked flames or smoking.

Wear protective gloves, acid-resistant

clothing and safety glasses. Pour battery

electrolyte only into suitable and appropriately

marked containers.

AS54.10-Z-0001-01A

4
Remove battery

AR54.10-P-0005GH

5
Press out template (6) and adapt the size to

the correct dimensions (a, b)Determine ACTUAL dimension (a) from the

drawing.

Divide the SPECIFIED dimension (a) by the

determined ACTUAL dimension (a) and copy

the template to the original size with the

corresponding factor.

Check dimensions for both axles.

6
Cut out template

7
Cut out holes (7, 8) for engine hood hinge

studs

8
Position template in the engine hood hinge

support using the stud holes

The template is drawn for the left side.

Turn over to obtain the right side.

9
Center the engine hood hinge support on the

template using the markings (9, 10, 11)

10
Remove template

11
Drill a hole at each center punch mark (3, 4, 5)

Only drill through the 2 upper panels. Do

not drill through the reinforcement panel (3rd

panel).

*201589005100

12
Cover windshield, paint surface and adjacent

components adequately in order to avoid

damage due to welding work

Cover apertures in the body in order to

prevent flying sparks: the foam in the

instrument panel burns easily.

c

General information on repairs to body

AH60.00-N-0001-01A

Danger!

The high voltage used for arc welding

presents a lethal hazard
.
Explosion hazard

when welding in area of materials easily

inflammable.
Injury hazard
from welding

spatter and UV-light while welding.
Risk of

poisoning
when inhaling welding vapors.
Use insulating mats. Wear protective clothing,

safety glasses, and protective mask.

Remove

highly inflammable materials from the danger

zone. Use air extractor.

AS00.00-Z-0007-01A

13
Plug weld each hole

*WE58.40-Z-1005-02A

14
Plug welds should be flat and ground smooth

15
Remove covers and clean the repair area

16
Prime untreated points in the area of the

engine hood hinge support

17
Prime the underside of the reinforcement

panel of the engine hood hinge

Access to underside of engine hood hinge

support through the recess for the wiper motor.

18
Spray the underside of the reinforcement

panel of the engine hood hinge support with

wax preservative

Access to underside of engine hood hinge

support through the recess for the wiper motor.

19
Install in the reverse order

Weld spot miller

201 589 00 51 00

Workshop equipment/MB testers
(see Workshop Equipment Manual)

WE58.40-Z-1005-02A
MIG inert gas welding equipment, aluminum weldable, sold by company Wieländer & Schill

Repair products

Number

Designation
Order number

BR00.45-Z-1004-01A
MB body sealant for sealing seams (suitable for painting)
001 989 63 20

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

Page 3202 of 4133

MERCEDES-BENZ ML350 1997 Complete Repair Manual Parts ordering notes
Part no.

Designation
Quantity

000 986 06 50
Priming stick
1

000 986 33 70 10
Wax preservative
1

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-o

Page 3203 of 4133

MERCEDES-BENZ ML350 1997 Complete Repair Manual
SM63.20-P-0003GI
Reinforce right front engine hood hinge support
16.1.02

MODELS
163.136 /154 /172 #A as of 145273,

163.136 /154 /172 #X as of 708319,

163.113 /128 /174 /175

P63.20-3439-12

Th

Page 3204 of 4133

MERCEDES-BENZ ML350 1997 Complete Repair Manual 3
Remove engine hood hinge on the front

passenger side

AR88.40-P-3060GH

*BR00.45-Z-1004-01A

Danger!

Risk of explosion
from explosive gas.
Risk

of poisoning and caustic burns from

swa

3
Remove engine hood hinge on the front

passenger side

AR88.40-P-3060GH

*BR00.45-Z-1004-01A

Danger!

Risk of explosion
from explosive gas.
Risk

of poisoning and caustic burns from

swallowing battery electrolyte.
Risk of injury

through burns to skin and eyes from battery

acid or when handling damaged lead-acid

batteries
No fire, sparks, naked flames or smoking.

Wear protective gloves, acid-resistant

clothing and safety glasses. Pour battery

electrolyte only into suitable and appropriately

marked containers.

AS54.10-Z-0001-01A

4
Remove battery

AR54.10-P-0005GH

5
Remove air conditioning blower motor

AR83.30-P-5560GH

6
Print out template (6) and adapt the size to

the correct dimensions (a, b)Determine ACTUAL dimension (a) from the

drawing.

Divide the SPECIFIED dimension (a) by the

determined ACTUAL dimension (a) and copy

the template to the original size with the

corresponding factor.

Check dimensions for both axles.

7
Cut out template

8
Cut out holes (7, 8) for engine hood hinge

studs

9
Position template in the engine hood hinge

support using the stud holes

The template is drawn for the left side.

Turn over to obtain the right side.

10
Center the engine hood hinge support on the

template using the markings (9, 10, 11)

11
Remove template

12
Drill a hole at each center punch mark (3, 4, 5)

Only drill through the 2 upper panels. Do

not drill through the reinforcement panel (3rd

panel).

*201589005100

13
Cover windshield, paint surface and adjacent

components adequately in order to avoid

damage due to welding work

Cover apertures in the body in order to

prevent flying sparks: the foam in the

instrument panel burns easily.

c

General information on repairs to body

AH60.00-N-0001-01A

Danger!

The high voltage used for arc welding

presents a lethal hazard
.
Explosion hazard

when welding in area of materials easily

inflammable.
Injury hazard
from welding

spatter and UV-light while welding.
Risk of

poisoning
when inhaling welding vapors.
Use insulating mats. Wear protective clothing,

safety glasses, and protective mask.

Remove

highly inflammable materials from the danger

zone. Use air extractor.

AS00.00-Z-0007-01A

14
Plug weld each hole

*WE58.40-Z-1005-02A

15
Plug welds should be flat and ground smooth

16
Remove covers and clean the repair area

17
Prime untreated points in the area of the

engine hood hinge support

18
Prime the underside of the reinforcement

panel of the engine hood hinge

Access to underside of engine hood hinge

support through the recess for the wiper motor.

19
Spray the underside of the reinforcement

panel of the engine hood hinge support with

wax preservative

Access to underside of engine hood hinge

support through the recess for the wiper motor.

20
Install in the reverse order

Weld spot miller

201 589 00 51 00

Workshop equipment/MB testers
(see Workshop Equipment Manual)

WE58.40-Z-1005-02A
MIG inert gas welding equipment, aluminum weldable, sold by company Wieländer & Schill

Repair products

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

Page 3205 of 4133

MERCEDES-BENZ ML350 1997 Complete Repair Manual
Number
Designation
Order number

BR00.45-Z-1004-01A
MB body sealant for sealing seams (suitable for painting)
001 989 63 20

Parts ordering notes
Part no.

Designation
Quantity

000 986 06 50
Primin

Page 3206 of 4133

MERCEDES-BENZ ML350 1997 Complete Repair Manual
AR88.40-P-3200GI
Remove/install engine hood lock
9.4.99

MODEL
163.136 /154 /172 #A as of 145273,

163.136 /154 /172 #X as of 708319,

163.113 /128 /157 /174 /175

P88.40-2058-06

1
Screws

2
E

Page 3207 of 4133

MERCEDES-BENZ ML350 1997 Complete Repair Manual
AP88.40-P-8821GH
Lubricating hood catch, locking hook and hinges
2.7.97

MODEL
163

Engine hood lock version up to

31/ 08/ 99

P88.40-0381-01 P88.40-0380-01
P88.40-2082-01

E
ngine hood lock versi

Page 3208 of 4133

MERCEDES-BENZ ML350 1997 Complete Repair Manual
AR88.40-P-3200GH
Removing and installing engine hood lock
8.4.99

MODEL
163.136 /154 /172 up to 31.8.99

P88.40-2054-06

1
Screw

2
Bottom section of engine hood lock

3
Engine hood control cable

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