MERCEDES-BENZ ML350 1997 Complete Repair Manual

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

1
Open engine hood and raise to vertical position

Have second person secure hood.

AR88.40-P-1000GI

2
Connect no load current retention unit


*WH58.30-Z-1005-09A

3
Disconnect battery ground cable

AR54.10-P-0003A

4
Remove trim panel of cylinder head cover

AR01.20-P-5014-02B


*BA01.20-P-1002-01A


*BA01.20-P-1003-01A

5
Remove bottom part of noise encapsulation

at front

AR94.30-P-5400GH

6
Remove electric fan (1)

Remove toward bottom.

AR20.40-P-5000M

7
Drain coolant

At radiator.

AR20.00-P-1142M


Notes on coolant
All engines

AH20.00-N-2080-01A

8
Remove charge air cooler (110/2)

AR09.41-P-6817MM

9.1
Attach guard plate for radiator/condenser

With automatic air conditioning, code

581a and AC system or Tempmatic USA,

code 580.

Attach additional AC condenser in the

vehicle.

y

Guard plate for radiator/condenser
Engine 606 in model 124,
Engine 606.961 in model 140,

Engine 112, 113, 604, 605, 611.960 in

MODEL 202,

Engine 602.983, 612.966 in MODEL 461,

Engine 628.962, 612.965, 606.964, 112.945,

113.962/ 982 in MODEL 463,

Engine 111, 112, 611.962, 612.962 in model

203,

Engines 112, 113, 611.961, 612.961, 613.961

in MODEL 210,

Engine 112 in model 170,

Engine 112 in MODEL 220,

Engine 113 in MODEL 211, 215, 220,

Engine 112 in MODEL 208,

Engine 112, 612.963, 628.963 in MODEL 163,
Engine 112.923 /943, 113.961 in MODEL 129,

Engine 137, 275 in MODEL 215, 220,

Engine 613.960, 628.960 in MODEL 220,

Engine 113.992 in model 230.474,

Engine 271 in model 209, 203,

Engine 285.950 in model 240.078 /178,

Engine 612.967 in model 209.316,

Engine 648 in model 220

Engine 112.951 in model 639.601/603/

605/701/703/705/801/803/805

Engine 646.983/984 in model 639.601/

603/605/701/703/705/801/803/805

Engine 646.982 in model

639.601/603/605/701/703/705

WF58.50-P-0110-01A

10
Remove seal rail (11)

11
Extract steering oil from reservoir

Hand pump

*210589007100

12.1
Disconnect power steering oil line (return line

radiator

!
power steering pump supply

reservoir) (18)

Seal connections.


Installation:
Install new sealing rings.


*BA46.30-P-1012-01A


Clamp

*000589543700

Set of stop plugs

*129589009100

12.2
Disconnect power steering oil line (feed line of

steering gear

!
radiator) (19)


Clamp

*000589543700

Set of stop plugs

*129589009100

Hexagon socket wrench

*WH58.30-Z-1001-06A

Hexagon socket wrench

*WH58.30-Z-1002-06A

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Page 2

13
Disconnect coolant hose to coolant pump (8),

coolant hose from thermostat housing (9) and

coolant hose from coolant expansion tank

(10) at radiator

Hexagon socket wrench

*WH58.30-Z-1001-06A

Hexagon socket wrench

*WH58.30-Z-1002-06A

14
Detach air guides (12)


Installation:
Replace fastening clamps

(13)

15
Unscrew bolts (16) at condenser (17) to

radiator

Avoid deformation of condenser lines.

Do not disconnect lines.

16
Remove attachment parts (20) and rubber

shock absorber (21)


Installation:
Ensure, that the rubber

shock absorbers do not drop when installing

the radiator.

Replace fastening clamps.

17
Take off fluid reservoir of AC (14) at radiator

Place to the side with lines connected.

External torx set

*001589760900

18
Remove bracket of charge air pipe at left

radiator

Installation:
Insert bracket of charge air

pipe into the bracket at the radiator.

19
Remove radiator (15)

Installation:
When installing, the mounting

studs of the radiator must be inserted into the

rubber grommets of the lower crossmember.

20
Install in the reverse order

21
Check headlamp adjustment, correct if

necessary

e

Check and correct headlamp adjustment

AP82.10-P-8260A

22
Inspect cooling system for leaks

AR20.00-P-1010HA

23
Fill power steering pump and bleed


Danger!

Risk of accident
caused by vehicle starting

off by itself when engine is running.
Risk of

injury
caused by contusions and burns when

working in engine during starting procedure
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

24
Run engine and inspect for leaks
Crankcase ventilation, cylinder head cover

Number

Designation
Engine

612.963

BA01.20-P-1002-01A
Bolt, cylinder head cover trim panel to

cylinder head cover
Nm
10

BA01.20-P-1003-01A
Bolt, cover panel to charge air distribution

pipe
Nm
10

Power steering pump

Number

Designation
Model

163.113

BA46.30-P-1012-01A
Banjo bolt, power steering oil line to radiator
Nm
30


Cooling system

Number

Designation
Engine

612.963

BF20.00-P-1001-02E
Cooling system
Total capacity
Liter
Y
11.0

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Page 3

Filling capacity of anticorrosion/

antifreeze agent down to

-37 °C
Liter
Y
5.5

Filling capacity of anticorrosion/

antifreeze up to -45 °C
Liter
Y
6.25

Specifications for Operating

Fluids
SheetBB00.40-P-0310-01A
SheetBB00.40-P-0325-00A

001 589 76 09 00

Set of stop plugs
External Torx set

Clamp
Hand pump

000 589 54 37 00129 589 00 91 00210 589 00 71 00

Commercially available tools
Number

Designation
Make (e. g.)
Order number

WH58.30-Z-1001-06A
6 mm hexagon socket wrench to 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 clamps with

worm drive
Hazet

Güldenwerther

Bahnhofstraße 25-28

D-42857 Remscheid

426-7

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

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AR82.60-P-7502EA
Remove/install radio
5.5.94

MODEL
129

with single-block unit, 2nd generation two-component unit control element and MB radios
MODEL
163

with CODE (257) Hi-Line radio

with CODE (259) Premium radio with Bose sound system

with CODE (352) COMAND operating and display system

with CODE (353) Audio 30 APS

with CODE (357) Navigation system - additional unit

with CODE (522) Modular control system (MCS) radio USA

with CODE (750) MB Audio 30 RDS radio

with CODE (752) Becker Mexico 2000 radio with traffic news decoder

with CODE (753) MB Audio 30 RDS radio

with CODE (756) MB Audio 10 RDS radio with CD compartment

MODEL
168

with CODE (353) Audio 30 APS

with CODE (750) MB Audio 30 radio with TP/RDS

with CODE (752) MB Audio 30 radio without TP/RDS

with CODE (753) MB Audio 10 CC radio with TP/RDS

with CODE (754) MB Audio 10 CC radio without TP/RDS

with CODE (756) MB Audio 10 CD radio with TP/RDS

with CODE (758) MB Audio 5 radio

with CODE (759) MB Audio 5 TP radio with RDS

MODEL
170

with CODE (510) MB Exquisit radio with traffic news decoder, with RDS (Becker)

with CODE (512) MB Special radio with traffic news decoder, with RDS
with CODE (515) MB Classic radio with traffic news decoder, with RDS

with CODE (516) MB Classic radio without traffic news decoder

with CODE (755) MB Special radio with CD tray

MODEL
202

with CODE (510) MB Exquisit radio with traffic news decoder, with RDS (Becker)

with CODE (512) MB Special radio with traffic news decoder, with RDS
with CODE (515) MB Classic radio with traffic news decoder, with RDS

with CODE (516) MB Classic radio without traffic news decoder

with CODE (750) Becker Europa 2000 radio

with CODE (751) Becker Grand Prix 2000 radio with RDS

MODEL
208

with CODE (510) MB Exquisit radio with traffic news decoder, with RDS (Becker)

with CODE (512) MB Special radio with traffic news decoder, with RDS
with CODE (515) MB Classic radio with traffic news decoder, with RDS

with CODE (516) MB Classic radio without traffic news decoder

MODEL
MODEL 210

with CODE (510a) MB Exquisit radio with traffic news decoder, with RDS (Becker)

with CODE (512a) MB Special radio with traffic news decoder, with RDS
with CODE (515a) MB Classic radio with traffic news decoder, with RDS

with CODE (516a) MB Classic radio without traffic news decoder

with CODE (750a) MB Audio 30 RDS radio

with CODE (753) MB Audio 30 RDS radio

with CODE (756a) MB Audio 10 RDS radio with CD compartment

MODELS
463.200 /204 /206 /207 /208 /209 /220 /221 /224 /225 /227 /228 /230 /231 /232 /233 /240 /241 /243 /2 44 /245 /246
/247 /248 /249 /250 /254 /300 /304 /307 /308 /309 /320 /321 /322 /323 /324 /325 /327 /328 /330 /331 /332 /333

with CODE (ER5) MB "Classic" radio or standard class stereo cassette radio
with CODE (ER6) MB "Special" radio or mid-class stereo cassette radio

with CODE (ER7) MB "Exquisit" radio or comfort class stereo cassette radio

MODEL
414.700

with CODE (EF8) Sound 10 radio
with CODE (EF9) Sound 20 radio
with CODE (EG5) Sound 30 radio

with CODE (EG6) Audio 10 comfort radio, D2B networked

with CODE (EU0) Sound 30 radio with single CD drive

with CODE (EF2) Audio 10 RDS with CD insertion slot

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

P82.60-0001-06

The figure shows removal of radio in

model 202

51
Removal assembly

A2
Radio

Remove/Install

1
Disconnect battery ground cable

On model 163, 210, insulate cable

terminal for ground lead to prevent

unintentional contact between disconnected

ground lead and ground point W10

AR54.10-P-0003A

Model 463 except 463.241 with code 979

AR54.10-P-0003G

Model 463.241 with code 979

AR54.10-P-0003PV

2
Pull out radio (A2)

Insert removal fixture (51) for this purpose.


*000589886300

Push back retaining springs (arrow) on

removed radio (A2) and pull out removal

fixture (51).

k

MB radio
Model 202

BT82.60-P-9309-01A

k

MB radio
as of 02/97

BT82.60-P-9309-01B

k

MB radio
MODEL 129 as of 02/91

BT82.60-P-9309-01C

3
Disconnect electrical connectors

4
Install in the reverse order

5
Enter radio code
Code 750, 751

AR82.60-P-7502-01A

Code 510a, 512a, 515a, 516a, 755, ER5,

ER6, ER7

AR82.60-P-7502-01B

Model 129

AR82.60-P-7502-01C

Model 168, 414

AR82.60-P-7502-01GC

Model 163

AR82.60-P-7502-01GH

Removal assembly

000 589 88 63 00

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Page 2

AR00.60-P-1000GH
Raising, jacking up vehicle
27.1.00

MODEL
163

P00.60-2013-09

Fig. item, etc.
Work instructions


Danger!
Lethal injuries
are possible if vehicle slips off

of lifting platform
Align vehicle between the four lifting platform

pillars and position the four support plates
at

the hoist mounting points specified by the

vehicle manufacturer.

AS00.00-Z-0010-01A


Danger!
Danger of accident
through self-acting

movement of the vehicle when jacked up
Risk of injury
through intrusion into engine

compartment or driveline where rotating parts

pose a serious hazard.
Make sure that the jack stands are securely

positioned.

Authorized person should occupy driver's seat.

Wear closed and close-fitting work clothes.

Do not grasp hot or rotating parts.

AS00.00-Z-0008-01A


If the support plates are not properly mounted

(012) at the vehicle's designated jacking

points (1,2) damage may occur to the side sill

covers (3).


The vehicle should be secured against tipping

or falling off the platform when removing any

units.


Lifting vehicle with inspection pit lift or garage

jack

AR00.60-P-1000-01GH

Inspection pit lift.

*WE58.40-Z-1002-05A

1
Forward jacking points

2
Rear jacking points

3
Side sill covers

011
Lifting platform

*WE58.40-Z-1001-05A

012
Support plates
All four support plates must be extended to an

equal distance (Dimension X).

Workshop equipment/MB testers
(see Workshop Equipment Manual)

WE58.40-Z-1001-05A
Two-column lift

WE58.40-Z-1002-05A
Inspection pit lift

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Page 1

AR68.30-P-4470GH
Remove/install rear roof frame paneling
24.2.97

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

P68.30-0507-06

1
Belt end fitting in 3rd seat row

2
Center paneling of roof frame

3
Side paneling of roof frame

4
Expanding anchor

5
Screw


Remove, Install

1.1
Remove belt end fitting at bottom of 3rd seat

row (1)
Only with 3rd seat row, code 847.

*BA91.40-P-1001-01D

2
Unclip center roof frame covering (2)

Installation:
Install paneling in door

rubber seal.

Long wedge

*115589035900

3.1
Remove expanding anchor (4) from side roof

frame covering (3)

up to 31.08.01

Installation:
Replace expanding anchor.

3.2
Remove screw (5) from side roof frame

paneling (3)

4.1Unclip side roof frame paneling in upper outer

corner

As of 01.09.01

4.2
Remove side roof frame paneling (3) upward
Only on 3rd seat row, code 847: remove

seatbelt and remove paneling


Installation:
Install paneling in door

rubber seal.

5.1
Disconnect connector from loudspeaker

As of 01.09.01 and with sound system,

code 810.

6
Install in the reverse order


Seat belts/belt tensioners

Number

Designation
Model 163 up to

08/99
Model 163 as of

09/99

BA91.40-P-1001-01D
Screw on belt end fitting
Nm
3535

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Assembly wedge

115 589 03 59 00

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d by Modification services.
Page 2

AR68.30-P-4470GH
Remove/install rear roof frame paneling
24.2.97

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

P68.30-0507-06

1
Belt end fitting in 3rd seat row

2
Center paneling of roof frame

3
Side paneling of roof frame

4
Expanding anchor

5
Screw


Remove, Install

1.1
Remove belt end fitting at bottom of 3rd seat

row (1)
Only with 3rd seat row, code 847.

*BA91.40-P-1001-01D

2
Unclip center roof frame covering (2)

Installation:
Install paneling in door

rubber seal.

Long wedge

*115589035900

3.1
Remove expanding anchor (4) from side roof

frame covering (3)

up to 31.08.01

Installation:
Replace expanding anchor.

3.2
Remove screw (5) from side roof frame

paneling (3)

4.1Unclip side roof frame paneling in upper outer

corner

As of 01.09.01

4.2
Remove side roof frame paneling (3) upward
Only on 3rd seat row, code 847: remove

seatbelt and remove paneling


Installation:
Install paneling in door

rubber seal.

5.1
Disconnect connector from loudspeaker

As of 01.09.01 and with sound system,

code 810.

6
Install in the reverse order


Seat belts/belt tensioners

Number

Designation
Model 163 up to

08/99
Model 163 as of

09/99

BA91.40-P-1001-01D
Screw on belt end fitting
Nm
3535

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d by Modification services.
Page 1

Assembly wedge

115 589 03 59 00

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d by Modification services.
Page 2