1997 MERCEDES-BENZ ML430 low oil pressure

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.

-----------------------------------------------------------------------------------------

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Page 1

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

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Page 1

AR20.20-P-3865HC
Remove/install the radiator
5.6.97

ENGINE
112.942 in MODEL 163.154

ENGINE
112.970 in MODEL 163.157

ENGINE
113.942 in MODEL 163.172

ENGINE
113.965 in MODEL 163.175

ENGINE
113.981 in MODEL 163.174

P20.20-2017-09

Shown on Model 163.154 with Engine 112

1
Viscous fan

2
Plate clamps of fan shroud

3
Fan shroud

4
Coolant line

5
Coolant line to expansion reservoir

6
Coolant line

7
Headlamps
17

Air deflector plate

18
Oil line (return line radiator

!
expansion

reservoir of power steering pump)

19
Oil line (feed line steering gear

!

radiator)

20
Fasteners

21
Damper rubber

8

Radiator crossmember

9
Rubber seal of radiator

10
ATF lines

11
Fan grille

12
Air guides

13
Clamps of air guides

14
Air conditioning system fluid reservoir

15
Radiator

16
Cover strips

Modification notes
23.3.00

Radiator with integral oil cooler for power steering pump
See step 5 and 16


Remove/install


External torx set

*001589760900


6 mm hexagon socket

*WH58.30-Z-1001-06A

7 mm hexagon socket

*WH58.30-Z-1002-06A

1.1
Remove air deflector plate (17)

Engine 113.942 only.

Danger!

Risk of injury
to skin and eyes from scalding

due to 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

2
Drain the coolant at the radiator


To drain the coolant, detach coolant line

at the bottom of the radiator or at the coolant

pump.


Installation:
Replace the hose clamps on

the radiator fitting for the coolant hose, as

they could cause damage to the screw/thread. AR20.00-P-1142HA

Hose clamp

*BA20.20-P-1004-01A

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Page 1

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

1
Open engine hood and raise to vertical position

Have second person secure hood.

AR88.40-P-1000GI

2
Connect no load current retention unit


*WH58.30-Z-1005-09A

3
Disconnect battery ground cable

AR54.10-P-0003A

4
Remove trim panel of cylinder head cover

AR01.20-P-5014-02B


*BA01.20-P-1002-01A


*BA01.20-P-1003-01A

5
Remove bottom part of noise encapsulation

at front

AR94.30-P-5400GH

6
Remove electric fan (1)

Remove toward bottom.

AR20.40-P-5000M

7
Drain coolant

At radiator.

AR20.00-P-1142M


Notes on coolant
All engines

AH20.00-N-2080-01A

8
Remove charge air cooler (110/2)

AR09.41-P-6817MM

9.1
Attach guard plate for radiator/condenser

With automatic air conditioning, code

581a and AC system or Tempmatic USA,

code 580.

Attach additional AC condenser in the

vehicle.

y

Guard plate for radiator/condenser
Engine 606 in model 124,
Engine 606.961 in model 140,

Engine 112, 113, 604, 605, 611.960 in

MODEL 202,

Engine 602.983, 612.966 in MODEL 461,

Engine 628.962, 612.965, 606.964, 112.945,

113.962/ 982 in MODEL 463,

Engine 111, 112, 611.962, 612.962 in model

203,

Engines 112, 113, 611.961, 612.961, 613.961

in MODEL 210,

Engine 112 in model 170,

Engine 112 in MODEL 220,

Engine 113 in MODEL 211, 215, 220,

Engine 112 in MODEL 208,

Engine 112, 612.963, 628.963 in MODEL 163,
Engine 112.923 /943, 113.961 in MODEL 129,

Engine 137, 275 in MODEL 215, 220,

Engine 613.960, 628.960 in MODEL 220,

Engine 113.992 in model 230.474,

Engine 271 in model 209, 203,

Engine 285.950 in model 240.078 /178,

Engine 612.967 in model 209.316,

Engine 648 in model 220

Engine 112.951 in model 639.601/603/

605/701/703/705/801/803/805

Engine 646.983/984 in model 639.601/

603/605/701/703/705/801/803/805

Engine 646.982 in model

639.601/603/605/701/703/705

WF58.50-P-0110-01A

10
Remove seal rail (11)

11
Extract steering oil from reservoir

Hand pump

*210589007100

12.1
Disconnect power steering oil line (return line

radiator

!
power steering pump supply

reservoir) (18)

Seal connections.


Installation:
Install new sealing rings.


*BA46.30-P-1012-01A


Clamp

*000589543700

Set of stop plugs

*129589009100

12.2
Disconnect power steering oil line (feed line of

steering gear

!
radiator) (19)


Clamp

*000589543700

Set of stop plugs

*129589009100

Hexagon socket wrench

*WH58.30-Z-1001-06A

Hexagon socket wrench

*WH58.30-Z-1002-06A

Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 2

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

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Page 1

1998-2005 SUSPENSION
Suspension - 163 Chassis
GENERAL INFORMATION
GENERAL NOTES ON WORKING ON VEHICLES WITH LEVEL CONTROL/ADS - AH32.00-P-0002-01A
All models with code 216b, 216c, 217a, 480
Fig. 1: Identifying Box Wrench (116 589 00 17 00)

The following instructions should be followed when disconnecting and connecting pressure lines:
Clean contaminated line connections before disconnecting them. Seal disconnected lines and hoses and
connections to components immediately with blind plugs.
Only use open box wrench and special tool when loosening and tightening pressure lines to avoid damage to the
line connections.
Check the component concerned and line connections for leaks after assembly work on the suspension
system.
NOTES ON CHECKING OIL LEVEL ON VEHICLES WITH LEVEL CONTROL/ADS - AH32.00-P-0003-01A
All models with SA Code 217a/ 480
Observe the following prerequisites when checking the oil level in the oil reservoir:
1. The vehicle must be standing on its wheels.
2. Check the oil level when the vehicle is ready to drive:
Vehicle ready for use with oil and coolant reservoirs filled.
Full fuel tank - compensate for any missing fuel by placing additional weight in trunk.
Spare wheel and vehicle tool kit in vehicle.
Unladen vehicle. Remove any luggage, fuel canisters etc. from the vehicle.
On vehicles with level control /ADS, the oil level in the oil reservoir may fall below the "min." mark
on the oil dipstick when the vehicle is loaded.

2001 Mercedes-Benz ML320
1998-2005 SUSPENSION Suspension - 163 Chassis

2001 Mercedes-Benz ML320
1998-2005 SUSPENSION Suspension - 163 Chassis
me
Saturday, October 02, 2010 3:37:35 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.
me
Saturday, October 02, 2010 3:37:38 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.

AD54.30-P-5000-03A
Directly controlled display instruments

troubleshooting chart IC

Directly controlled display instruments or indicator

lamp/warning message:

D
Outside temperature indicator

D
Fuel gauge

D
Oil pressure gauge (models 129 and 140 only)

D
Left turn signal indicator lamp

D
Right turn signal indicator lamp

D
High beam indicator lamp

D
Fuel reserve indicator lamp

D
Airbag SRS indicator lamp/MIL

D
AIRBAG OFF indicator lamp (only model 163 except

I )
D
Low brake fluid level/parking brake indicator lamp (only brake

fluid direct)

(both functions via CAN on model 163)

D
Low windshield washer fluid level indicator lamp (except

models 163 and 168)
D

Low ECL indicator lamp (except models 163 and 168)

D
Generator charge indicator lamp

D
Seat belt reminder lamp

D
Seat belt/backrest lock reminder lamp

D
Exterior lamp failure indicator lamp

D
Hydraulic fluid level indicator lamp (models 202 and 210 only)

D
ADS MIL, suspension

D
Turn signal clicking

D
Seat belt reminder lamp

D
Light reminder lamp

D
Key reminder lamp

D
Soft top reminder lamp (model 170 only)

D
Steering lock warning lamp (

I )

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Page 1

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

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Page 1