MERCEDES-BENZ ML350 1997 Complete Repair Manual

GF54.30-P-3017A
Quartz, location/task/function
8.7.99

MODEL
129, 140 as of 1.6.96,

163, 168, 170,

202 as of 1.8.96,

208,

210 as of 1.6.96,

215, 220

P54.30-0519-01

Piezo-electric effect:

A thin quartz plate (c) is coated on two opposing sides with a conductive material (a), (b) (see

illustration). If a tensile or compressive load is applied to the array, an electrical voltage "U" i
s

produced between the points (d) and (e). The polarity of the generated voltage depends on the

direction of load (compression/tension).

Reversed piezo-electric effect:

If, however, a voltage is applied to the points (d) and (e), the quartz plate increases or decreases


in length.

Task:

Mechanical vibrations can be converted into electrical oscillations using the piezo-electric effect.


For example, for microphones, knock sensors, pressure sensors.

Electrical oscillations can be converted into mechanical vibrations or motion using the reversed

piezo-electric effect: piezo-electric speakers, actuators.

Both effects are combined in the quartz resonator: If an AC voltage whose frequency is roughly

equal to the mechanical resonant frequency (fundamental or harmonic component) of the quartz

plate is applied to the points (d) and (e), the quartz is stimulated to generate resonant vibrations


which stabilize the frequency of the electrical oscillations. For this reason, quartz resonators are


often used where a high degree of frequency stability is required (e.g. in clock generators

(oscillators) for electronic clocks and microprocessors).

Copyright DaimlerChrysler AG 05.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1

AR46.20-P-0600GH
Removing and installing rack-and-pinion steering
1.3.97

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

P46.20-2126-09

Shown on model 163.154 (vehicles

without speed-sensitive power steering)

1
Front axle carrier

10a
Tie rod joint

21
Rubber mount
25d

Nut

25f
Steering coupling shield

30f
Return line

30i
High-pressure expansion hose

80a
Lower steering shaft

23

Rack-and-pinion steering

23a
Bolts

23h
Shim

23i
Shim

25
Steering coupling

Modification notes
10.9.03

Reference to adjusting toe on front axle replaced by

reference to chassis alignment check
Step 16.1

Removing, installing

Danger!

Risk of fatal injury
if the vehicle slips or

topples off 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 injury
with
trapped or crushed

fingers when removing and installing or

aligning hoods, doors, trunk lid/tailgate and

sliding roof.
When moving components ensure that no

body parts or limbs are in the area of

movement.

AS00.00-Z-0011-01A

1
Open engine hood

AR88.40-P-1000GI

2
Extract oil from power steering pump supply

reservoir

Hand pump

*210589007100

3
Raise vehicle

4
Remove front axle gear

AR33.30-P-0525GH

5
Press tie rod joints (10a) off steering knuckles


Installation:
Replace self-locking nuts.

AR46.40-P-0200-02C


*BA46.40-P-1001-01C

Thrust piece

*140589006300

Puller

*202589023300

6
Turn steering wheel to horizontal position

(front wheels in straight-ahead position)

7
Remove key and engage steering lock

8.1
Unplug speed-sensitive power steering

connector from timing case
On vehicles with speed-sensitive power

steering code 213a

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9
Detach return line (30f) and high-pressure

expansion hose (30i)

Connection fittings or banjo bolts

depending on the version. Seal off line

connections with plugs.


Installation:
Replace sealing rings.


Connection fitting, return line

*BA46.20-P-1001-01D

Connection fitting, high-pressure

expansion hose

*BA46.20-P-1002-01D

Banjo bolt, return line

*BA46.20-P-1004-01D

Banjo bolt, high-pressure expansion hose

*BA46.20-P-1005-01D

Plug

*129589009100

10
Detach nut (25d) and bolt from steering

coupling (25) and pull lower steering shaft

(80a) upwards out of steering coupling (25)

Do not use force as the corrugated tube is

sensitive to lateral forces. Enlarge clamping

groove a little with a screwdriver if necessary.


Installation:
Replace nut (25d).


Installation:
Turn rack-and-pinion

steering to center position and fit steering

coupling.

AR46.20-P-0600-01GH


*BA46.10-P-1001-01D

11
Detach rack-and-pinion steering (23) from

front axle carrier (1) by unscrewing bolts (23a)

The installed position of the shims (23h,

23i) on the right-hand side, between the

rubber mount and the front axle carrier, must

be observed as the shims are of different

thicknesses.


Installation:
Attach rack-and-pinion

steering to front axle carrier.

AR46.20-P-0600-03GH


Assessing condition of steering gear when

repairing accident vehicles

AH46.20-P-9409-01A

12
Check rubber mount (21) of rack-and-pinion

steering mounting for damage
Replace rubber mount if necessary:
#

Removing rubber mounts on rack-and-pinion

steering mounting

AR46.20-P-0600-02GH

13
Install in the reverse order

14
Fill and bleed power steering pump
Engines 112, 113

AR46.30-P-0010B
Engines 111, 612, 628
AR46.30-P-0010P

15
Check steering for function and leaks

There is a grease cushion under the cover
cap. A small amount of escaping grease is to

be regarded as normal and must not be

confused with leakage.

16.1
Check toe on front axle and adjust if necessary
When installing a new rack-and-pinion

steering, see:

#

Performing chassis alignment check

AR40.20-P-0200A


Steering shaft

Number

Designation
Model 163

BA46.10-P-1001-01D
Self-locking nut, steering coupling to steering shaft

and rack-and-pinion steering
Nm
28


Steering gear

Number

Designation
Model 163

BA46.20-P-1001-01D
Screwed connection fitting from return line

to rack-and-pinion steering
Nm
15

BA46.20-P-1002-01D
Screwed connection fitting from high-

pressure expansion hose to rack-and-pinion

steering
Nm
15

BA46.20-P-1003-01D
Bolted connection, rack-and-pinion steering

to front axle carrierNm
50

BA46.20-P-1004-01D
Banjo bolt, return line to rack-and-pinion

steering
Nm
30

BA46.20-P-1005-01D
Banjo bolt, high-pressure expansion hose to

rack-and-pinion steering
Nm
30

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Tie rod

Number

Designation
Model 163

BA46.40-P-1001-01C
Self-locking nut, tie rod to steering knuckle
Nm
55

202 589 02 33 00

Thrust piece

Puller

Hand pump

210 589 00 71 00 140 589 00 63 00

Set of plugs

129 589 00 91 00

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AR20.40-P-5000GH
Remove/install electric fan
22.6.00

ENGINE
113.965 in MODEL 163.175

ENGINE
113.981 in MODEL 163.174

P20.40-2025-06

1
Connector

2
Electrical connections

3
Tie strap

4
Electric fan

5
Screws

6
Sheet metal nuts

7
Sheet metal clamps

8
Retainer tabs

9
Protective caps

10
Bracket


Remove/Install

1
Disconnect electrical plug (1).

2
Unbolt electrical connections (2)

For this step detach protective caps (9).

Insulate wire ends, in order to avoid a

short circuit due to an unintended ground

contact.

3
Unclip cable straps (3)

4
Press coolant hose out of bracket (10)

5
Remove engine compartment paneling
AR61.20-P-1105GH

6
Unbolt electric fan (4) at the bottom

For this step unscrew bolts (5) and

remove sheet metal nuts (6).

7
Take off plate clamps (7)

8
Remove electric fan (4)


Installation:
Ensure, that the retainer tabs

(8) of the electric fan are seated in the

mounts of the radiator on right and left

9
Install in the reverse order

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Page 1

AR20.20-P-3865HC
Remove/install the radiator
5.6.97

ENGINE
112.942 in MODEL 163.154

ENGINE
112.970 in MODEL 163.157

ENGINE
113.942 in MODEL 163.172

ENGINE
113.965 in MODEL 163.175

ENGINE
113.981 in MODEL 163.174

P20.20-2017-09

Shown on Model 163.154 with Engine 112

1
Viscous fan

2
Plate clamps of fan shroud

3
Fan shroud

4
Coolant line

5
Coolant line to expansion reservoir

6
Coolant line

7
Headlamps
17

Air deflector plate

18
Oil line (return line radiator

!
expansion

reservoir of power steering pump)

19
Oil line (feed line steering gear

!

radiator)

20
Fasteners

21
Damper rubber

8

Radiator crossmember

9
Rubber seal of radiator

10
ATF lines

11
Fan grille

12
Air guides

13
Clamps of air guides

14
Air conditioning system fluid reservoir

15
Radiator

16
Cover strips

Modification notes
23.3.00

Radiator with integral oil cooler for power steering pump
See step 5 and 16


Remove/install


External torx set

*001589760900


6 mm hexagon socket

*WH58.30-Z-1001-06A

7 mm hexagon socket

*WH58.30-Z-1002-06A

1.1
Remove air deflector plate (17)

Engine 113.942 only.

Danger!

Risk of injury
to skin and eyes from scalding

due to contact with hot coolant spray.
Risk of

poisoning
if coolant is swallowed.
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

2
Drain the coolant at the radiator


To drain the coolant, detach coolant line

at the bottom of the radiator or at the coolant

pump.


Installation:
Replace the hose clamps on

the radiator fitting for the coolant hose, as

they could cause damage to the screw/thread. AR20.00-P-1142HA

Hose clamp

*BA20.20-P-1004-01A

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3.1
Remove viscous fan (1)

Engine 112.942 /970 and 113.942.

Right-hand thread!

AR20.40-P-5660C

3.2
Remove electric fan

Only Engine 113.965 /981.

AR20.40-P-5000GH
4.1
Pull off plate clamps of fan shroud (2)

Only for Engine 112.942, from 5/98.

5.1
Remove fan shroud (3)

Only for Engine 112.942 /970 und

113.942. Unscrew the bolts at bottom of fan

shroud for this step


Installation:
If installing a new radiator

with integral power steering pump oil cooler, a

new fan shroud is required if a radiator

without integral oil cooler was previously
installed.

6
Remove headlamp (7).

AR82.10-P-4730GH

7
Remove radiator crossmember (8)

AR62.30-P-2300GH

8
Detach coolant line (4, 6) and expansion

reservoir coolant line (5) at the radiator


Installation:
Replace the hose clamps on

the radiator fitting for the coolant hose, as

they could cause damage to the screw/thread.

Hose clamp

*BA20.20-P-1004-01A

9
Remove the rubber seal on radiator (9)

10.1
Remove oil line (return line of radiator
!

power steering pump expansion reservoir)

(18) and oil line (feed line of steering gear

!

radiator) (19)

From 5/98 only, seal off the connections.

Set of plugs

*129589009100

11
Unscrew ATF lines (10) at the radiator

Seal off the connections.


*BA20.20-P-1001-01A


*BA20.20-P-1003-01A

Set of plugs

*129589009100

12.1
Detach the connector from the fan and
remove the fan grille (11)

Only for Engine 112.942 /970 and 113.942.

13
Unscrew the condenser from the radiator
Do not disconnect the lines.

14
Remove fasteners (20) and damper rubber

(21)

The damper rubber (21) is designed to

prevent possible vibrations between the

condenser and radiator (15) during off-road

driving.

15
Remove air conditioning system fluid

reservoir (14) from the radiator

Place aside with the lines connected.

Detach the condenser from the radiator.

16
Remove radiator (15)

When installing, the spigots on the

radiator must be inserted in the rubber

grommets in the bottom crossmember.

Installation:
On Model 163.154 with

Engine 112.942 before VIN end number

043553, when installing a new radiator with

integral power steering pump oil cooler,

additional operations are required, if they

have not already been carried out:

#
v

Retrofit the bracket for the oil cooler line of

the power steering pump

SM46.30-P-0002A

k

Radiator with integral oil cooler for the power

steering pump

BT20.20-P-0001-01A

17
Detach air guides (12)

Replace the clamps on air guides (13).

18
Install in the reverse order

19
Pour in coolant

AR20.00-P-1142HA

20
Check the headlamp setting and correct if

necessary

e

Check and adjust the headlamp setting

AP82.10-P-8260GH

Danger!

Risk of accident
caused by vehicle starting

off when engine is running.
Risk of injury


caused by contusions and burns when

working in engine during starting procedure
Secure the 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

21
Check the oil level in the automatic

transmission and correct if necessary

AR27.00-P-0101A

22
Check the cooling system for leaks

AR20.00-P-1010HA


Radiator, coolant hoses

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Number
Designation
Engine

112.942/

970,

113.942/

965/981

BA20.20-P-1001-01A
Union nut on automatic transmission

ATF line to radiatorNm
20

BA20.20-P-1003-01A
Banjo bolt
M12X1.5
Nm
30

BA20.20-P-1004-01A
Hose clamp
Nm
3

129 589 00 91 00

Set of plugs

External Torx set

001 589 76 09 00

Commercially available tools
Number

Designation
Make (e. g.)
Order number

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

Güldenwerther

Bahnhofstraße 25-28

D-42857 Remscheid

426-7

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AR20.40-P-5000M
Remove/install electric fan
24.8.99

ENGINE
612.963 in MODEL 163.113

P20.40-2015-06

Shown on Model 163.113 with

Engine 612.963

1
Clutch

2
Electrical lines circuit 30

3
Clips

4
Captive nuts

5
Bolts

M4/7
Electric suction fan engine and AC

with integrated control


Remove/Install


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


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

1
Place the vehicle on lifting platform

AR00.60-P-1000GH

2
Open engine hood and raise to vertical position

Have second person secure hood.

AR88.40-P-1000GI

3
Connect quiescent current retention device


*WH58.30-Z-1005-09A

4
Disconnect ground cable of battery

AR54.10-P-0003A

5
Detach coupling (1) at electrical connector of

fan

6
Disconnect electrical lines circuit 30 (2) at
electric fan

7
Unclip wiring harness from bracket

8
Remove front part of noise encapsulation

AR94.30-P-5400GH

9
Detach clamps (3) at bottom side of electric fan

10
Unscrew screws (5)

11
Remove captive nuts (4)

12
Unhinge electric suction fan engine and AC

with integrated control (M4/7) at top of

radiator and take out toward bottom


Installation:
Insert retaining lugs of

electric fan into the mounts at radiator.

13
Install in the reverse order

Commercially available tools

Number

Designation
Make (e. g.)
Order number

WH58.30-Z-1005-09A
CMP 12.2 quiescent current retention unit
Hans Zeheter

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AR20.20-P-3865MM
Remove/install radiator
10.11.99

ENGINE
612.963 in MODEL 163.113

P20.20-2080-09

1
Electric fan

2
Low temperature cooler

3
Bolts (low temperature cooler)
110/2

Charge air cooler

4
Lamp units

5
Cover strips

6
Radiator crossmember

P20.20-2081-09

8
Coolant hose for coolant pump

9
Coolant hose of thermostat housing

10
Coolant hose of coolant expansion tank

11
Seal strip

12
Air ductings
19

Power steering oil line (feed line of
steering gear

!
radiator)

20
Attachment parts

21
Damper rubber

13

Mounting clips

14
Air conditioning fluid reservoir

15
Radiator

16
Bolts

17
Capacitor

18
Power steering oil line

(Return line of radiator

!

Power steering pump supply reservoir)


Removal/installation


Danger!

Risk of injury
to
fingers being jammed or

pinched
when removing, 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

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d by Modification services.
Page 1