1997 MERCEDES-BENZ ML430 Heater hose

the feed hose of the
liftgate washer system
to the front edge of the
C-pillar panelingthe CD changer bracket. Pull the
C-pillar paneling away from the
body for better accessibility.
13Route the new D2B
wiring harness along
the feed hose of the
liftgate washer system
up to the right A-pillar Fasten the D2B wiring
harness to the body with inline
clips.
14Route the new D2B
wiring harness along
the vehicle wiring
harness from the right
footwell to the top side
of the transmission
tunnel to the firewall Fasten the D2B wiring
harness to the vehicle wiring
harness using tie straps.
15Route the exchange
D2B wiring harness (1)
on the carpet, through
under the heater
housing (2) to the left
side
16Route exchange D2B
wiring harness (1) to
the radio installation
opening D2Fasten the B-wiring
harness to the vehicle wiring
harness using tie straps.
17Screw the screw into
the top left corner
behind the cover for the
CD-changer

18Screw the screw into
the bracket of the load
compartment cover and
install the load
compartment cover
19Install the front load
compartment hooks on
the right C-pillar
20Screw in the screw for
the outer rear seat belt
on the right-side *BA91.40-P-1001-01D
21Install right footwell
cover AR68.30-P-4010GH
22Install right door sill
molding AR68.30-P-4100GH
23Install the cover on the AR68.10-P-1520GH

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
Saturday, October 02, 2010 3:30:10 PMPage 308 © 2006 Mitchell Repair Information Company, LLC.

1
Open cooling system cap (2) on coolant

expansion reservoir (1)

Cap with detent:

Turn cap carefully as far as the first detent,

release pressure, and then unscrew cap.

2-stage and 1-stage cap: Rotate cap half

a revolution in a counterclockwise direction,

release overpressure, then unscrew cap.

2.1Remove engine compartment paneling
Models 129, 202, 208, 210

AR61.20-P-1105AB

Models 163.172/ 174/ 175

AR61.20-P-1105GH

Models 163.113/ 128

AR94.30-P-5400GH

Model 211

AR61.20-P-1105T

Models 215, 220

AR61.20-P-1105M

Model 230

AR61.20-P-1105R

2.2Remove underride guard
Only on model 463

3.1
Remove air guide
Only on model 163 with engine 113.942

4
Drain coolant

Model 163: For draining coolant, detach

bottom coolant line at radiator or at coolant

pump.

Collect coolant Observe regulations for

disposal of coolant.


Installation:
On model 163 replace
radiator connection of hose clamps to coolant

hose, otherwise this can cause a damage to

the bolt/thread.


Hose clamp

*BA20.20-P-1004-01A

Pouring in

5
Pour in coolant

All except engine 137

*BF20.00-P-1001-02K


Engine 137

*BF20.00-P-1001-02M


Notes on coolant level
Engines 112, 113, 137, 275, 285

AH20.00-P-1142-01V


Notes on coolant level
Model 163 with engines 111, 112, 113

AH20.00-P-1142-01GH

6
Bleed cooling system

Let engine run, put heater on full heat

output.

Except stationary heater, code 228

AR20.00-P-1142-06GA

With stationary heater code 228

7
Inspect cooling system for leaks

AR20.00-P-1010HA


Radiator, coolant hoses

Number

Designation
Engines

112.942/

970,

113.942/

965/981

BA20.20-P-1004-01A
Hose clamp
Nm
3

Designation
Engines

112.910 /920

in model 202,

112.940

in model 208
Engines

112.911/921/941

in model 210
Engines

112.922/944/972

in model 220

BF20.00-P-1001-02K
Cooling system
Total capacity
Liters
Y
9.5
Y
10.0
Y
10.5

Capacity of

anticorrosion/antifreeze agent

down to -37°C

Liters

Y
4.75
Y
5.0
Y
5.0

Capacity of anticorrosion/

antifreeze agent down

to -45°C

Liters

Y
5.25
Y
5.5
Y
5.5

Specifications for Operating

Fluids
SheetBB00.40-P-0310-01ABB00.40-P-0310-01ABB00.40-P-0310-01A
SheetBB00.40-P-0325-00ABB00.40-P-0325-00ABB00.40-P-0325-00A

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

P01.30-0299-06

20
Bolts cylinder head
!
timing case cover

21
Cylinder head bolts

22
Cylinder head left

23
Cylinder head right

24
Left cylinder head gasket

25
Right cylinder head gasket

26
Dowel sleeves


Remove/Install

Notes on self-locking nuts and bolts
All models

AH00.00-N-0001-01A


External torx set

*001589760900

Torx bit set

*000589011000


Danger!

Risk of explosion
caused by oxyhydrogen

gas.
Risk of poisoning and caustic burns


caused by swallowing battery acid.
Risk of

injury caused by burns to skin and eyes from

battery acid or when handling damaged lead-

acid batteries
No fire, sparks, open flames or smoking.

Wear acid-resistant gloves, clothing and

safety glasses. Pour battery acid only into

suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1
Disconnect battery ground cable


Installation:
After connecting, read out

fault memory, encode radio and normalize

power windows.

Vehicles with stationary heater: Set time on

timer for stationary heater
AR54.10-P-0003A

Notes on battery
All models

AH54.10-P-0001-01A

Danger!

Risk of death

caused by vehicle slipping or

toppling off of the lifting platform.
Align vehicle between the columns of the

hydraulic hoist and position the four support

plates below the hoist support points specified

by the vehicle manufacturer.

AS00.00-Z-0010-01A

2
Place the vehicle on lifting platform

AR00.60-P-1000GH
3.1
Remove air guide (1)


Only with engine 113.942

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

4
Drain coolant

Remove coolant hose at bottom on

radiator.

AR20.00-P-1142HA

5
Remove engine cover

6.1
Remove viscous fan (2)

All except model 163.174 /175 with

engine 113.981 /965.

Right-hand thread!

AR20.40-P-5660C

7.1
Remove the fan shroud (3).

Only model 163.154 /157 /172. Unscrew

bolts (4) from bottom of fan shroud

7.2
Remove electric fan

Only model 163.174/ 175.

AR20.40-P-5000GH

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

P01.30-0299-06

20
Bolts cylinder head
!
timing case cover

21
Cylinder head bolts

22
Cylinder head left

23
Cylinder head right

24
Left cylinder head gasket

25
Right cylinder head gasket

26
Dowel sleeves


Remove/Install

Notes on self-locking nuts and bolts
All models

AH00.00-N-0001-01A


External torx set

*001589760900

Torx bit set

*000589011000


Danger!

Risk of explosion
caused by oxyhydrogen

gas.
Risk of poisoning and caustic burns


caused by swallowing battery acid.
Risk of

injury caused by burns to skin and eyes from

battery acid or when handling damaged lead-

acid batteries
No fire, sparks, open flames or smoking.

Wear acid-resistant gloves, clothing and

safety glasses. Pour battery acid only into

suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1
Disconnect battery ground cable


Installation:
After connecting, read out

fault memory, encode radio and normalize

power windows.

Vehicles with stationary heater: Set time on

timer for stationary heater
AR54.10-P-0003A

Notes on battery
All models

AH54.10-P-0001-01A

Danger!

Risk of death

caused by vehicle slipping or

toppling off of the lifting platform.
Align vehicle between the columns of the

hydraulic hoist and position the four support

plates below the hoist support points specified

by the vehicle manufacturer.

AS00.00-Z-0010-01A

2
Place the vehicle on lifting platform

AR00.60-P-1000GH
3.1
Remove air guide (1)


Only with engine 113.942

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

4
Drain coolant

Remove coolant hose at bottom on

radiator.

AR20.00-P-1142HA

5
Remove engine cover

6.1
Remove viscous fan (2)

All except model 163.174 /175 with

engine 113.981 /965.

Right-hand thread!

AR20.40-P-5660C

7.1
Remove the fan shroud (3).

Only model 163.154 /157 /172. Unscrew

bolts (4) from bottom of fan shroud

7.2
Remove electric fan

Only model 163.174/ 175.

AR20.40-P-5000GH

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

AR47.10-P-4000GH
Empty fuel tank if fuel pump is faulty
28.10.97

MODEL
163.113 with ENGINE 612.963

MODEL
163.128 with ENGINE 628.963

MODEL
163.136 with ENGINE 111.977

MODEL
163.154 with ENGINE 112.942

MODEL
163.157 with ENGINE 112.970

MODEL
163.172 with ENGINE 113.942

MODEL
163.174 with ENGINE 113.981

MODEL
163.175 with ENGINE 113.965

P47.20-2076-06

1
Fondsitzkonsole

2
Cover of left C-pillar

3
Seat retaining cable

4
Wiring harness

P47.10-2077-09

84
Closing cover

90/10
Ground line (vacuum unit)

90/11
Fuel return line
90/12

Fuel feed line

90/13
Stationary heater connection

90/14
Extraction hose


Remove, Install


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.
Fire, sparks, open flames or smoking

forbidden.

Pour fuels only into suitable and appropriately

marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

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

AR47.10-P-4000GH
Empty fuel tank if fuel pump is faulty
28.10.97

MODEL
163.113 with ENGINE 612.963

MODEL
163.128 with ENGINE 628.963

MODEL
163.136 with ENGINE 111.977

MODEL
163.154 with ENGINE 112.942

MODEL
163.157 with ENGINE 112.970

MODEL
163.172 with ENGINE 113.942

MODEL
163.174 with ENGINE 113.981

MODEL
163.175 with ENGINE 113.965

P47.20-2076-06

1
Fondsitzkonsole

2
Cover of left C-pillar

3
Seat retaining cable

4
Wiring harness

P47.10-2077-09

84
Closing cover

90/10
Ground line (vacuum unit)

90/11
Fuel return line
90/12

Fuel feed line

90/13
Stationary heater connection

90/14
Extraction hose


Remove, Install


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.
Fire, sparks, open flames or smoking

forbidden.

Pour fuels only into suitable and appropriately

marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

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

stationary heater timer.
Notes on batteryAll modelsAH54.10-P-0001-
01A
Risk of death caused
by vehicle slipping
or toppling off of the
lifting platform.Align vehicle between the columns of the
lifting platform and pos ition the four support
plates below the lifti ng platform support points
specified by the vehicle manufacturer.AS00.00-Z-0010-
01A
2Place the vehicle on
lifting platform AR00.60-P-
1000GH
3.1Remove air guide (1) Only for engine 113.942.
Risk of injury to
skin and eyes caused
by 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 containers.
Wear protective gloves, pr otective clothing and
safety glasses.AS20.00-Z-0001-
01A
4Drain coolant Detach coolant hose at bottom of radiator.AR20.00-P-
1142HA
5Remove engine trim
panel
6.1Remove viscous fan
(2) All except model 163.174 /175 with Engine
113.981 /965.
Right-hand thread!AR20.40-P-
5660C
7.1Remove fan shroud
(3) Only model 163.154 /157 /172. unscrew
screws (4) of bottom fan shroud.
7.2Remove electric fan Only models 163.174/ 175.AR20.40-P-
5000GH
8Attach guard plate
for radiator /
condenser
Guard plate for
radiator / condenserEngine 606 in model 124,
Engine 606.961 in model 140,
Engines 112, 113, 604, 605, 611.960 in model
202,
Engines 602.983, 612.966 in model 461,
Engine 628.962, 612.965, 606.964, 112.945,
113.962/982 in model 463,
Engines 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 models 211, 215, 220, WF58.50-P-0110-
01A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 85 © 2006 Mitchell Repair Information Company, LLC.

8
Disconnect coolant feed hose (3) to fuel cooler

Raise fuel cooler.

Hose clamp pliers (length 210 mm;

adjustment range 80 mm)

*WH58.30-Z-1026-02A

9
Install in the reverse order


Danger!
Risk of accident
as vehicle may start off by

itself with the engine running.
Risk of injury


as working around the engine during start-up

or while running may result in contusions and

burns
Secure vehicle to prevent it from moving off

by itself.

Wear closed and tight-fitting work clothes.

Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

10
Pour in coolant
*BF20.00-P-1001-02E

Switch heater to maximum and warm up

engine at moderate revs. Top up coolant

constantly at coolant expansion reservoir.

Close coolant expansion reservoir once

coolant temperature is 60-70 °C.


Note on coolant level
Models 124, 129, 140, 168, 170, 202, 208,

210, 220, 463

AH20.00-P-1142-01A

11
Inspect cooling system for leaks

AR20.00-P-1010HA

12
Run engine and inspect fuel system for leaks

Crankcase ventilation, cylinder head cover

Number

Designation
Engine

612.963

BA01.20-P-1002-01A
Screw of trim panel of cylinder head cover

to cylinder head cover
NM
10

BA01.20-P-1003-01A
Screw attaching cover panel to charge air

distribution pipe
NM
10


Cooling system

Number

Designation
Engine

612.963

BF20.00-P-1001-02E
Cooling system
Total capacity
Liter
Y
11,0

Capacity of anticorrosion/

antifreeze agent down to -37 °C
Liter
Y
5,5

Capacity of anticorrosion/

antifreeze agent down to -45 °C
Liter
Y
6,25

Specifications for Service

Products
SheetBB00.40-P-0310-01A
SheetBB00.40-P-0325-02A

129 589 00 91 00

Set of closure plugs

Circuit

000 589 54 37 00

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e.g.) g.)
Order number

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2