1997 MERCEDES-BENZ ML500 roof

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
d by Modification services.
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
d by Modification services.
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

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

AR68.30-P-4470GH
Remove/install rear roof frame paneling
24.2.97

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

P68.30-0507-06

1
Belt end fitting in 3rd seat row

2
Center paneling of roof frame

3
Side paneling of roof frame

4
Expanding anchor

5
Screw


Remove, Install

1.1
Remove belt end fitting at bottom of 3rd seat

row (1)
Only with 3rd seat row, code 847.

*BA91.40-P-1001-01D

2
Unclip center roof frame covering (2)

Installation:
Install paneling in door

rubber seal.

Long wedge

*115589035900

3.1
Remove expanding anchor (4) from side roof

frame covering (3)

up to 31.08.01

Installation:
Replace expanding anchor.

3.2
Remove screw (5) from side roof frame

paneling (3)

4.1Unclip side roof frame paneling in upper outer

corner

As of 01.09.01

4.2
Remove side roof frame paneling (3) upward
Only on 3rd seat row, code 847: remove

seatbelt and remove paneling


Installation:
Install paneling in door

rubber seal.

5.1
Disconnect connector from loudspeaker

As of 01.09.01 and with sound system,

code 810.

6
Install in the reverse order


Seat belts/belt tensioners

Number

Designation
Model 163 up to

08/99
Model 163 as of

09/99

BA91.40-P-1001-01D
Screw on belt end fitting
Nm
3535

Copyright DaimlerChrysler AG 17.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR68.30-P-4470GH
Remove/install rear roof frame paneling
24.2.97

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

P68.30-0507-06

1
Belt end fitting in 3rd seat row

2
Center paneling of roof frame

3
Side paneling of roof frame

4
Expanding anchor

5
Screw


Remove, Install

1.1
Remove belt end fitting at bottom of 3rd seat

row (1)
Only with 3rd seat row, code 847.

*BA91.40-P-1001-01D

2
Unclip center roof frame covering (2)

Installation:
Install paneling in door

rubber seal.

Long wedge

*115589035900

3.1
Remove expanding anchor (4) from side roof

frame covering (3)

up to 31.08.01

Installation:
Replace expanding anchor.

3.2
Remove screw (5) from side roof frame

paneling (3)

4.1Unclip side roof frame paneling in upper outer

corner

As of 01.09.01

4.2
Remove side roof frame paneling (3) upward
Only on 3rd seat row, code 847: remove

seatbelt and remove paneling


Installation:
Install paneling in door

rubber seal.

5.1
Disconnect connector from loudspeaker

As of 01.09.01 and with sound system,

code 810.

6
Install in the reverse order


Seat belts/belt tensioners

Number

Designation
Model 163 up to

08/99
Model 163 as of

09/99

BA91.40-P-1001-01D
Screw on belt end fitting
Nm
3535

Copyright DaimlerChrysler AG 17.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
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
d by Modification services.
Page 1

AN68.30-P-0001-02B
Modify roof paneling for installing handle and

clamping strap mount
Model 163.113 /154 #A as of 289565,

Model 163.113 #X as of 754620,

Model 163.128/ 157/ 175

with code (847), 3rd seat row

P68.30-2527-10

1
Remove accessory hook.

2
Position template (1) to roof paneling.

Fasten template with adhesive tape.

3
Mark points which must be cut out for installing pivot handle and

clamping strap.

4
Remove template (1).

5
Cut out cutouts for pivot handle and clamping strap mount.

Do not cut into window airbag or wiring harness.

6
Repeat on opposite side. .

P68.30-2528-10

6
Install accessory hook (2), clamping strap mount (3) and handle

(4).

7
Repeat on opposite side. .

Copyright DaimlerChrysler AG 12.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AN68.30-P-0001-02A
Modify roof paneling for installing handle and

clamping strap mount
Model 163.113 /154 #A up to 289564,

#X up to 754619

Model 163.136/ 172

with code (847), 3rd seat row


Handles

Number

Designation
MODEL

Series 163

BA68.70-P-1001-02A
Screw for pivot handle/mount on roof frame
Nm
2.5

P68.30-2055-10

1
Remove clothes hook and accessory hook.

2
Position template (1) to roof paneling.

Fasten template with adhesive tape.

3
Mark points which must be cut out for installing the handle.

4
Remove template (1).

5
Cut out cutouts for handle.

P68.30-2170-10

Only on vehicles with safety standard FMVSS201.

6.1
Install shock absorber (5).


Danger of cracks. Carefully pull roof paneling downward and

install shock absorber between roof paneling and roof frame.

The flat side of the shock absorber (5) points in the direction of

the roof frame.

P68.30-2056-10

7
Install accessory hook (2), clamping strap mount (3) and pivot

handle (4).


On vehicles with FMVSS201
install special clamping strap

mounts and pivot handles with screws (6)

.

8
Repeat on opposite side.

Copyright DaimlerChrysler AG 12.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1