1997 MERCEDES-BENZ ML500 open hood

AR88.40-P-3020GH
Adjust engine hood
8.4.99

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

P88.40-2067-09

1
Bolts

2
Engine hood

3
Engine hood hinge
7

Locknut

8
Nuts

4

Bolts

5
Engine hood catch upper section

6
Stop buffer

Longitudinal, height and transverse

adjustment


Danger!

Risk of injury
to
fingers being jammed or

pinched
when Remove/install 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

1
Open engine hood (2)

For slight range of adjustments for

longitudinal and height adjustment

2
Loosen bolts (1) on engine hood hinge (3)

and adjust engine hood (2)

3
Tighten bolts (1)


*BA88.40-P-1001-01C

For larger range of adjustments for

longitudinal and height adjustment

4.1
Remove gas-operated strut from engine hood

(2) and put down in engine compartment

Risk of breakage. Do not remove the

retainer otherwise the preload will be lost.

AR88.40-P-3010GH

As of VIN A145273, X708319.

5
Remove cover on air intake

AR83.25-P-1405GH

6
Remove rubber cover from engine hood hinge


Installation:
Replace rubber cover.

7
Cut seam sealing along engine hood hinge so

that hinge can be moved


Installation:
Replace seam sealing. Paint

sealant after curing.

*BR00.45-Z-1004-01A

8
Loosen nuts (8) on engine hood hinge (3)

9
Adjust engine hood (2) so that front edges of

front fenders are flush with engine hood and

top edges are aligned

For larger range of adjustment in

longitudinal direction loosen engine hood

catch upper section (5) and tighten.


*BA88.40-P-1004-01C

10
Tighten nuts (8) for engine hood hinge (3)


*BA88.40-P-1002-01C

11.1
Install gas-operated strut

As of VIN A145273, X708319.

AR88.40-P-3010GH

12
Adjust stop buffer (6)

Unscrew locknut (7). Adjust height of stop

buffer so that top edges of front fenders and

engine hood are flush If required, place

spacer plates below engine hood catch upper

section.

13
Fasten stop buffer (6)

Tighten locknut (7).

Transverse adjustment

14
Loosen bolts (4) from engine hood catch

upper section (5)

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR88.40-P-3100GH
Remove/install control cable for engine hood
5.5.00

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

P88.40-2140-06

Illustrated up to VIN A145272, X708318

1
Clips

2
Rubber grommet

3
Engine hood control cable


Removing and installing

1
Open engine hood and raise to vertical position
Up to VIN A145272, X708318.

AR88.40-P-1000GH

As of VIN A145273, X708319.

AR88.40-P-1000GI

2.1
Remove upper frame cross member
Only up to VIN A145272, X708318

AR62.30-P-2300GH
2.2Remove engine hood lock
Only as of VIN A145273, X708319.

AR88.40-P-3200GI

3.1
Unhook engine hood control cable from clip at

bottom of radiator cross member
Only as of VIN A145273, X708319.

4
Remove cover from fuse and relay box

5 screws.

5
Unhook clips (1) from body

6
Remove left cover below instrument panel
Left hand drive vehicle.

AR68.10-P-1500GH

Vehicles with right-hand steering up to

VIN A145272, X708318.

AR68.10-P-1520GH

Vehicles with right-hand steering as of

VIN A145273, X708319.

AR68.10-P-1520GI

7
Remove paneling in left footwell

AR68.30-P-4010GH

8
Unhook engine hood control cable at side at

clip in footwell

9
Remove rubber grommet (2) from fuse and

relay box

10
Pull out engine hood control cable (3) through
firewall on engine side and remove


Installation:
Ensure that engine hood

control cable is routed cleanly along fuse and

relay box.

11
Install in the reverse order

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR88.40-P-3060GH
Remove/install engine hood hinge
16.4.97

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

P88.40-0365-01
P88.40-0364-01

1
Screws

2
Engine hood hinge

3
Nuts


Removing and installing


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
1.1
Remove engine hood

Only when both engine hood hinges are

removed.

AR88.40-P-3000GH
1.2
Open engine hood and raise to vertical position

Up to VIN A145272, X708318.

AR88.40-P-1000GH

As of VIN A145273, X708319.

AR88.40-P-1000GI

2
Remove cover on air intake

AR83.25-P-1405GH

3
Remove rubber cover from engine hood hinge


Installation:
Replace rubber cover.

4
Cut joint seal along engine hood hinge so that

hinge can be moved


Installation:
Replace seam sealing. Paint

sealant after curing.

*BR00.45-Z-1004-01A

5
Mark installation position of engine hood

hinge (2)

Facilitates installation.

6.1
Remove gas strut

As of VIN A145273, X708319.

AR88.40-P-3010GH

Danger of breaking!
Do not remove the

retainer otherwise the preload will be lost.

7
Remove screws (1)


Support engine hood at rear to prevent

damage.


*BA88.40-P-1001-01C

8
Unscrew nuts (3)


*BA88.40-P-1002-01C

9
Remove engine hood hinge (2)

Installation:
Align engine hood hinge at
marks made previously.

10
Install in the reverse order

11
Check alignment of engine hood
If necessary:
#

Adjust engine hood

AR88.40-P-3020GH


Engine hood

Number

Designation
Model 163

BA88.40-P-1001-01C
Screw for engine hood hinge on engine hood
Nm
10

BA88.40-P-1002-01C
Nut for engine hood hinge on body
Nm
18

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 1

AR88.40-P-3200GI
Remove/install engine hood lock
9.4.99

MODEL
163.136 /154 /172 #A as of 145273,

163.136 /154 /172 #X as of 708319,

163.113 /128 /157 /174 /175

P88.40-2058-06

1
Screws

2
Engine hood lock bottom section

3
Engine hood control cable

4
Electrical connector

5
Screws

6
Engine hood lock top section


Removing and installing

1
Open engine hood and raise to vertical position

AR88.40-P-1000GI

2
Unscrew screws (1) and remove engine hood

lock bottom section (2) upward


*BA88.40-P-1003-01C

3.1
Disconnect electrical connector (4) from

engine hood lock bottom section (2)

Only when equipped with
ATA
.
4
Unhook engine hood control cable (3) from

engine hood lock bottom section (2)

Pull out engine hood control cable slightly.

5
Remove engine hood lock bottom

section (2)


Installation:
Ensure that engine hood

control cable is routed carefully.

6
Unscrew screws (5) and remove engine hood

lock top section (6)

Mark installation position for engine hood

lock top section on engine hood.


*BA88.40-P-1004-01C

7
Install in the reverse order

8
Check alignment of engine hood

If necessary:
#

Adjust engine hood

AR88.40-P-3020GH

9
Lubricate engine hood lock

e

Lubricate hood lock, safety hook and hinges

AP88.40-P-8821GH

10
Perform function check

11
Check function of safety hook

For this purpose, close engine hood,

unlock and check arrest on radiator cross

member.


Engine hood

Number

Designation
Model 163

BA88.40-P-1003-01C
Screw for engine hood lock on radiator cross

member
Nm
12

BA88.40-P-1004-01C
Screw for engine hood lock top section on engine

hood
Nm
12

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR88.40-P-3200GH
Removing and installing engine hood lock
8.4.99

MODEL
163.136 /154 /172 up to 31.8.99

P88.40-2054-06

1
Screw

2
Bottom section of engine hood lock

3
Engine hood control cable mount

4
Screw

5
Upper section of engine hood lock with

safety hook


Removal, installation

1
Open engine hood and position upright
Up to 08.99

AR88.40-P-1000GH

As of 09.99

AR88.40-P-1000GI

2
Unscrew screws (1) and remove upper

section of engine hood lock (2) upward

*BA88.40-P-1003-01C

3
Remove release lever on inside of vehicle

and unhook engine hood cable from lever

4
Unhook engine hood cable from bottom
section of engine hood lock (2)


Pull engine hood cable out slightly. Press

holder (3) on engine hood cable carefully off

engine hood lock.

5
Remove bottom section of engine hood lock (2)


Installation:
Ensure that engine hood

cable is routed carefully.

6
Unscrew screws (4) and remove upper

section of engine hood lock (5)

Mark installation position of upper section

of engine hood lock on engine hood.


*BA88.40-P-1004-01C

7
Install in opposite order

8
Lubricate engine hood lock

e

AP88.40-P-8821GH

9
Check for proper function

10
Check safety hook for proper function

For this purpose, close engine hood,

release and check arrest on radiator cross

member

11
Check engine hood fit
If necessary
#

Adjust engine hood

AR88.40-P-3020GH

Engine hood

Number

Designation
Model 163

BA88.40-P-1003-01C
Screw for engine hook lock on radiator cross

member
Nm
12

BA88.40-P-1004-01C
Screw for engine hood lock upper section on

engine hood
Nm
12

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR88.40-P-3000GH
Remove/install engine hood
25.3.97

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

P88.40-2062-01

1
Screws

2
Gas pressure strut


Removing and installing


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

1
Open engine hood and raise to vertical position

Up to VIN A145272, X708318.

AR88.40-P-1000GH

As of VIN A145273, X708319.

AR88.40-P-1000GI

2
Mark position of engine hood hinges on

engine hood

Facilitates installation.

3.1
Remove gas strut (2)


Secure engine hood with helper to avoid

damage.

AR88.40-P-3010GH

As of VIN A145273, X708319.

4
Remove screws (1)


Installation:
Paint screws.


*BA88.40-P-1001-01C

5
Remove engine hood


Use helper to avoid damage. Set down on

suitable surface.

6
Install in the reverse order

Align engine hood on engine hood hinges

at markings made previously.

7
Check alignment of engine hood

If necessary:
#

Adjust engine hood

AR88.40-P-3020GH


Engine hood

Number

Designation
Model 163

BA88.40-P-1001-01C
Screw for engine hood hinge on engine hood
Nm
10

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR88.40-P-3010GH
Remove/install gas-operated strut on engine hood
6.4.99

MODEL
163.136 /154 /172 #A as of 145273,

163.136 /154 /172 #X as of 708319,

163.113 /128 /157 /174 /175

P88.40-2063-06

1
Gas pressure strut

2
Fuse


Remove, Install

1
Open engine hood

2
Secure engine hood

3
Lift retainer (2) on top of gas-operated strut

(1) and detach gas-operated strut at the top


Risk of breakage. Do not remove the

retainer otherwise the preload will be lost.

4
Lift retainer on bottom of gas-operated strut

and remove gas-operated strut (1)

When replacing gas pressure strut:
#

Danger!

Risk of injury
due to drilling gas-filled

equipment or components (gas filling not

flammable)
Wear safety goggles and face mask.

AS00.00-Z-0006-01A

o

Degas and drain gas pressure strut

OS00.00-P-1001-01A

5
Install in the reverse order

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

Fig. 9: Replacing Intake Air Dust Filter
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RECEIVER-DRIER
Removal & Installation
1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove headlight
units. Remove headlight units. Remove upper frame crossmember, release hood release control cable and
remove crossmember. See Fig. 6
.
2. Remove bolts from receiver-drier refrigerant lines. See Fig. 5
. Disconnect refrigerant lines from receiver-
drier. Plug exposed openings to protect A/C system from debris and moisture. Discard "O" rings. Loosen
receiver-drier clamp bolt. Remove receiver-drier. To install, reverse removal procedure.
3. When installing a new receiver-drier, add 0.34 ounce of NEW refrigerant oil to receiver-drier. Use NEW
"O" rings. Tighten refrigerant line bolts to specification. See TORQUE SPECIFICATIONS
.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
WIRING DIAGRAMS
ApplicationFt. Lbs. (N.m)
Compressor Mounting Bolts15 (20)
Refrigerant Line-To-Compressor Bolt15 (20)
Refrigerant Line-To-Condenser Bolt15 (20)
Steering Column Bolt15 (20)
Steering Column Nut13 (18)
INCH Lbs. (N.m)
Expansion Valve Self-Locking Nut89 (10)
Refrigerant Line-To-Receiver-Drier Bolt89 (10)

2001 Mercedes-Benz ML320
2000-01 MANUAL A/C-HEATER SYSTEMS ML 320, ML 430 & ML 55
me
Saturday, October 02, 2010 3:25:10 PMPage 25 © 2006 Mitchell Repair Information Company, LLC.