MERCEDES-BENZ ML350 1997 Complete Repair Manual

Fig. 106: Identifying Dial Indicator Holder (363 589 02 20 00)
Fig. 107: Identifying Dial Indicator (001 589 53 21 00)
Determine the play in the supporting
joint (7)
and pushing of the wheel hub. If measurement yields a play > or = 0,4 mm
the supporting joint (7) must be replaced, refer
to: ?
Replace supporting jointAR33.20-P-
0440GH
6Repeat the operation on the other
side of the vehicle
Install
7Remove dial gage and gage stand
8Fit front wheels AP40.10-P-
4050GH

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:22 PMPage 62 © 2006 Mitchell Repair Information Company, LLC.

AR82.62-P-7850GH
Remove/install front door speakers in mirror triangle
17.5.01

MODELS
163.113 #A as of 289565,

163.113 #X as of 754620,

163.154 /174 #A as of 289565,

163.128 /157 /175

P82.62-2232-11

1
Mirror triangle

2
Retaining clamps

3
Bracket

H4/23
Left front door speaker, mirror triangle

H4/23x1
Left front door speaker connector, mirror triangle

H4/24
Right front door speaker, mirror triangle

H4/24x1
Right front door speaker connector, mirror triangle


Remove/install

1
Unclip mirror triangle (1) from door

Assembly wedge

*110589035900

2
Disconnect left front door speaker connector,

mirror triangle (H4/23x1) or right front door

speaker connector, mirror triangle (H4/24x1)

from left front door speaker, mirror triangle

(H4/23) or right front door speaker, mirror

triangle (H4/24)

3
Remove retaining clips (2)

4
Remove speaker from mirror triangle

Disconnect plug from bracket (3).

5
Install in the reverse order

Assembly wedge

110 589 03 59 00

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AR07.16-P-1100MM
Remove, install fuel cooler
5.11.99

ENGINE
612.963 in MODELS 163.113

P47.00-2042-12

1
Fuel feed hose

2
Fuel drain hose

3
Coolant feed hose

4
Coolant return flow hose

5
Fuel cooler

7
Bolts of fuel cooler

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

Op. no.
Operation text

P
075890
REMOVING AND INSTALLING FUEL COOLER

P
075895
REPLACE FUEL COOLER


Remove, Install


Danger!
Risk of injury
to
fingers being jammed or

squeezed
when removing and installing or

aligning hoods, doors, tailgate/tailgate and

sliding roof.
When moving components ensure that no

body parts or limbs are in the area of motion.

AS00.00-Z-0011-01A


Danger!
Risk of injury
to skin and eyes suffering

scalding from contact with hot coolant spray.
Risk of poisoning
from swallowing coolant.
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


Danger!
Risk of explosion
from fuel igniting,
risk of

poisoning
from inhaling and swallowing fuel

as well as
risk of injury
to eyes and skin

from contact with fuel.
No fire, sparks, naked flames or smoking.

Pour fuels only into suitable and appropriately

marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1
Open engine hood and raise to vertical position


Have second person secure hood.

AR88.40-P-1000GI

2
Remove trim panel of cylinder head cover

AR01.20-P-5014-02B


*BA01.20-P-1002-01A
*BA01.20-P-1003-01A

3
Drain coolant

At radiator.

AR20.00-P-1142M

4
Close fuel feed hose (1) at the fuel cooler (5)

Set of plugs

*129589009100

*WH58.30-Z-1001-06A
*WH58.30-Z-1002-06A

5
Detach fuel outlet hose (2)

Clamp

*000589543700

Set of plugs

*129589009100

*WH58.30-Z-1001-06A
*WH58.30-Z-1002-06A

6
Disconnect coolant return flow hose (4) to

thermostat housing

Hose clamp pliers (length 210 mm;

adjustment range 80 mm)

*WH58.30-Z-1026-02A

7
Unscrew bolts (7) at fuel cooler

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8
Disconnect coolant feed hose (3) to fuel cooler

Raise fuel cooler.

Hose clamp pliers (length 210 mm;

adjustment range 80 mm)

*WH58.30-Z-1026-02A

9
Install in the reverse order


Danger!
Risk of accident
as vehicle may start off by

itself with the engine running.
Risk of injury


as working around the engine during start-up

or while running may result in contusions and

burns
Secure vehicle to prevent it from moving off

by itself.

Wear closed and tight-fitting work clothes.

Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

10
Pour in coolant
*BF20.00-P-1001-02E

Switch heater to maximum and warm up

engine at moderate revs. Top up coolant

constantly at coolant expansion reservoir.

Close coolant expansion reservoir once

coolant temperature is 60-70 °C.


Note on coolant level
Models 124, 129, 140, 168, 170, 202, 208,

210, 220, 463

AH20.00-P-1142-01A

11
Inspect cooling system for leaks

AR20.00-P-1010HA

12
Run engine and inspect fuel system for leaks

Crankcase ventilation, cylinder head cover

Number

Designation
Engine

612.963

BA01.20-P-1002-01A
Screw of trim panel of cylinder head cover

to cylinder head cover
NM
10

BA01.20-P-1003-01A
Screw attaching cover panel to charge air

distribution pipe
NM
10


Cooling system

Number

Designation
Engine

612.963

BF20.00-P-1001-02E
Cooling system
Total capacity
Liter
Y
11,0

Capacity of anticorrosion/

antifreeze agent down to -37 °C
Liter
Y
5,5

Capacity of anticorrosion/

antifreeze agent down to -45 °C
Liter
Y
6,25

Specifications for Service

Products
SheetBB00.40-P-0310-01A
SheetBB00.40-P-0325-02A

129 589 00 91 00

Set of closure plugs

Circuit

000 589 54 37 00

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e.g.) g.)
Order number

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Page 2

WH58.30-Z-1001-06A
6 mm socket hexagon on flexible shaft for hose clamps with worm drive
Hazet

Güldenwerther

Bahnhofstrasse 25-28

D-42857 Remscheid

426-6

WH58.30-Z-1002-06A
7 mm hexagon socket wrench to flexible shaft for hose clips with worm

drive
Hazet

Güldenwerther

Bahnhofstrasse 25-28

D-42857 Remscheid

426-7

WH58.30-Z-1026-02A
Hose clamp pliers (length 210 mm; adjustment range 80 mm)
Hazet

Güldenwerther

Bahnhofstrasse 25-28

D-42857 Remscheid

798-12

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AR80.20-P-4004GH
Removing, installing fuel filler flap central locking motor
12.3.97

MODEL
163

P80.20-0478-06

1
Fuel filler flap

2
Outer screws

3
Inner screws

4
Fuel filler fitting

5
Screws

6
Connector

M14/10
Filler flap CL actuating motor


Removal, installation

1
Remove paneling on C-pillar

Remove paneling on left C-pillar

AR68.30-P-4490GH

2
Remove fuel filler flap (1)

3
Unscrew outer screws (2) on fuel filler


When installing:
Ensure that rubber seal

is properly seated

4
Unscrew inner screws (3) on fuel filler

5
Unscrew filler flap CL actuating motor (M14/10)

Push filler fitting to right and unscrew

screws from filler flap CL actuating motor

6
Disconnect connector (6)

7
Reinstall in opposite order

8
Check for proper function

Actuate central locking with fuel filler flap

open

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AR80.20-P-4004GH
Removing, installing fuel filler flap central locking motor
12.3.97

MODEL
163

P80.20-0478-06

1
Fuel filler flap

2
Outer screws

3
Inner screws

4
Fuel filler fitting

5
Screws

6
Connector

M14/10
Filler flap CL actuating motor


Removal, installation

1
Remove paneling on C-pillar

Remove paneling on left C-pillar

AR68.30-P-4490GH

2
Remove fuel filler flap (1)

3
Unscrew outer screws (2) on fuel filler


When installing:
Ensure that rubber seal

is properly seated

4
Unscrew inner screws (3) on fuel filler

5
Unscrew filler flap CL actuating motor (M14/10)

Push filler fitting to right and unscrew

screws from filler flap CL actuating motor

6
Disconnect connector (6)

7
Reinstall in opposite order

8
Check for proper function

Actuate central locking with fuel filler flap

open

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AR80.20-P-4004GH
Removing, installing fuel filler flap central locking motor
12.3.97

MODEL
163

P80.20-0478-06

1
Fuel filler flap

2
Outer screws

3
Inner screws

4
Fuel filler fitting

5
Screws

6
Connector

M14/10
Filler flap CL actuating motor


Removal, installation

1
Remove paneling on C-pillar

Remove paneling on left C-pillar

AR68.30-P-4490GH

2
Remove fuel filler flap (1)

3
Unscrew outer screws (2) on fuel filler


When installing:
Ensure that rubber seal

is properly seated

4
Unscrew inner screws (3) on fuel filler

5
Unscrew filler flap CL actuating motor (M14/10)

Push filler fitting to right and unscrew

screws from filler flap CL actuating motor

6
Disconnect connector (6)

7
Reinstall in opposite order

8
Check for proper function

Actuate central locking with fuel filler flap

open

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AP47.20-P-0780BB
Replace fuel filter
2.3.99

ENGINE
611.960 in MODEL 202.133 /134 /193 /194

ENGINE
611.961 in MODEL 210.006 /007 /206 /606

ENGINE
612.961 in MODEL 210.016 /216 /616

ENGINE
612.963 in MODEL 163.113

ENGINE
613.961 in MODEL 210.026 /226

ENGINE
613.960 in MODEL 220.026 /126

P47.20-0289-01

Shown on engine 611.960

70
Fuel filter housing

70/1
Fuel filter input

70/2
Fuel filter output

70/3
Threaded ring

70/4
Cap

70/5
Seal

70/6
Filter element

P07.16-2101-01

Shown on engine 612.961

70/1
Fuel line input

70/2
Fuel line output

70/3
Threaded ring

70/4
Cap

70/5
Seal

70/6
Filter element

70/7
Fuel return line

70/8
Fuel feed line


Remove/install and replacing


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


Danger!
Risk of explosion
from fuel igniting,
risk of

poisoning
from inhaling and swallowing fuel

as well as
risk of injury
to eyes and skin

from contact with fuel.
No fire, sparks, naked flames or smoking.

Pour fuels only into suitable and appropriately

marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1
Remove trim panel of charge air distribution

pipe

2
Disconnect fuel return line (70/7) and fuel

feed line (70/8 )

3
Unscrew threaded ring (70/3) and remove

together with cover (70/4).

If the fuel filter housing is soiled inside,
it must be removed and cleaned (against
separate order):

#
f

Remove/install fuel full-flow filter

AR47.20-P-1070HB

4
Replace filter insert (70/6)

After inserting the filter element

Fill fuel filter housing with fuel.

5
Replace sealing ring (70/5)

6
Mount threaded ring with cover so that the

groove latches at the fuel filter housing

Tighten threaded ring by hand.

7
Mount fuel return line (70/7) and fuel feed line

(70/8 )

8
Install trim panel of charge air distribution pipe


*BA01.20-P-1003-01A


Danger!
Risk of accident.
Accidents may result if the

vehicle starts off unintentionally with the

engine running.
Risk of injury.
Crushing and

burn injuries may result while working on

engine during when it is being started or when

it is in operation.
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

9
Run engine and inspect fuel filter for leaks

Crankcase ventilation, cylinder head cover

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Number
Designation
Engine

611.960/

961/962
Engine

612.961/

962/967
Engine

612.963
Engine

613.960/

961

BA01.20-P-1003-01A
Screw attaching cover panel to charge air

distribution pipe
Nm
10101010

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