1997 MERCEDES-BENZ ML500 dimensions

Fig. 401: Identifying Welding Bead Catcher (129 589 01 98 00)
Workshop equipment/MB testers
1. Expose damaged cable or plug/coupling in easily accessible position and cut off.
Separate cores in wiring harness offset by approx. 45 mm (B).
Fig. 402: Identifying Wiring Harness Offset Distance

2. Cut new section of cable to match old cable.
When cutting the line, add an allowance of approx. 50 mm (C) for loop formation (strain-relief).
3. Remove approx. 15 mm (D) of insulation at line ends.
4. Select solder cup as shown in table below.
Fig. 403: Identifying Dimensions For Cutting Line
WE58.40-Z-1007-03AHot-air gun

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:49 PMPage 278 © 2006 Mitchell Repair Information Company, LLC.

15
Adjust gap dimensions
Gap dimensions

*BE60.00-P-1001-01D

Feeler gage

*129589032100

16
Align engine hood catch upper section (5)

centered in longitudinal and transverse
direction to engine hood catch lower section

and tighten


*BA88.40-P-1004-01C

17
Ensure that engine hood catch catches

properly

For this purpose, close engine hood and

pull upward with a jerk.

18
Release engine hood and ensure that safety

hook catches on radiator crossmember

19
Close engine hood (2)

Test and adjustment values, gap dimensions at hoods, doors and covers

Number

Designation
Model 163

BE60.00-P-1001-01D
Gap

dimension
Engine hood to fender
Dimension "A"
mm
5.0 (
F
0.5)

Engine hood to headlamp
Dimension "R"

mm
5.0 (
F
0.5)

Engine hood to radiator grille

Dimension "O"

mm
5.0 (
F
0.5)

Radiator grill to headlamp
Dimension "N"

mm
-

Fig., see
AR60.00-P-0700-

01GH


Engine hood

Number

Designation
Model 163

BA88.40-P-1001-01C
Bolt, engine hood hinge on engine hood
Nm
10

BA88.40-P-1002-01C
Nut, engine hood hinge to body
Nm
18

BA88.40-P-1004-01C
Bolt, engine hood catch upper section to engine

hood
Nm
12

129 589 03 21 00

Feeler gage

Auxiliary repair materials

Number

Designation
Order number

BR00.45-Z-1004-01A
MB body sealant for sealing seams (suitable for painting)
001 989 63 20

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

15
Adjust gap dimensions
Gap dimensions

*BE60.00-P-1001-01D

Feeler gage

*129589032100

16
Align engine hood catch upper section (5)

centered in longitudinal and transverse
direction to engine hood catch lower section

and tighten


*BA88.40-P-1004-01C

17
Ensure that engine hood catch catches

properly

For this purpose, close engine hood and

pull upward with a jerk.

18
Release engine hood and ensure that safety

hook catches on radiator crossmember

19
Close engine hood (2)

Test and adjustment values, gap dimensions at hoods, doors and covers

Number

Designation
Model 163

BE60.00-P-1001-01D
Gap

dimension
Engine hood to fender
Dimension "A"
mm
5.0 (
F
0.5)

Engine hood to headlamp
Dimension "R"

mm
5.0 (
F
0.5)

Engine hood to radiator grille

Dimension "O"

mm
5.0 (
F
0.5)

Radiator grill to headlamp
Dimension "N"

mm
-

Fig., see
AR60.00-P-0700-

01GH


Engine hood

Number

Designation
Model 163

BA88.40-P-1001-01C
Bolt, engine hood hinge on engine hood
Nm
10

BA88.40-P-1002-01C
Nut, engine hood hinge to body
Nm
18

BA88.40-P-1004-01C
Bolt, engine hood catch upper section to engine

hood
Nm
12

129 589 03 21 00

Feeler gage

Auxiliary repair materials

Number

Designation
Order number

BR00.45-Z-1004-01A
MB body sealant for sealing seams (suitable for painting)
001 989 63 20

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

Danger!

Risk of explosion
from explosive gas.
Risk

of poisoning and caustic burns from

swallowing battery electrolyte.
Risk of injury


through burns to skin and eyes from battery

acid or when handling damaged lead-acid

batteries
No fire, sparks, naked flames or smoking.

Wear protective gloves, acid-resistant

clothing and safety glasses. Pour battery

electrolyte only into suitable and appropriately

marked containers.

AS54.10-Z-0001-01A

4
Remove battery

AR54.10-P-0005GH

5
Press out template (6) and adapt the size to

the correct dimensions (a, b)Determine ACTUAL dimension (a) from the

drawing.

Divide the SPECIFIED dimension (a) by the

determined ACTUAL dimension (a) and copy

the template to the original size with the

corresponding factor.

Check dimensions for both axles.

6
Cut out template

7
Cut out holes (7, 8) for engine hood hinge

studs

8
Position template in the engine hood hinge

support using the stud holes

The template is drawn for the left side.

Turn over to obtain the right side.

9
Center the engine hood hinge support on the

template using the markings (9, 10, 11)

10
Remove template

11
Drill a hole at each center punch mark (3, 4, 5)

Only drill through the 2 upper panels. Do

not drill through the reinforcement panel (3rd

panel).


*201589005100

12
Cover windshield, paint surface and adjacent

components adequately in order to avoid

damage due to welding work

Cover apertures in the body in order to

prevent flying sparks: the foam in the

instrument panel burns easily.

c

General information on repairs to body

AH60.00-N-0001-01A


Danger!

The high voltage used for arc welding

presents a lethal hazard
.
Explosion hazard


when welding in area of materials easily

inflammable.
Injury hazard
from welding

spatter and UV-light while welding.
Risk of

poisoning
when inhaling welding vapors.
Use insulating mats. Wear protective clothing,

safety glasses, and protective mask.

Remove

highly inflammable materials from the danger

zone. Use air extractor.

AS00.00-Z-0007-01A

13
Plug weld each hole

*WE58.40-Z-1005-02A

14
Plug welds should be flat and ground smooth

15
Remove covers and clean the repair area

16
Prime untreated points in the area of the

engine hood hinge support

17
Prime the underside of the reinforcement

panel of the engine hood hinge

Access to underside of engine hood hinge

support through the recess for the wiper motor.

18
Spray the underside of the reinforcement

panel of the engine hood hinge support with

wax preservative

Access to underside of engine hood hinge

support through the recess for the wiper motor.

19
Install in the reverse order

Weld spot miller

201 589 00 51 00

Workshop equipment/MB testers
(see Workshop Equipment Manual)

WE58.40-Z-1005-02A
MIG inert gas welding equipment, aluminum weldable, sold by company Wieländer & Schill

Repair products

Number

Designation
Order number

BR00.45-Z-1004-01A
MB body sealant for sealing seams (suitable for painting)
001 989 63 20

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

3
Remove engine hood hinge on the front

passenger side

AR88.40-P-3060GH

*BR00.45-Z-1004-01A


Danger!

Risk of explosion
from explosive gas.
Risk

of poisoning and caustic burns from

swallowing battery electrolyte.
Risk of injury


through burns to skin and eyes from battery

acid or when handling damaged lead-acid

batteries
No fire, sparks, naked flames or smoking.

Wear protective gloves, acid-resistant

clothing and safety glasses. Pour battery

electrolyte only into suitable and appropriately

marked containers.

AS54.10-Z-0001-01A

4
Remove battery

AR54.10-P-0005GH

5
Remove air conditioning blower motor

AR83.30-P-5560GH

6
Print out template (6) and adapt the size to

the correct dimensions (a, b)Determine ACTUAL dimension (a) from the

drawing.

Divide the SPECIFIED dimension (a) by the

determined ACTUAL dimension (a) and copy

the template to the original size with the

corresponding factor.

Check dimensions for both axles.

7
Cut out template

8
Cut out holes (7, 8) for engine hood hinge

studs

9
Position template in the engine hood hinge

support using the stud holes

The template is drawn for the left side.

Turn over to obtain the right side.

10
Center the engine hood hinge support on the

template using the markings (9, 10, 11)

11
Remove template

12
Drill a hole at each center punch mark (3, 4, 5)

Only drill through the 2 upper panels. Do

not drill through the reinforcement panel (3rd

panel).


*201589005100

13
Cover windshield, paint surface and adjacent

components adequately in order to avoid

damage due to welding work

Cover apertures in the body in order to

prevent flying sparks: the foam in the

instrument panel burns easily.

c

General information on repairs to body

AH60.00-N-0001-01A


Danger!

The high voltage used for arc welding

presents a lethal hazard
.
Explosion hazard


when welding in area of materials easily

inflammable.
Injury hazard
from welding

spatter and UV-light while welding.
Risk of

poisoning
when inhaling welding vapors.
Use insulating mats. Wear protective clothing,

safety glasses, and protective mask.

Remove

highly inflammable materials from the danger

zone. Use air extractor.

AS00.00-Z-0007-01A

14
Plug weld each hole

*WE58.40-Z-1005-02A

15
Plug welds should be flat and ground smooth

16
Remove covers and clean the repair area

17
Prime untreated points in the area of the

engine hood hinge support

18
Prime the underside of the reinforcement

panel of the engine hood hinge

Access to underside of engine hood hinge

support through the recess for the wiper motor.

19
Spray the underside of the reinforcement

panel of the engine hood hinge support with

wax preservative

Access to underside of engine hood hinge

support through the recess for the wiper motor.

20
Install in the reverse order

Weld spot miller

201 589 00 51 00

Workshop equipment/MB testers
(see Workshop Equipment Manual)

WE58.40-Z-1005-02A
MIG inert gas welding equipment, aluminum weldable, sold by company Wieländer & Schill

Repair products

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

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.

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

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

Fig. 76: Identifying Template And Carpet
MODIFY PANELING ON D-PILLAR - AN68.30-P-0001-01A
MODEL 163.113 /154 #A up to 289564, 163.113 #X up to 754619, 163.154 #X up to 716524, 163.136 /172
When working ensure that the seatbelt is correctly installed, operates properly and that damage to the outer
paneling surface is prevented.
1. Glue hole template (2) for seatbelt onto D-pillar paneling (1).
Position edge of template to edge of paneling.
2. Mark dimensions of oblong hole (3) on D-pillar paneling (1).
3. Remove hole template (2).
4. Cut out oblong hole (3) for seatbelt.
5. Debug hole edges with P240 sand paper.
6. Polish hole edges with P600 sand paper.
To avoid possible chafing of the seatbelt, a uniform smooth surface is required.
7. Repeat on opposite side.

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Interior Equipment - 163 Chassis
me
Saturday, October 02, 2010 3:35:22 PMPage 78 © 2006 Mitchell Repair Information Company, LLC.