MERCEDES-BENZ ML350 1997 Complete Repair Manual

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

Parts ordering notes
Part no.

Designation
Quantity

000 986 06 50
Priming stick
1

000 986 33 70 10
Wax preservative
1

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 3

SM63.20-P-0003GI
Reinforce right front engine hood hinge support
16.1.02

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

163.136 /154 /172 #X as of 708319,

163.113 /128 /174 /175

P63.20-3439-12

The template shown is for the left side

(turn over for the right side)

6
Template

7
Hole, hinge assembly bolt, rear

8
Hole, hinge assembly bolt, front

9
Center punch position

10
Center punch position

11
Center punch position

a
80 mm

b
100 mm

P63.20-3435-06

1
Hinge assembly bolt, front

2
Hinge assembly bolt, rear

3
Center punch mark

4
Center punch mark

5
Center punch mark

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

Op. no.
Operation text

Time
Acc. no.
Code

P
023540
REINFORCE LEFT ENGINE HOOD HINGE SUPPORT
037 WU/3.1 hrs.
88 237 36
---

P
023541
REINFORCE RIGHT ENGINE HOOD HINGE SUPPORT
040 WU/3.3 hrs.
88 237 36
---

P
023542
REINFORCE (BOTH) ENGINE HOOD HINGE SUPPORTS
053 WU/4.4 hrs.
88 237 36
---


Remove/install

1
Ensure that the recirculated air function is

deactivated

2
Remove engine hood

AR88.40-P-3000GH

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

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

Number
Designation
Order number

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

Parts ordering notes
Part no.

Designation
Quantity

000 986 06 50
Priming stick
1

000 986 33 70 10
Wax preservative
1

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 3

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

AP88.40-P-8821GH
Lubricating hood catch, locking hook and hinges
2.7.97

MODEL
163

Engine hood lock version up to

31/ 08/ 99

P88.40-0381-01 P88.40-0380-01
P88.40-2082-01

E
ngine hood lock version as of

01/ 09/ 99

P88.40-2083-01

1
Oil locking hook (arrow)


Use engine oil

2
Inspect ease of operation of locking hook

3
Grease hood lock (arrows)

*BR00.45-Z-1001-06A

Repair products

Number

Designation
Order number

BR00.45-Z-1001-06A
MB longlife grease
000 989 63 51

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

OS00.00-P-1001-01A
Releasing gas from gas strut and emptying


Danger!

Risk of injury
from drilling gas-filled

subassemblies or components (gas filling non-

combustible)
Wear safety glasses and face mask.

AS00.00-Z-0006-01A

P88.40-0216-01

1
Clamp gas-operated strut in machine vise of pillar drilling machine.

Conrod must point away from body, no other persons must be within danger area.

2
Drill gas-operated strut approx. 20 mm (dimension a) from bottom of gas-operated strut

4

with a 3 mm drill (arrow). Drill with as little force as possible.

3
Unclamp gas-operated strut, pump gas-operated strut empty by pressing conrod in several

times.

Observe regulations for disposal of hydraulic oil.

4
Dispose of gas-operated strut (worn part).

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