1997 MERCEDES-BENZ ML500 maintenance

MAINTENANCE
CLEANING AND PRESERVING ENGINE AN D ENGINE COMPARTMENT - AP01.00-P-1000ZZ
ENGINE all
machining phasePolishingmm97.250 to 97.265-
BE01.40-P-
1004-01FCylinder lengthmm129.5-
BE01.40-P-
1005-01FUndercutmm12-
BE01.40-P-
1006-01FStroke setting with 70 mm stone
length on 70th stroke scale of
machinemm130-
BE01.40-P-
1007-01FStone overrun at top and bottommm9.5-
BE01.40-P-
1008-01FEngine speedPre-honingrpm125-
Precision honingrpm125-
Polishingrpm125-
Lappingrpm230-
BE01.40-P-
1009-01FFeedPre-honing4-
Precision honing3-
Polishing2-
Lapping1-
BE01.40-P-
1010-01FStrokePre-honingrpm57-
Precision honingrpm57-
Polishingrpm57-
Lappingrpm80-
BE01.40-P-
1011-01FDisplayPre-honing%20 to 30-
Precision honing%20 to 30-
Polishing%20 to 30-
Lapping%20 to 30-
BE01.40-P-
1012-01FStroke setting with 70 mm felt
length on 70th stroke scale of
machinemm115-
BE01.40-P-
1013-01FFelt insert overrun at top and
bottommm2 to 4-
BE01.40-P-
1014-01FOperating time of honing machineS70-
1The engine and engine compartment must be
preserved after every cleaning.Applies for vehicles up to 12/89 and in the
period 6/93-7/94
The form and materials for masking are to

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Front axle shaft
MAINTENANCE
FRONT AXLE CARRIER - RETIGHTENING BOLTS - AP33.10-P-3373GH
MODEL 4JG163.### ## up to 221505, WDC163.### ## up to 734087
Outer joint: ?
*BF33.30-P-
1002-02C
3Drive out outer joint (37b) AR33.30-P-
0660-02GH
4
Pull inner rubber boot (37l) or outer
rubber boot (37m) off front axle
shaft (37)
Removal:
Left-hand front axle shaft:
The inner rubber boot (37l) can only be
removed when the outer joint (37b) is
driven out.
Right-hand front axle shaft:
The inner rubber boot (37l) cannot be
replaced as the shaft has a reinforcement in
the center.
If necessary, replace front axle shaft
Installation: To push on the rubber
boots, place suitable assembly sleeve on
the splined shaft profile of the rear axle
shaft.

5Replace circlips (37o, 37p)
6Assemble in the reverse order
Install
7Install front axle shaft (37) AR33.30-P-
0620GH
NumberDesignationModel 163
BF33.30-P-1001-02CFilling capacityInner joint rubber bootg155
Inner joint inner chamberg110
BF33.30-P-1002-02CFilling capacityOuter joint rubber bootg155
Outer joint inner chamberg65

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
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KEY TO BODY PLATE - AH00.00-P-4000-01A
Model 100, 107, 108, 109, 111, 112, 113, 114, 115, 116, 123, 124, 126, 129, 140, 163, 168, 170, 201, 202, 208,
210
Engine numberThe engine number is the identification number for
every engine. It also provides information on the
version of this engine.
Sales DesignationIs used for several model series. 240 D is used for
instance for models 115, 123. Is used to determine a
microfiche of the replacement part literature only in
combination with the model (= the first 3 digits of
the chassis number).
Transmission numberThe complete transmission number is specified on
the data card. It is the identification number or every
transmission.
Groups and SA (optional equipment) numbers (as
of 1983, not on vehicle data card in maintenance
booklet)The special equipment numbers are arranged based
on ascending groups. Special equipment numbers are
listed several times, if they pertain to several groups.
e.g.: special equipment number 56 149/2 can appear
in groups 67, 72, 73, 74.
LampsIt is essential to state the manufacturer for
determining headlamp parts, as different
manufacturer's parts are not completely
interchangeable.
SA (optional equipment) code numberThe 3-digit codes for special equipments are written
in ascending order in lines. The slash that was used
earlier is omitted. Thus, 410 corresponds to 41/0, 466
corresponds to 46/6 etc. The meaning of the special
equipment code can be found in the "Code list of
special versions - Passenger cars".
EquipmentCode for color and material dependent interior trim.
PaintworkColor code for the original paintwork, single-
colored. In the event of multicolor painting,
additional codes are listed in fields 32-35.
Lock system number (not on all vehicle data cards)The lock system numbers of master and secondary
keys are identical.
Differentiating characteristic H=master key,
N=secondary key. The lock system number has to be
specified when ordering spare keys or locks for
certain vehicles in order to sustain a consistent
closing system.

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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clothing, safety gloves and eye protection
Potential risks
Risk of death
Risk of explosion caused by liquefied petroleum gas leaking out of the system in closed rooms or when gas the
tank is overheated due to work being done.
Risk of burn injuries caused by explosions.
Risk of frostbite to skin and body parts caused by liquefied petroleum gas spraying out and by coming into
contact with components that are near the valve when the tank is being emptied. Risk of poisoning or risk of
suffocation caused by inhaling liquefied petroleum gas.
Safety instructions/precautions
Wear protective clothing, safety gloves and eye protection
Keep suitable fire extinguishing equipment at hand
Keep any flammable materials and objects away from the equipment
Avoid making any sparks
Perform a fire check of the surroundings after work has carried out
Never perform work in closed rooms
Before commencing any work, ensure that all sources of ignition have been eliminated. Ensure adequate
ventilation of the immediate area around the vehicle.
Adequate ventilation means an exchange of air at least 3 times an hour at a distance of 3 meters from the gas
shutoff valve.
Close the gas shutoff valves at the compressed-gas tanks before commencing repair work.
Close off gas tank valve if vehicle is to remain in closed rooms, e.g. in halls or garages, for longer periods of
time.
Maintenance and repair work may only be carried out by specially trained personnel.
Due to the fact that explosions can occur when the gas system has leaks, a leak test must be performed before
restarting the system after repairs have been done in which the pipes and lines of the gas system have been
opened.
In the Federal Republic of Germany, this leak test can only be performed by specially trained DVFG personnel
as per the DVGW Work Sheet G 607.
(DVFG - German Liquefied Petroleum Gas Association)

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Workshop equipment
MAINTENANCE
PREFACE - AP00.20-P-0000-01C
These "Service Documents" contain all the maintenance operations for the basic and national versions of the
following models:
Model 170, 129, 140, 202 as of 1.6.97
Model 210 as of 1.3.97
Models 163, 168, 203, 208, 209, 215, 220, 230
Type 414
This maintenance manual became necessary with the introduction of the Active Service System (ASSYST). It
contains all maintenance operations for vehicles with the Active Service System (ASSYST) and is divided into
the two volumes 4 and 4.1.
The system for demand-related complete vehicle maintenance is described in the Introduction into Service
manual "Active Service System (ASSYST)".
If the support plates are
not properly mounted
(012) at the vehicle's
designated jacking points
(1, 2) damage may occur
to the side sill covers (3).
The vehicle should be
secured against tipping or
falling off the platform
when removing any units.
Lifting vehicle with
inspection pit lift or
garage jack
Inspection pit lift.
AR00.60-P-1000-01GH
*WE58.40
-Z-1002-05A
1Forward jacking points
2Rear jacking points
3Side sill covers
011Lifting platform *WE58.40-Z-1001-05A
012Support platesAll four support plates
must be extended to an
equal distance (Dimension
X).
WE58.40-Z-1001-05ATwo-post lifting platform
WE58.40-Z-1002-05APit lift

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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These maintenance documents contain instructions relating to carrying out maintenance and repair operations
on Mercedes-Benz passenger cars. They are intended for the exclusive use of workshops affiliated to the
Mercedes-Benz Organization.
The instructions form the basis for proper and competent service and maintenance.
The nature in which the operations are described is based on the training standard of a fitter who has completed
vocational training and has good knowledge of our products. This level of knowledge is essential for carrying
out the described work.
The continuous further development and improvement of our vehicles may lead to deviations between the
actual technical status of the vehicles and the operation descriptions.
DaimlerChrysler AG reserves the right to make alterations and modifications at any time and without prior
notice.
If there are any open questions relating to repair procedures, please take up the matter with the competent
contact person in the relevant national organization (for DCVD refer to valid Service Information Group 99).
Additional information about the breakdown and structure of the work descriptions and the meaning of the
symbols (Logos) can be found in the Workshop Information System WIS.
Each described maintenance operation has a number (operation item) which is stated in the head line. The
operation item in the maintenance manual is identical with that on the SERVICE SHEET for the Active Service
System (ASSYST), enabling the appropriate texts and data to be found straight away if required when
performing maintenance jobs.
Maintenance operations which are not described have no number (operation item) on the SERVICE SHEET.
The group numbers familiar from the workshop literature are used for the first two digits of the 4-digit operation
item numbers. This ensures the assignment of each maintenance operation to the group.
DaimlerChrysler AG
Global Service & Parts
July 2004
SAFETY NOTES/WARNING NOTES - AP00.20-P-0000-02A
Safety information (hazardous situations for persons), warnings (quality of work, property damage).
These notes are identified by the following symbols (logos):
The logo " " represents safety information (dangerous situations for persons).
The lo
go " "represents a warning (work quality, property damage).

2004 Mercedes-Benz ML350
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For these vehicles the service sheet for the Active Service System (ASSYST) and the maintenance manual
volume 4 apply.
With the ASSYST service sheet the previous distinction between care service and maintenance service no
longer applies. Instead, the service category A (minor service) and service category B (major service) have been
introduced.
The service scopes for each model series can be seen in the respective valid service sheet.
The order no. is stated on the particular SERVICE SHEET.
On manual transmissions, automatic transmissions, transfer cases, front axles and rear axles the service item
"Check fluid level" has been replaced by an inspection of all visible parts for leaks.
In view of the fact that these components are not oil consumers, as is the case for the engine, a loss of oil can
occur only to the outside.
If any leaks are present, the procedure, as before, is to determine the cause and to rectify it subject to a separate
repair order.
The service operations carried out should be documented in the boxes in front of the operation titles. It is
essential to ensure that the specified service operations are carried out in full.
An indication is given in the boxes after the operation titles of which service operations should be carried out
for service category A (minor service) or service category B (major service). Enter a cross behind these boxes to
identify any items which are not in proper order when the vehicle is received.
Additional operations should be defined by the service adviser in agreement with the customer and an indication
should be made on the service sheet whether these additional operations are to be carried out.
Fig. 642: Service Intervals/Work Sheets


2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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SPECIAL SERVICE PROCEDURES - AP00.20-P-0000-06B
Have the brake fluid replaced if more than 2 years have elapsed since the last change; this is best done in the
spring.
The coolant should be inspected for correct anticorrosion/ antifreeze concentration before the beginning of, and
during the cold season of the year. Depending on the model series, the coolant has to be replaced every 3 years
or 15 years (or after 250,000 km).
Refer to the particular valid service sheet for further additional operations based on kilometers or years.
SERVICE DATE REMINDER - AP00.20-P-0000-07B
The confirmation in the service booklet must be filled out completely and signed for every service (A or B).
Confirmation in the service booklet
Fig. 643: Identifying Service Date Reminder

SERVICE CARD FOR UNITS - AP00.20-P-0000-08A
Mercedes-Benz
Service card - major assembly
Maintenance
During the first service after exchanging a Mercedes-Benz genuine major assembly the operations listed in the
maintenance sheet or maintenance manual are to be carried out and confirmed.
Running-in:
The first 1 500 km
WARNING:When vehicles without service display are inspected, the assembly will be
serviced within the scope of the following care and/or maintenance
service.

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Saturday, October 02, 2010 3:47:52 PMPage 402 © 2006 Mitchell Repair Information Company, LLC.