MERCEDES-BENZ ML350 1997 Complete Repair Manual

BR00.45-Z-1013-02A
Loctite 243 sealant
003 989 31 71

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

AR72.10-P-2400GH
Removing and installing outer door handle on front door
12.2.97

MODEL
163

P72.10-0488-06

1
Handle

2
Lock cylinder guide

3
Rotating rod

4
Base

5
Base

6
Screw

7
Retaining strap

8
Bearing bracket

9
Screw

10
Screw opening

Operation no. of operation texts or of standard texts and flat rates
Division
Operation
no.
Operation text

P
727240
REPLACING OUTER DOOR HANDLE ON LEFT FRONT DOOR

P
727241
REPLACING OUTER DOOR HANDLE ON LEFT FRONT DOOR, WITHOUT BEARING BRACKET

P
727242
REPLACING OUTER DOOR HANDLE ON LEFT FRONT DOOR, WITH BEARING BRACKET

P
727243
REPLACING OUTER DOOR HANDLE ON LEFT FRONT DOOR (INCLUDING TRANSFERING LOCKING CYLINDER)

P
727265
REPLACING OUTER DOOR HANDLE ON RIGHT FRONT DOOR

P
727266
REPLACING OUTER DOOR HANDLE ON RIGHT FRONT DOOR, WITHOUT BEARING BRACKET

P
727267
REPLACING OUTER DOOR HANDLE ON RIGHT FRONT DOOR, WITH BEARING BRACKET

P
727268
REPLACING OUTER DOOR HANDLE ON RIGHT FRONT DOOR (INCLUDING TRANSFERING LOCKING CYLINDER)


Removal, installation

1
Loosen screw (6)

Accessible through opening (10) on inner

side of door, loosen screw (6) max. 5 turns


*BA72.10-P-1003-01D

2
Pull off cylinder guide (2) outward to remove


Installation:
Insert rotary rod (3) into door

lock actuating mechanism

3
Pull handle (1) toward rear together with base

(4) out of bearing bracket (8)

4
Remove base (5)


Installation:
Insert base (5) into bearing

bracket (8)

5.1
Remove bearing bracket (8)

Only if bearing bracket is defective. The

bearing bracket (8) can only be removed
through the installation opening in the inner

door panel. For this purpose

#

Remove door liner on front door

AR72.10-P-1000GH

6
Install in opposite order

7
Adjust clearance between handle (1) and

actuating lever on door lock with eccentric

adjustment screw

Eccentric adjustment screw:

Accessible through opening on end of door.

Use Phillips screwdriver

8
Check for proper function

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Front door

Number

Designation
Model 163

BA72.10-P-1003-01D
Screw for door handle
Nm
3

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Page 2

AR72.10-P-1000GH
Remove/install front door liner
11.2.97

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

P72.10-2161-06

1
Door liner

2
Door handle cover

3
Bolt

4
Cover

5
Clips

6
Bowden cable

7
Sheet metal clip nuts

8
Door foil

9
Entrance lamp

10
Bolt


Remove/install

1
Open crank window

2
Remove cover for door handle (2)

Press cover off using assembly wedge at

bottom.

Assembly wedge

*110589035900

3
Unscrew bolts (3)

4.1
Unclip SRS panel and unscrew screw (10)

As of vehicle identification number

A145273, X708319.

5
Remove cover (4) with installation wedge

Assembly wedge

*110589035900

6
Press door liner (1) off of inner door panel at

bottom, front and rear with assembly wedge

Position assembly wedge directly next to

clips (5).

Assembly wedge

*110589035900

7
Lift door liner (1) up and out

8
Unhook control cable (6) from inner door

actuation

9.1
Remove entrance lamp (9)
As of vehicle identification number

A145273, X708319.

10
Lay down door liner

11
Check sheet metal clip nuts (7) on inner door

panel


Replace damaged sheet metal clip nuts.

12
Check door foil (8) on inner door panel and

clips (5) on door


Replace damaged door foil Replace all

clips.

13
Install in the reverse order

Assembly wedge

110 589 03 59 00

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Page 1

AF72.10-P-6003-01A
Adjusting front door lock


Front door

Number

Designation
Model 163

BA72.10-P-1004-01D
Screw on door lock
Nm
8

P72.10-2031-11

1
Remove plug for adjustment screw on front door lock

2
Press door handle inward and remove adjustment screw (1) on

door lock. Do not remove tool.

Note that door lock in right front door has left-hand thread.

P72.10-2032-01

3
Pull door handle outward approx. 1 mm and hold in this position

4
Press adjustment screw in direction of door inner paneling with attached tool and tighten

5
Release door handle

6
Observe motion of adjustment screw through access hole while pulling door handle outward

Door handle should have 1-2 mm of play (a) before the adjustment screw moves.

P72.10-2033-01

The lock opens when the door handle is pulled out approx. 15 mm (b).

7
Reinstall plug for adjustment screw on door lock

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AR72.10-P-4011GH
Removing and installing front door lock
13.2.97

MODEL
163

P72.10-0487-06

1
Guide rail

2
Door lock

3
Screws

4
Control cable

5
Connector

M14/5
Right front door central locking

motor (not illustrated)

M14/6
Left front door central locking
motor (not illustrated)

Operation no. of operation texts or of standard texts and flat rates
Division
Operation

no.
Operation text

P
724290
REPLACING LOCK ON LEFT FRONT DOOR

P
724300
REPLACING LOCK ON RIGHT FRONT DOOR


Removal, installation

1
Remove door liner on front door

AR72.10-P-1000GH

2
Remove outer door handle on front door

AR72.10-P-2400GH

3
Remove bearing bracket for door handle

4
Pull door foil off of inner door panel

Installation:
Replace damaged foil

5
Remove window lift mechanism

guide rail (1)

6
Unscrew screws (3)

*BA72.10-P-1004-01D

7
Disconnect connector (5) on central locking

motor (M14/5 or M14/6)

8
Remove door lock (2)


Remove door lock (2) downward through

installation opening

9
Unhook control cable (4)

10
Install in opposite order


Front door

Number

Designation
Model 163

BA72.10-P-1004-01D
Screw on door lock
Nm
8

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Page 1

SI72.10-P-0001A
Service Information on adjusting front door lock
19.6.98

MODEL
163

Repairs concerning complaints about the front door not being

able to be opened after unlocking the vehicle, should be addressed in

the following manner:

1.
Adjust the door lock

2.
If attempt to adjust door lock was unsuccessful, replace door

lock.
The majority of door locks being returned under warranty for this

complaint have been found to be servicable after adjustment.

1

Adjust front door lock
If adjustment unsuccessful
#

AF72.10-P-6003-01A

Replace front door lock

AR72.10-P-4011GH

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SI72.10-P-0002GH
Service Information: Modification of the front door
6.5.03

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

P72.10-2740-06

1
Side airbag

2
Attachment hole

3
Locating hole

4
Locating pin

Due to a design modification to the door skin, both parts must be

checked when
exchanging
the door or the sidebag.

1

Check the replacement door to see if the

aligning bore for the sidebag is present

Should the replacement door
not
have an

aligning bore and the sidebag is equipped

with a fixing pin:

#

Modify the front door

SM72.10-P-0004A

2
Check to see of the fixing pin is present for

the replacement sidebag

If there is
no
fixing pin present on the

sidebag, the door does
not
need to be

modified.

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AR88.70-P-9060GH
Removing and installing mirror adjustment motor
12.2.97

MODEL
163

P88.70-0256-04

1
Screw

2
Connector

M21/1
Left electrically adjustable and heated
exterior rearview mirror

M21/2
Right electrically adjustable and

heated exterior rearview mirror (not

illustrated)

Operation no. of operation texts or of standard texts and flat rates
Division
Operation

no.
Operation text

P
883476
REPLACING MOTOR FOR LEFT ELECTRICALLY ADJUSTABLE EXTERIOR REARVIEW MIRROR

P
883478
REPLACING MOTOR FOR RIGHT ELECTRICALLY ADJUSTABLE EXTERIOR REARVIEW MIRROR


Removal, installation

1
Remove covering on outside rearview mirror

Remove mirror housing covering only.

AR88.70-P-9040GH

2
Unscrew screw (1)

3
Disconnect connector (2) and remove mirror

adjustment motor (M21/1 or M21/2)

4
Install in opposite order

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AR88.70-P-9040GH
Removing and installing outside rearview mirror cover
12.2.97

MODEL
163.113 /136 /154 /172 /174 up to 31.8.01

P88.70-0255-06

1
Frame

2
Mirror housing paneling

3
Catches in mirror housing

4
Outer catch

5
Bolt

6
Clips

Operation no. of operation texts or standard texts and flat rates
Range

Op. no.
Operation text

P
883424
REPLACING HOUSING FOR LEFT OUTSIDE REARVIEW MIRROR

P
883425
CONVERTING HOUSING FOR LEFT OUTSIDE REARVIEW MIRROR (MIRROR REMOVED)

P
883427
REPLACING HOUSING FOR RIGHT OUTSIDE REARVIEW MIRROR

P
883428
CONVERTING HOUSING FOR RIGHT OUTSIDE REARVIEW MIRROR (MIRROR REMOVED)

P
883430
REPLACING HOUSINGS FOR BOTH OUTSIDE REARVIEW MIRRORS


Remove/install

1
Remove mirror glass

AR88.70-P-9020GH

2
Release catch in mirror housing (3)

Press mirror housing out of frame (1) with

slight pressure

3
Release paneling for mirror housing (2) from

frame (1)

Outer catch (4) only accessible if mirror

housing is pivoted toward door

4
Remove mirror housing paneling (2)

5
Unscrew screw (5) from frame (1)

Torx bit set

*000589011000

6
Unclip frame (1) from mirror actuator motor

Pivot mirror housing back to initial

position. Unclip clips (6) from actuator motor.

6
Remove frame (1)

7
Install in the reverse order


Torx bit set

000 589 01 10 00

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