1997 MERCEDES-BENZ ML430 tailgate

AR88.40-P-3000GH
Remove/install engine hood
25.3.97

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

P88.40-2062-01

1
Screws

2
Gas pressure strut


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
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
Mark position of engine hood hinges on

engine hood

Facilitates installation.

3.1
Remove gas strut (2)


Secure engine hood with helper to avoid

damage.

AR88.40-P-3010GH

As of VIN A145273, X708319.

4
Remove screws (1)


Installation:
Paint screws.


*BA88.40-P-1001-01C

5
Remove engine hood


Use helper to avoid damage. Set down on

suitable surface.

6
Install in the reverse order

Align engine hood on engine hood hinges

at markings made previously.

7
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

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

REMOVE/INSTALL REAR ROOF FRAME PANELING - AR68.30-P-4470GH
MODEL 163.113 /128 /136 /154 /157 /172 /174 /175
Fig. 67: Identifying Rear Roof Frame Paneling Components

20headliner (11)
21Unfasten headliner (11) from
Velcro strips (8) Installation: Only with electric sliding/ tilting
roof in glass version, Code (414a): align headliner at
sliding/tilting roof frame.

22Remove wiring harness (9)
from headliner (11)
23
Unclip screw frame for
headliner / overhead control
panel (10) from headliner

24Remove headliner (11)
through tailgate
25Install in the reverse order

Remove, Install
1.1Remove belt end fitting at bottom of
3rd seat row(1)Only with 3rd seat row, code 847.
*BA91.40-P-

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Interior Equipment - 163 Chassis
me
Saturday, October 02, 2010 3:35:22 PMPage 66 © 2006 Mitchell Repair Information Company, LLC.

AR46.20-P-0600GH
Removing and installing rack-and-pinion steering
1.3.97

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

P46.20-2126-09

Shown on model 163.154 (vehicles

without speed-sensitive power steering)

1
Front axle carrier

10a
Tie rod joint

21
Rubber mount
25d

Nut

25f
Steering coupling shield

30f
Return line

30i
High-pressure expansion hose

80a
Lower steering shaft

23

Rack-and-pinion steering

23a
Bolts

23h
Shim

23i
Shim

25
Steering coupling

Modification notes
10.9.03

Reference to adjusting toe on front axle replaced by

reference to chassis alignment check
Step 16.1

Removing, installing

Danger!

Risk of fatal injury
if the vehicle slips or

topples off the 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


Danger!

Risk of injury
with
trapped or crushed

fingers when removing and installing or

aligning hoods, doors, trunk lid/tailgate and

sliding roof.
When moving components ensure that no

body parts or limbs are in the area of

movement.

AS00.00-Z-0011-01A

1
Open engine hood

AR88.40-P-1000GI

2
Extract oil from power steering pump supply

reservoir

Hand pump

*210589007100

3
Raise vehicle

4
Remove front axle gear

AR33.30-P-0525GH

5
Press tie rod joints (10a) off steering knuckles


Installation:
Replace self-locking nuts.

AR46.40-P-0200-02C


*BA46.40-P-1001-01C

Thrust piece

*140589006300

Puller

*202589023300

6
Turn steering wheel to horizontal position

(front wheels in straight-ahead position)

7
Remove key and engage steering lock

8.1
Unplug speed-sensitive power steering

connector from timing case
On vehicles with speed-sensitive power

steering code 213a

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

AR20.40-P-5000M
Remove/install electric fan
24.8.99

ENGINE
612.963 in MODEL 163.113

P20.40-2015-06

Shown on Model 163.113 with

Engine 612.963

1
Clutch

2
Electrical lines circuit 30

3
Clips

4
Captive nuts

5
Bolts

M4/7
Electric suction fan engine and AC

with integrated control


Remove/Install


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


Danger!
Risk of death.
Death may result if vehicle

slips or topples from the 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

1
Place the vehicle on lifting platform

AR00.60-P-1000GH

2
Open engine hood and raise to vertical position

Have second person secure hood.

AR88.40-P-1000GI

3
Connect quiescent current retention device


*WH58.30-Z-1005-09A

4
Disconnect ground cable of battery

AR54.10-P-0003A

5
Detach coupling (1) at electrical connector of

fan

6
Disconnect electrical lines circuit 30 (2) at
electric fan

7
Unclip wiring harness from bracket

8
Remove front part of noise encapsulation

AR94.30-P-5400GH

9
Detach clamps (3) at bottom side of electric fan

10
Unscrew screws (5)

11
Remove captive nuts (4)

12
Unhinge electric suction fan engine and AC

with integrated control (M4/7) at top of

radiator and take out toward bottom


Installation:
Insert retaining lugs of

electric fan into the mounts at radiator.

13
Install in the reverse order

Commercially available tools

Number

Designation
Make (e. g.)
Order number

WH58.30-Z-1005-09A
CMP 12.2 quiescent current retention unit
Hans Zeheter

Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1

AR20.20-P-3865MM
Remove/install radiator
10.11.99

ENGINE
612.963 in MODEL 163.113

P20.20-2080-09

1
Electric fan

2
Low temperature cooler

3
Bolts (low temperature cooler)
110/2

Charge air cooler

4
Lamp units

5
Cover strips

6
Radiator crossmember

P20.20-2081-09

8
Coolant hose for coolant pump

9
Coolant hose of thermostat housing

10
Coolant hose of coolant expansion tank

11
Seal strip

12
Air ductings
19

Power steering oil line (feed line of
steering gear

!
radiator)

20
Attachment parts

21
Damper rubber

13

Mounting clips

14
Air conditioning fluid reservoir

15
Radiator

16
Bolts

17
Capacitor

18
Power steering oil line

(Return line of radiator

!

Power steering pump supply reservoir)


Removal/installation


Danger!

Risk of injury
to
fingers being jammed or

pinched
when removing, 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

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Page 1

AR20.00-P-1250B
Remove oil from cooling and heating system
22.7.97

ENGINE
611.960 in MODEL 202.134 /193 /194 /133

ENGINE
611.961 in MODEL 210.006 /206 /007 /606

ENGINE
611.962 in MODEL 203.006 /004 /206 /204 /706

ENGINE
612.961 in MODEL 210.616 /216 /016

ENGINE
612.962 in MODEL 203.016 /216

ENGINE
612.963 in MODEL 163.113

ENGINE
613.960 in MODEL 220.026

ENGINE
613.961 in MODEL 210.026 /226

ENGINE
628.960 in MODEL 220.028 /128

ENGINE
628.961 in MODEL 211.028

ENGINE
628.963 in MODEL 163.128

ENGINE
646.951 in MODEL 211.004

ENGINE
646.961 in MODEL 211.006 /206 /606

ENGINE
647.961 in MODEL 211.016 /216 /616

ENGINE
648.961 in MODEL 211.023 /026 /223 /226

ENGINE
612.967 in MODEL 209.316

ENGINE
612.990 in MODEL 203.018 /218 /718

ENGINE
646.962 in MODEL 203.007 /207 /707

ENGINE
646.963 in MODEL 203.008 /208 /708

P20.00-2078-06

Shown on engine 611.962

1
Coolant expansion reservoir

18
Radiator

20
Coolant thermostat


Remove/Install


Danger!

Risk of accident
caused by vehicle starting

off 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


Danger!

Risk of injury
from
fingers being jammed

or crushed
when removing / install / aligning
hoods, doors, trunk lid/tailgate or sliding roof.
With moving components, ensure that no

body parts or limbs are within the operating

range of moving parts.

AS00.00-Z-0011-01A


Danger!

Risk of injury
to skin and eyes suffering

scalding from contact with hot coolant spray.
Risk of poisoning
if coolant is swallowed.
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

1
Open the engine hood and raise to vertical

position
Model 163

AR88.40-P-1000GI

Model 202

AR88.40-P-1000E

Model 203

AR88.40-P-1000P

Model 209

AR88.40-P-1000Q

Model 210

AR88.40-P-1000F

Model 211

AR88.40-P-1000T

Model 220

AR88.40-P-1000M

Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1

13
Unhook vertical adjustment cable (6) from

vertical adjustment handle (5)

14
Guide vertical adjustment cable (6) through

grommet (12)


Installation:
If a new rear seat cushion

frame is used, the grommet must be installed

in the new rear seat cushion frame.

15
Remove handle locking device (13) from rear

seat cushion frame

16
Unhook horizontal adjustment cable (8) at clip

(10) and at front of rear seat cushion frame

Risk of breakage!

17
Unscrew bolts from horizontal adjustment

handle

18
Detach horizontal adjustment cable (8) from

horizontal adjustment handle

Risk of breakage!

Pull out horizontal adjustment handle.

19
Remove rear seat seat belt buckle

40% rear seat without side airbag in left

and right rear, code 293.

AR91.40-P-1516GH

40% rear seat with side airbag in left and
right rear, code 293.

AR91.40-P-1516GK

60% rear seat outer seat.

AR91.40-P-1516GJ

20
Unscrew mounting screws for rear seat

cushion frame (2)

Installation:
Replace damaged shims at

the diagonal supports of the rear seat.


*BA91.12-P-1010-03A

21
Remove rear seat cushion frame (3)

Remove rear seat cushion frame through

tailgate

22
Install in the reverse order


Rear seats

Number

Designation
Model

163 as of

09/99

BA91.12-P-1009-03A
Bolt for clamping band to seat frame
Nm
45

BA91.12-P-1010-03A
Screw for bracket to seat frame
Nm
23

Torx bit set

000 589 01 10 00

Copyright DaimlerChrysler AG 14.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 2

AR88.30-P-0200-04GH
Prepare cutting tool

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e. g.)
Order number

WH58.30-Z-1010-10A
Cutting tool kit (compressed-air tool + blades)
Europe:

The Barn

Holly Tree Farm

Holmes Chapel Road

Lower Withington,

Cheshire, SK11 9DT

England

Tel.:

+44 1477 571700

Japan:

Osaka Chamber of

Commerce

2-8 Hommachibashi

Chuo-ku

Osaka, Japan, 540-

0029

Tel.:+81 6 6944 6445

USA:

SPX

Dealer Equipment

Services Tel.:

+1-888-458-4040

P88.30-2070-01

Observe general notes, guidelines and safety precautions for operation of pneumatic tools

contained in the operating instructions, included with the tool kit to avoid hazards and incorrect

operation.

Sharpen blades before use and while cutting with wet whetstone WK8 to obtain best results.

Detach detachable components from front fender, rear fender and tailgate with the following

blades:

-
Blade WK24ZV (5) with adjustment arm WK11B (6) when using pneumatic tool WK10HD
(3).

-
Blade WK24S (1) or WK6 with handle WK7 (2) for manual use.

P88.30-2071-01

1
Attach felt pads (4) at the bottom of the pneumatic tool (vehicle side) as well as the back of

the blade to protect the paint work.

2
Adjust cutting depth with adjustment arm WK11B (6).

To separate the detachable components from the front fender and rear fender, adjust rear

adjustment arm WK11 to a=25 mm, on tailgate to a=40 mm.

3
Set compressed air valve to p=6 bar for operation of pneumatic

tool and turn power control on tool to

position 1/2 - 2/3.

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Page 1