1997 MERCEDES-BENZ ML430 tailgate

being jammed or squeezed
when removing and
installing or aligning hoods,
doors, trunk lid/tailgate or
sliding roof.ensure that no body parts or
limbs are within the operating
range of moving parts.
1Open engine hoodModel 163.136/154 /172 #A up
to 145272,
Model 163.136 /154 /172 #X up
to 708318AR88.40-P-1000GH
Model 163.136 /154 /172 #A as
of 145273,
Model 163.136 /154 /172 #X
from 708319,
Model
163.113/128 /157 /174 /175AR88.40-P-1000GI
2Disconnect battery ground
line Insulate cable lug of ground
line for protection against
unintentional contact of
disconnected ground line.AR54.10-P-0003A
Notes on batteryAll modelsAH54.10-P-0001-
01A
3Remove air cleaner housing Installation: Apply liquid
lubricant to the mounting
rubbers and to the connection to
the air hose.
Lubricant
*BR00.45-Z-1002-
06A
4.1Remove engine trim panel Engine 112, 113 only.
Pull the engine cover
vertically upwards and detach it
from the cylinder head covers.
5Slacken poly V-belt Do not remove the poly-V-
belt!
Engine 111AR13.22-P-1202A
Engine 603.931/972,
Engine 113.942AR13.22-P-1202B
Engine 113.981/965AR13.22-P-1202BA
6Disconnect electrical line
circuit 30 (B+) (1) and
electrical line circuit 61 (D+)
(2) On engine 112, 113 take off
cover sleeve (4).

*BA15.40-P-1001-
01A
*BA15.40-P-1002-
01A
7Unscrew bolts (3) of the
generator (G2) *BA15.40-P-1003-
01A
8Take out generator (G2)
9Install in the reverse

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 61 © 2006 Mitchell Repair Information Company, LLC.

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

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

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.
RISK OF ACCIDENT AND INJURY
Please make sure that:
The vehicle is centered lengthwise and crosswise between the lifting platform columns.
The support plates on the lifting platform support points are all positioned at the same height.
The vehicle is first raised a few inches (wheels are still touching the ground) and the position and fit of
the support plates and lift points are checked before raising the vehicle to the full lifted position.
The vehicle is not raised off the lifting platform plates when components are being supported.
If the arms of the lifting platform or the support plates are not positioned properly, or if components of the
vehicle are supported so that the vehicle raises off the platform, then the vehicle can slip off the platform and
cause life-threatening injuries to you or other people.
Before removing axles and assemblies from the vehicle, make sure the vehicle is secured to the platform or that
sand bags are used to balance the vehicle out.
Otherwise the vehicle could tip because of the uneven distribution of weight. This could cause life-threatening
injuries to you or other people.
RISK OF INJURY CAUSED BY FINGERS BEING JAMMED OR PINCHED WHEN REMOVING, INSTALLING OR
ALIGNING HOODS, DOORS, TRUNK LID/ REAR-END DOOR OR SLIDING ROOF. - AS00.00-Z-0011-01A
When moving components, ensure that no body parts or limbs are within the operating range of moving
parts.
Risk of injury
When working on hoods, doors, trunk lids/tailgates and sliding roofs and on their connecting mechanisms,
serious injuries can occur due to cutting, jamming or pinching of body parts like fingers and hands.
Safety instructions/precautions
Be careful when working in hazardous areas.
When moving components, secure the movement area of the mechanism to prevent interference.
Use special tool or other means to ensure safe distance to dangerous areas. NOTE: In Germany, lift platform operators must observe the following regulations and
guidelines: "Berufsgenossenschaftvorschrift (BGV) D29 fur Hebebuhnen" and
the guidelines issued by the lift platform manufacturer. In other countries,
operators must comply with all relevant statutory and accident prevention
regulations.

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:47 PMPage 223 © 2006 Mitchell Repair Information Company, LLC.

Wear protective gloves
RISK OF INJURY FROM FINGERS BEING PINCHED OR JAMMED WHEN WORKING ON GAS STRUTS UNDER
PRESSURE - AS00.00-Z-0012-01A
Remove and install gas struts only in relaxed position and on components which have been secured
properly.
Injury hazard
Risk of injury from pinching or crushing when working on gas struts under pressure.
When removing and installing gas struts not in the relaxed position injury can result to body parts from
pinching, crushing or jamming.
Rules of behavior/protective measures
Remove and install gas struts only in relaxed position (pressure or thrust rod completely extended).
Support components held by gas strut (tailgates, doors, trunk lids, seat frame, etc.) in position by suitable
means before removing gas struts.
Replace damaged retaining clips or keepers.
When moving components secure motion area of mechanism against reaching in.
RISK OF INJURY & RICK OF POISONING - AS00.00-Z-0013-01A
Depressurize the hydraulic system completely before starting any work on the system. Wear protective
clothing and eye protection.
Possible hazards
Risk of injury
When disengaging hydraulic lines without first depressurizing the system, dangerous skin or eye injuries may
occur due to the very high pressures (in excess of 200 bar). If hydraulic fluid, particularly central hydraulic fluid
(especially harmful), comes into contact with unprotected skin, this may cause damage to the skin.
Risk of poisoning
If hydraulic fluid is swallowed, this may lead to poisoning symptoms such as headache, giddiness, abdominal
pain, vomiting, diarrhea, cramps and unconsciousness.
Protective measures/guidelines
When commencing work on hydraulic systems, these must be depressurized; the system must be drained
if necessary.
Do not pour hydraulic fluid into beverage containers.

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:47 PMPage 224 © 2006 Mitchell Repair Information Company, LLC.

AR88.40-P-3020GH
Adjust engine hood
8.4.99

MODEL
163.113 /128 /136 /154 /157 /172 /174 /175

P88.40-2067-09

1
Bolts

2
Engine hood

3
Engine hood hinge
7

Locknut

8
Nuts

4

Bolts

5
Engine hood catch upper section

6
Stop buffer

Longitudinal, height and transverse

adjustment


Danger!

Risk of injury
to
fingers being jammed or

pinched
when Remove/install or aligning

hoods, doors, trunk lid/tailgate or sliding roof.
When moving components, ensure that no

body parts or limbs are within the operating

range of moving parts.

AS00.00-Z-0011-01A

1
Open engine hood (2)

For slight range of adjustments for

longitudinal and height adjustment

2
Loosen bolts (1) on engine hood hinge (3)

and adjust engine hood (2)

3
Tighten bolts (1)


*BA88.40-P-1001-01C

For larger range of adjustments for

longitudinal and height adjustment

4.1
Remove gas-operated strut from engine hood

(2) and put down in engine compartment

Risk of breakage. Do not remove the

retainer otherwise the preload will be lost.

AR88.40-P-3010GH

As of VIN A145273, X708319.

5
Remove cover on air intake

AR83.25-P-1405GH

6
Remove rubber cover from engine hood hinge


Installation:
Replace rubber cover.

7
Cut seam sealing along engine hood hinge so

that hinge can be moved


Installation:
Replace seam sealing. Paint

sealant after curing.

*BR00.45-Z-1004-01A

8
Loosen nuts (8) on engine hood hinge (3)

9
Adjust engine hood (2) so that front edges of

front fenders are flush with engine hood and

top edges are aligned

For larger range of adjustment in

longitudinal direction loosen engine hood

catch upper section (5) and tighten.


*BA88.40-P-1004-01C

10
Tighten nuts (8) for engine hood hinge (3)


*BA88.40-P-1002-01C

11.1
Install gas-operated strut

As of VIN A145273, X708319.

AR88.40-P-3010GH

12
Adjust stop buffer (6)

Unscrew locknut (7). Adjust height of stop

buffer so that top edges of front fenders and

engine hood are flush If required, place

spacer plates below engine hood catch upper

section.

13
Fasten stop buffer (6)

Tighten locknut (7).

Transverse adjustment

14
Loosen bolts (4) from engine hood catch

upper section (5)

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR88.40-P-3020GH
Adjust engine hood
8.4.99

MODEL
163.113 /128 /136 /154 /157 /172 /174 /175

P88.40-2067-09

1
Bolts

2
Engine hood

3
Engine hood hinge
7

Locknut

8
Nuts

4

Bolts

5
Engine hood catch upper section

6
Stop buffer

Longitudinal, height and transverse

adjustment


Danger!

Risk of injury
to
fingers being jammed or

pinched
when Remove/install or aligning

hoods, doors, trunk lid/tailgate or sliding roof.
When moving components, ensure that no

body parts or limbs are within the operating

range of moving parts.

AS00.00-Z-0011-01A

1
Open engine hood (2)

For slight range of adjustments for

longitudinal and height adjustment

2
Loosen bolts (1) on engine hood hinge (3)

and adjust engine hood (2)

3
Tighten bolts (1)


*BA88.40-P-1001-01C

For larger range of adjustments for

longitudinal and height adjustment

4.1
Remove gas-operated strut from engine hood

(2) and put down in engine compartment

Risk of breakage. Do not remove the

retainer otherwise the preload will be lost.

AR88.40-P-3010GH

As of VIN A145273, X708319.

5
Remove cover on air intake

AR83.25-P-1405GH

6
Remove rubber cover from engine hood hinge


Installation:
Replace rubber cover.

7
Cut seam sealing along engine hood hinge so

that hinge can be moved


Installation:
Replace seam sealing. Paint

sealant after curing.

*BR00.45-Z-1004-01A

8
Loosen nuts (8) on engine hood hinge (3)

9
Adjust engine hood (2) so that front edges of

front fenders are flush with engine hood and

top edges are aligned

For larger range of adjustment in

longitudinal direction loosen engine hood

catch upper section (5) and tighten.


*BA88.40-P-1004-01C

10
Tighten nuts (8) for engine hood hinge (3)


*BA88.40-P-1002-01C

11.1
Install gas-operated strut

As of VIN A145273, X708319.

AR88.40-P-3010GH

12
Adjust stop buffer (6)

Unscrew locknut (7). Adjust height of stop

buffer so that top edges of front fenders and

engine hood are flush If required, place

spacer plates below engine hood catch upper

section.

13
Fasten stop buffer (6)

Tighten locknut (7).

Transverse adjustment

14
Loosen bolts (4) from engine hood catch

upper section (5)

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR88.40-P-3060GH
Remove/install engine hood hinge
16.4.97

MODEL
163.113 /128 /136 /154 /157 /172 /174 /175

P88.40-0365-01
P88.40-0364-01

1
Screws

2
Engine hood hinge

3
Nuts


Removing and installing


Danger!

Risk of injury
to
fingers being jammed or

squeezed
when removing and installing or

aligning hoods, doors, trunk lid/tailgate or

sliding roof.
When moving components, ensure that no

body parts or limbs are within the operating

range of moving parts.

AS00.00-Z-0011-01A
1.1
Remove engine hood

Only when both engine hood hinges are

removed.

AR88.40-P-3000GH
1.2
Open engine hood and raise to vertical position

Up to VIN A145272, X708318.

AR88.40-P-1000GH

As of VIN A145273, X708319.

AR88.40-P-1000GI

2
Remove cover on air intake

AR83.25-P-1405GH

3
Remove rubber cover from engine hood hinge


Installation:
Replace rubber cover.

4
Cut joint seal along engine hood hinge so that

hinge can be moved


Installation:
Replace seam sealing. Paint

sealant after curing.

*BR00.45-Z-1004-01A

5
Mark installation position of engine hood

hinge (2)

Facilitates installation.

6.1
Remove gas strut

As of VIN A145273, X708319.

AR88.40-P-3010GH

Danger of breaking!
Do not remove the

retainer otherwise the preload will be lost.

7
Remove screws (1)


Support engine hood at rear to prevent

damage.


*BA88.40-P-1001-01C

8
Unscrew nuts (3)


*BA88.40-P-1002-01C

9
Remove engine hood hinge (2)

Installation:
Align engine hood hinge at
marks made previously.

10
Install in the reverse order

11
Check alignment of engine hood
If necessary:
#

Adjust engine hood

AR88.40-P-3020GH


Engine hood

Number

Designation
Model 163

BA88.40-P-1001-01C
Screw for engine hood hinge on engine hood
Nm
10

BA88.40-P-1002-01C
Nut for engine hood hinge on body
Nm
18

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 1