1997 MERCEDES-BENZ ML430 run flat

29
Slacken cylinder head bolts (21) in stages,

unscrew

Loosen cylinder head bolts according to
loosening schematic only after engine has

cooled down to prevent cylinder head from

distorting.

AR01.30-P-5800-09B


Installation:
Observe tightening pattern

and tightening instructions of cylinder head

bolts.
Oil thread and head contact surface of

cylinder head bolts.
AR01.30-P-5800-07B

Screwdriver insert

*000589031000

Screwdriver insert

*000589041000


*BA01.30-P-1001-01D

30
Remove cylinder head


Installation:

On Engine 112/113 observe

porous points in the left and right cylinder

head. If porous points are present, sealant

must be applied to the cylinder head gasket.


Notes on application of sealant to cylinder

head gasket.
Engine 112, 113

AH01.30-P-1000-04VA

The sealant must be applied within

10 minutes.

Loctite 5900 sealant.

*BR00.45-Z-1015-01A

31
Inspect version of cylinder head gasket
Assignment of cylinder head gasket


Information for assigning the cylinder head

gaskets
Engine 112, 113

AH01.30-P-1000-06V

32
Check cylinder head bolts (21)


AR01.30-P-5800-03B

*BE01.30-P-1001-04B

33
Clean sealing surfaces, inspect for cracks,

shrink holes and flatness, clean threaded

holes.

Pay attention to dowel sleeves (26) for

locating the cylinder head.

Sealing surfaces of crankcase and

cylinder head are provided with an 0.8 mm

thick silicone layer during series production.

At the time of repair installation, silicone

sealant is applied to the sealing area only in

case of any shrink holes.

The sealant must be applied within

10 minutes.

Loctite 5900 sealant.

*BR00.45-Z-1015-01A

34
Install in the reverse order

Danger!

Risk of accident
caused by vehicle starting

off by itself when engine is running.
Risk of

injury
caused by contusions and burns when

working in engine during starting procedure
Secure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.

Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

35
Run engine and inspect for leaks

36
Inspect cooling system for leaks

Warm up engine to operating temperature

and then inspect cooling system or leaks.

AR20.00-P-1010HA

37
Read out and erase fault memory

Stored faults which can result from cables

being disconnected or from simulation during

removal and installation or test work, have to

be processed and erased in the fault

memories after completing the work:

#

Diagnosis Manual Volume 2 Index 0:

Connecting and using test equipment.

Cylinder head/cylinder head bolts

Number

Designation
Engine

112.910/911/912/
913/914/915/
916/917/920/
921/922/923/
940/941/942/
943/944/945/
946/947/949/
951/953/954/
955/960/961/

970/972/973/975
Engine

113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/987/
988/990/991/

992/993

BE01.30-P-1001-04B
Cylinder head bolt
Thread diameter
M
1111

Length (L) when new
mm
141.5141.5

Length (L)
mm
T
144.5
T
144.5

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 5

AR47.20-P-1070M
Removing and installing fuel full-flow filter
24.8.99

ENGINE
612.963 in MODEL 163.113

P47.20-2043-06

1
Fuel feed line

2
Fuel return flow line

3
Fuel cooler

4
Bolts of fuel cooler

70
Fuel full-flow filter

Operation no. of operation texts or standard texts and flat rates
Sector

Op. no.
Operation text

P
075560
REMOVING AND INSTALLING FUEL FULL-FLOW FILTER

P
075563
REPLACING FUEL FULL-FLOW FILTER

P
075564
REPLACING FUEL FULL-FLOW FILTER (AFTER INSPECTING)

Removing, installing

Danger!

Risk of injury
from fingers being
jammed or

bruised
when removing or installing and

aligning hood, doors, trunk lid/tailgate or

sliding roof
Ensure that no parts of your body or limbs are

within the operating range when moving such

components.

AS00.00-Z-0011-01A

Danger!

Risk of explosion
as a result of fuel vapors

igniting.
Risk of poisoning
as a result of

inhaling fuel vapors.
Risk of injury
as a

result of fuel coming into contact with skin

and eyes.
No fire, naked flame or smoking.

Pour fuels only into suitable and appropriate

marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1
Open hood and raise to vertical position


Have assistant secure hood.

AR88.40-P-1000GI

2
Remove trim panel of charge air distribution

pipe

AR01.20-P-5014-02B

*BA01.20-P-1002-01A
*BA01.20-P-1003-01A

3
Disconnect fuel lines (1, 2) at fuel full-flow

filter (70)


Collect fuel which flows out.

Pay attention to use of locking arm. See:
#

Disconnecting and connecting fuel lines at

engine.

AR47.25-P-1000-01A

4
Take off fuel cooler (3)

Take off only the bolts (4) and raise fuel

cooler slightly.

5
Remove fuel full-flow filter (70)


Collect fuel which flows out.

Installation:
If the fuel full-flow filter has been

drained, it must be filled with fuel after being

installed and before starting the engine to

ensure engine starts properly.

*BA47.20-P-1001-02A

6
Install in the reverse order

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

The rapid connection method must only be used inside the vehicle or in the trunk because the connection is
not watertight. They are not permissible for CAN lines.
Fig. 9: Identifying Repair Method Using Rapid Connection Technology

Flat conductor cable repair method
Select crimp contacts in the wiring harness repair kit an d insert into the tool head of the open manual crimp
pliers (2). The flat conductor cable (7) must make contact with the tool head, and the correct edge of the flat
conductor cable (7) must make contac t with the adjusting stop (3). The optical adjusting device (4) in the
manual crimp pliers (2) must be fully visible between 2 conductor tracks. Press the manual crimp pliers (2)
together all the way. After it has been pressed down al l the way, it can be opened again. Remove the finished
crimp connection.
Fig. 10: Identifying Flat Conductor Cable Repair Method

Comparison of circular conductor repair methods
CrimpingRaychem/cable tail
repair methodSolderingRapid connection
technology
Applications Repair cables
Replace damaged
contacts
Repair connectors
Additional line
connectionRepair cables
Cable extension
Integrate repaired
cables (cable tails,
replacement wires) in
the wiring harnessReplace soldered
contacts (special
applications)Repair cables
Additional line
connection
Wire end
connection

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 19 © 2006 Mitchell Repair Information Company, LLC.

Parts ordering notes
INSUFFICIENT AIR CONDITIONING DURING IDLING - AF83.30-P-6007A
MODEL 163.154 #A up to 289564, 163.154 #X, 163.136 /172 with CODE (580) Air conditioning or
Tempmatic for USA
Modification notes
Operation no. of operation texts or standard texts and flat rates
Damage
codeCauseRemedy
83 751
Pressure sensor (B12) occasionally indicates wrong
pressure value to control and operating module
(N19/22) (depending on temperature).
1 Connect pressure gauge and HHT.

Air conditioning/automatic air conditioning
occasionally does not function, refrigerant
compressor does not run.2 Call up air conditioning actual values
with HHT.

3 Compare refrigerant pressure
between pressure gauge (high pressure
side) and HHT.


If pressure difference is greater than
2 bars.?
4 Remove/install/replace pressure
sensor on receiver/drier.

Part no.DesignationQuantity
140 830 00 72Pressure sensorAs required
21.6.04Work steps 1-2 erased
CategoryOp.
no.Operation textTimeAcc.
no.Code
P023731Install modified wiring harness for auxiliary fan (after
checking)015
WU--
Damage
codeCauseRemedy
50 041 73
Fuse f44 blows due to
repeated switch-on of
additional fan
1 Check whether service auxiliary wiring harness (2)
for additional fan has already been installed
The original additional fan connector (M4x1) is
already fastened next to the new additional fan
connector (3) with adhesive tape.


If auxiliary wiring harness (2) is already
installed: ?
2 Ensure that a 40 A fuse is located at position f44


2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 156 © 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

8.1
Check wheel sensor, valve body and sealing

rubber for damage
Vehicles with tire pressure monitor (code 475)

Do not remove wheel sensor for this.


Do not use compressed air, solvents or

detergents to clean the wheel sensor. Wipe

off dirt with a clean, lint-free cloth only.

Do not retighten the female torx bolt and

union nut.

Replace all valve components of wheel

electronics if:
D
The wheel sensor mounting bolt or union

nut is visibly loose.

Replace the wheel sensor if:

D
The wheel sensor is obviously damaged.

D
Tire sealant was used.

Install new wheel sensors:

#

Replace wheel sensor.

AR40.15-P-0080A

8.2
Install new valve (43g).
Vehicles without tire pressure monitor (code

475)

9
Checking condition of rim

AR40.10-P-1010-01A


Mounting

10
Moisten rim flange and tire beads with soapy

water and align assembly head at a small

distance (X, Y) to the disk wheel

Only use soapy water for fitting and

removing tires.

11
Place tire obliquely on the rim and pull on

over the rim flange using the tire installer


Position wheels with wheel sensors so

that the wheel sensor is approximately 180°

opposite the mounting head.

Do not apply compressive force to the wheel
sensor otherwise it will be damaged.


Observe the running direction on tires with

specified running direction.


Put as little stress as possible on bead

area.

12
Align the match points of the tire and disk

wheel with each other and remove the disk

wheel with tire from the tire mounting device

13
Inflate tires without valve element up to max.

3 bar

Do
not
unscrew valve element on disk

wheels with tire pressure monitor sensor.

The tire must slide evenly over the safety

shoulders of the disk wheel, otherwise coat

the tire beads with soapy water again.

14
Screw the valve element into the valve (43g)

and adjust the tire inflation pressure to the

specified value

Observe the tire pressure information in

the fuel filler flap of the vehicle.

15
Balance wheel

AR40.10-P-1040A

124 589 17 63 00 129 589 00 59 00

Removal tool

Assembly tool

Copyright DaimlerChrysler AG 06.07.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 2

AP40.10-P-4050GH
Remove/install wheels, rotate if necessary
15.7.97

MODEL
163

1-5
Tightening sequence

P40.10-0004-01
P40.00-0208-01


Remove

Danger!

Lethal injuries
are possible if vehicle slips off

of lifting platform
Align vehicle between the columns of the

lifting platform and position the four support

plates
at the lifting platform support points

specified by the vehicle manufacturer.

AS00.00-Z-0010-01A



Comply with notes on tires / rims

AH40.10-P-9411-01A

1
Raise vehicle.

AS00.00-Z-0010-01A

2
Unscrew wheel bolts, remove wheels

3
Check wheel bolts


The round contact shoulders on the lug

bolts must be free of oil and grease.

Replace bolts that have a damaged thread,

worn dacromet coating at radius seat or

corroded radius seat.

4
Check tires for damage and wear - measure

depth of tread

AP40.10-P-4051Z

5
Check disk wheels
D
check for contamination,

D
check that spherical caps are free of oil

and grease,

D
check centering, spherical caps and rim

flanges for damage,

D
check corrosion of lay-on surface

6
Check front wheel hub, brake disk bowl at

attachment face for contamination and

corrosion
Clean corroded surfaces with a wire brush or

an emery cloth.


Install

7
Change wheels around if necessary retaining

the same running direction


This excludes vehicles with mixed tires at

the front and rear axle.

Between

5,000 and 10,000 km according to wear.

8
Fit wheels, tighten wheel bolts

Observe tightening sequence "1-5".


*BA40.10-P-1001-01A


*126589040900

9
Lower vehicle, correct tire inflation pressure

(including spare wheel)


In the case of loss of tire pressure,

determine cause and replace tire if necessary.

On versions with spare tire attached to

underside of vehicle, check tire inflation

pressure of spare tire before lowering the

vehicle.

c
Deletion of spare tire with model 163.174

with TIREFIT

AH40.10-P-0001-01A


Wheels

Number

Designation
Models

163.113/128/
136/154/157/

172/175
Model

163.174

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