1997 MERCEDES-BENZ ML500 headlamp

Steel spring suspension of front axle
Repair materials
REMOVE/INSTALL REAR SPRING - AR32.20-P-0230GH
MODEL 163.113 /128 /136 /154 /157 /172 /174 /175
1Remove, Install

Risk of fatal accident from
vehicle slipping or toppling off
the lift platform
Jack up vehicleAlign vehicle between the columns of lifting
platform and position the four support plates
below the support strong points specified by the
vehicle manufacturer.
AS00.00-Z-
0010-01A
2
Measure spring preload of
torsion bar spring (16a) using
caliper gage at bore
Installation: Restore spring preload.
3
Unscrew bolt (16c) and then
release tension of torsion bar
spring (16a) Installation: regrease bolt (16c). The rubber
bellows (16i) must be filled with grease.*BR00.45-Z-
1005-06A
4Undo bolt (16f) in profile sleeve
(16e). *BA32.20-P-
1001-01A
5Slide back profile sleeve (16e).
6Remove torsion bar spring
(16a). Installation: The position of the torsion bar
spring (16a) relative to the clamping lever (16d)
is indicated (arrow).

7Loosen bolt (16h). Remove end
cover (16g). *BA32.20-P-
1002-01A
8Remove torsion bar spring (16a)
from clamping lever (16d). Installation: Grease gearing on torsion bar
spring. Observe markings.*BR00.45-Z-
1005-06A
9Install in the reverse order
10
Check vehicle level at front and
rear axles with electronic
inclinometer and adjust if
necessary.
AR40.20-P-
0301GH
11

Check and correct headlamp
adjust
Check and correct headlamp
adjustment
AP82.10-P-
8260GH
Number Designation Model 163
BA32.20-P-1001-01ABolt on profile sleeveNM23
BA32.20-P-1002-01ABolt in end coverNMapprox.23
NumberDesignationOrder number
BR00.45-Z-1005-06APasteA 000 989 76 51

2001 Mercedes-Benz ML320
1998-2005 SUSPENSION Suspension - 163 Chassis
me
Saturday, October 02, 2010 3:37:35 PMPage 7 © 2006 Mitchell Repair Information Company, LLC.

Rear axle shock absorber
Fig. 9: Identifying Tensioning Device (203 589 01 31 00)

Fig. 10: Identifying Tensioning Plates (163 589 00 63 00)

REMOVE/INSTALL TORSION BAR ON FRONT AXLE - AR32.20-P-0300GH
MODEL 163.113 /128 /136 /154 /157 /172 /174 /175
Compress rear spring.AR32.20-P-0200-06GH
Spring
compressorFig. 2
Tensioning platesFig. 3
4Install in the reverse order
Testing
5Check and correct
headlamp adjustment
Check and correct
headlamp adjustmentAP82.10-P-8260GH
NumberDesignationModel Series 163
BA32.25-P-1003-03DSelf-locking nut, shock
absorber to rear springNM30

2001 Mercedes-Benz ML320
1998-2005 SUSPENSION Sus pension - 163 Chassis
me
Saturday, October 02, 2010 3:37:35 PMPage 9 © 2006 Mitchell Repair Information Company, LLC.

Rear axle torsion strut
seating.
6Remove nuts (75a) from
top spring strut mounting
on frame side member *BA32.25-P-1002-03D
7Detach nut (75u) from
lower suspension strut
mounting to lower
transverse control arm (67) Counterhold threaded
rod.
*BA32.25-P-1001-03D
Lethal injuries are
possible if vehicle slips off
of lifting platformAlign 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
8Support lower transverse
control arm (67)
9Remove link rod (78f)
between lower transverse
control arm (67) and
torsion bar (77) *BA32.20-P-1001-04F
10Detach lower transverse
control arm (67) from rear
axle carrier Installation: The rear
axle shaft must be
horizontal when
tightening the bolts (67b).
*BA35.20-P-1003-07A
11Lower the lower transverse
control arm (67) carefully,
pull out of guide and swing
downwards
12Press the suspension strut
upwards out of the
transverse control arm (67)
and remove In the event of
stiffness, if necessary
hammer the shock
absorber (75) carefully out
of the lower transverse
control arm (67) using a
plastic-headed mallet.
13Install in the reverse order
Inspect
14Check and correct
headlamp adjustment
Check and correct
headlamp adjustment AP82.10-P-8260GH
NumberDesignationModel Series 163

2001 Mercedes-Benz ML320
1998-2005 SUSPENSION Suspension - 163 Chassis
me
Saturday, October 02, 2010 3:37:36 PMPage 26 © 2006 Mitchell Repair Information Company, LLC.

Fig. 25: Headlamps Leveling Circuit

2001 Mercedes-Benz ML320
2001 SYSTEM WIRING DIAGRAMS Mercedes-Benz - ML320
me
Saturday, October 02, 2010 3:27:59 PMPage 51 © 2006 Mitchell Repair Information Company, LLC.

Fig. 66: Headlamp Washer Circuit

2001 Mercedes-Benz ML320
2001 SYSTEM WIRING DIAGRAMS Mercedes-Benz - ML320
me
Saturday, October 02, 2010 3:28:00 PMPage 133 © 2006 Mitchell Repair Information Company, LLC.