engine MERCEDES-BENZ ML320 1997 Complete Repair Manual

coming into contact with
components of a 220 V
system
Risk of death caused by
work performed on
liquefied gas systemsMODEL allAS00.00-Z-0022-01A
Risk of injury. Skin or eye
injuries may result when
handling hot or glowing
objects.MODEL allAS00.00-Z-0002-01A
Risk of injury when
handling liquid nitrogen or
from touching extremely
cool objects. Risk of
asphyxiation from inhaling
nitrogen gas.MODEL allAS00.00-Z-0003-01A
Risk of death. Death may
occur if body parts are
drawn into rotating vehicle
parts.MODEL allAS00.00-Z-0004-01A
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 burnsMODEL allAS00.00-Z-0005-01A
Risk of injury caused by
drilling gas-filled
assemblies or components
(noncombustible gases)MODEL allAS00.00-Z-0006-01A
The high voltage used for
arc welding presents a lethal
hazard. Explosion hazard
when welding in the area of
highly combustible
materials. Risk of injury
from weld splatter and UV
light when welding. Risk of
poisoning when inhaling
welding vapors.MODEL allAS00.00-Z-0007-01A
Risk of accident caused by
vehicle starting off on its
own when jacked up. Risk
of injury caused by rotating
parts when working on MODEL 906, 613, 671,
171, 203, 209, 164, 169,
219, 245, 251AS00.00-Z-0008-01A

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running engine or drive
train.
Risk of injury. Moving parts
can pinch, crush or, in
extreme cases even sever
extremities.MODEL allAS00.00-Z-0009-01A
Risk of injury caused by
fingers being jammed or
pinched when removing,
installing or aligning hoods,
doors, trunk lid/rear-end
door or sliding roof.MODEL allAS00.00-Z-0011-01A
Risk of injury from fingers
being pinched or jammed
when working on gas struts
under pressureMODEL allAS00.00-Z-0012-01A
Risk of injury to skin or
eyes from hydraulic fluid
spraying out under pressure.
Risk of poisoning from
swallowing hydraulic fluid.MODEL allAS00.00-Z-0013-01A
Risk of injury. Rubber
mounts and bearing parts
can suddenly come loose
during installation/ removal
and shoot wildly through
the air.MODEL allAS00.00-Z-0014-01A
Risk of explosion from
pressurized spray cansMODEL 100, 107, 108,
109, 111, 112, 113, 114,
115, 116, 123, 124, 126,
129, 140, 163, 168, 170,
201, 202, 208, 210, 215,
216, 220, 221, 251 ...AS00.00-Z-0015-01A
Risk of poisoning caused by
inhaling vapors or
swallowing adhesive. Risk
of injury caused by glue
coming into contact with
skin and eyesMODEL 163, 169, 199,
204, 209, 211, 215, 216,
219, 221, 240, 245, 397,
461, 463, 613, 638, 639,
671, 684, 901, 902, 903,
904 ...AS00.00-Z-0016-01A
Injury hazard of cutting or
scraping on sharp vehicle
partsMODEL allAS00.00-Z-0017-01A
Risk of explosion caused by
escaping natural gas or an
overheated compressed-gas
tanks when working on MODEL 901, 902, 903,
904, 957.AS00.00-Z-0018-01A

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natural gas powered
vehicles. Risk of frostbite to
body parts caused by
escaping natural gas or
contact with components
near the valves when
draining compressed-gas
tanks. Risk of poisoning or
suffocation caused by
inhaling natural gas. 6/07
G/02/07. This WIS printout
will not be recorded by the
updateservice.
Risk of explosion caused by
liquefied petroleum gas
escaping or pressurized gas
reservoirs overheating when
working on vehicles
operated with liquefied
petroleum gas. Risk of
frostbite to body parts
caused by liquefied
petroleum gas exiting under
pressure. Risk of poisoning
or risk of suffocation caused
by inhaling liquefied
petroleum gas.ENGINE 111.984 For
Fluid Gas ConcernAS00.00-Z-0023-01A
Risk of injury caused by
burns to skin and eyes. Risk
of poisoning caused by
inhaling fumes when
working with heat-
shrinkable tubing.MODEL 124, 126, 129,
140, 163, 164, 168, 169,
170, 171, 199, 202, 203,
204, 208, 209, 210, 211,
215, 216, 219, 220, 221,
230, 240, 245, 251, 374,
375, 414, 450, 454, 461,
463, 638, 690, 901, 902,
903, 904, 905, 930, 932,
933, 934, 940, 942, 943,
944, 950, 952, 953, 954,
957, 958, 970, 972, 974,
975, 976 ...AS00.19-Z-0001-01A
Risk of injury caused by
burns to skin and eyes, risk
of poisoning caused by
inhaling fumes during
soldering.MODEL 124, 126, 129,
140, 163, 164, 168, 169,
170, 171, 199, 202, 203,
208, 209, 210, 211, 215,
216, 219, 220, 221, 230,
240, 245, 251, 414, 461,
463...AS00.19-Z-0002-01A

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211, 215, 216, 219, 220, 221,
230, 240, 245, 251, 414, 461
as of 1.4.94, 463
Assessment of damage
in wiring harnessesModel 124, 126, 129, 140,
163, 164, 168, 169, 170, 171,
199, 202, 203, 208, 209, 210,
211, 215, 216, 219, 220, 221,
230, 240, 245, 251, 414, 461,
463AH00.19-P-1000-05A
Assessment of airbag
and belt tensioner units
in accident vehiclesModel 129, 202 up to 30.6.93
Model 124, 126, 140AH91.00-P-0006-01A
Assessment of airbag
and belt tensioner units
in accident vehiclesModel 129 as of 1.7.93, 163,
164, 168, 169, 170, 171, 199,
202 as of 1.7.93, 203, 208,
209, 210, 211, 215, 216, 219,
220, 221, 230, 240, 245, 251,
414, 461 as of 1.4.94, 463,
638, 901, 902, 903, 904, 905,
906, WD1, WD2, WD3, WD6,
WD7, XD1, XD2, XD3, XD4,
XD5, XD6, XD7, YD1, YD2,
YD3, YD4, YD5, YD6, YD7AH91.00-P-0006-01B
Notes regarding plug
connections AH00.19-P-1000-06A
Advantages of repairing
wiring harnesses AH00.19-P-1000-03A
Repair methods for
wiring harnesses AH00.19-P-1000-04A
Repair supplemental
restraint system (SRS)
squib wiring harnessModel 124, 129, 140, 163,
164, 168, 169, 170, 171, 202,
203, 208, 209, 210, 211, 215,
216, 219, 220, 221, 230, 240,
245, 251, 414, 461 as of
1.4.94, 463
Model 126 with code 291
Airbag for driver and front
passenger (for front passenger
only if driver airbag standard)
Model 126 with code 442
Airbag in steering wheelAR54.18-P-0600A
Repairing wiring
harnessModel 168.031 ## up to
180747 with engine 166.940
Engine wiring harness at body
side
Model 168.033 ## up to AR54.18-P-0100GF

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180747 with engine 166.960
Engine wiring harness at body
side
Repairing wiring
harnessModel 168.007 with engine
668.941
Engine wiring harness at body
side
Model 168.008 with engine
668.940
Engine wiring harness at body
sideAR54.18-P-0100GD
Repairing wiring
harnessModel 168.007 with engine
668.941
Engine wiring harness
Model 168.008 with engine
668.940
Engine wiring harnessAR54.18-P-0100GC
Install left front repair
wiring harnessModel
168.007/008/031/032/033
Only vehicles with one-piece
wiring harnessAR54.18-P-0700GC
Install right front repair
wiring harnessModel
168.007/008/031/032/033
Only vehicles with one-piece
wiring harnessAR54.18-P-0701GC
Install left rear repair
wiring harnessModel
168.007/008/031/032/033
Only vehicles with one-piece
wiring harnessAR54.18-P-0702GC
Install right rear repair
wiring harnessModel
168.007/008/031/032/033
Only vehicles with one-piece
wiring harnessAR54.18-P-0703GC
General repair method
for wiring harness. AR00.19-P-0100A
Checking wiring harness AR54.18-P-0600-01A

Electrical connection setFig. 336
126-pin socket boxFig. 337

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Fig. 394: Wrapping Insulating Tape Around Corrugated Hose At Both Ends
PROTECT REPAIR AREA AFTER CABLE REPAIRS - AR00.19-P-0100-08C
Protect repair area by wrapping fabric tape around it.
1. Wrap fabric tape around repair area as per original condition.
Fabric tape restores the appearan ce of the repair area and provides pr otection from chafing. In parts of
vehicle subject to high levels of st ress (e.g. engine compartment) fabric tape should only be used together
with other (watertight) protective measures.
REPAIRING WIRING HARN ESS USING SOLDER CONNECTORS - AR00.19-P-0100-09A
Fig. 395: Identifying New Passe nger Vehicle Wiring Harness Repair Kit (220 589 04 99 00)
Fig. 396: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00)

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the side jacking points.
Fig. 639: Identifyin g Lifting At Rear

RAISING, JACKING UP VEHICLE - AR00.60-P-1000GH
MODEL 163
Fig. 640: Raising, Jacking Up Vehicle

Fig. item, etc.Work instructions
Lethal injuries are
possible if vehicle slips
off of lifting platformAlign 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 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

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These instructions are to be read carefully and complied with in full In order to rule out any risk of personal
injury, to avoid impairing the reliability and safety of the vehicle, and to prevent damage to the vehicle as a
result of work improperly carried out.
It is therefore not possible for DaimlerChrysler AG to evaluate in the last consequence every situation which
might present a risk of injury for the operative. It is therefore an urgent necessity that everyone who carries out
repair work on Mercedes-Benz passenger cars by applying his professional knowledge satisfies himself that his
own safety is not at risk and that the vehicle will not suffer any negative effects, in particular of a safety
engineering nature, as a result of the repair procedure adopted.
It is therefore expressly pointed out that all work for the operations described must be carried out in compliance
with valid directives and instructions from the responsible local authorities and those relating to health, work
safety and environmental protection.
ADDITIONAL DESIGNATION FOR MODELS AND COMPONENTS - AP00.20-P-0000-03A
Models and components, in addition to their 3 to 6-figure designation (e.g. 124 or 124.028), may have different
versions, dates and work procedures. These differences are indicated b
y the following additional designations:

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For these vehicles the service sheet for the Active Service System (ASSYST) and the maintenance manual
volume 4 apply.
With the ASSYST service sheet the previous distinction between care service and maintenance service no
longer applies. Instead, the service category A (minor service) and service category B (major service) have been
introduced.
The service scopes for each model series can be seen in the respective valid service sheet.
The order no. is stated on the particular SERVICE SHEET.
On manual transmissions, automatic transmissions, transfer cases, front axles and rear axles the service item
"Check fluid level" has been replaced by an inspection of all visible parts for leaks.
In view of the fact that these components are not oil consumers, as is the case for the engine, a loss of oil can
occur only to the outside.
If any leaks are present, the procedure, as before, is to determine the cause and to rectify it subject to a separate
repair order.
The service operations carried out should be documented in the boxes in front of the operation titles. It is
essential to ensure that the specified service operations are carried out in full.
An indication is given in the boxes after the operation titles of which service operations should be carried out
for service category A (minor service) or service category B (major service). Enter a cross behind these boxes to
identify any items which are not in proper order when the vehicle is received.
Additional operations should be defined by the service adviser in agreement with the customer and an indication
should be made on the service sheet whether these additional operations are to be carried out.
Fig. 642: Service Intervals/Work Sheets


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Run in gently, but briskly.
Avoid high load, high rpm and high speed.
Automatic transmissions: do not use kick-down and do not brake the vehicle by shifting down manually.
After 1 500 km
Gradually bring the vehicle up to its full road and engine speeds.
MAINTENANCE - AP00.20-P-0000D
MODEL 210 as of 1.3.97, 129,140,170, 202 as of 1.6.97, 163, 168, 203, 208, 209, 215, 220, 230, 414 ASSYST
Preface AP00.20-P-0000-01C
Safety notes/warning
notes AP00.20-P-0000-02A
Additional designation
for models and
components AP00.20-P-0000-03A
Service intervals/work
sheets general
information AP00.20-P-0000-04C
Special service
procedures AP00.20-P-0000-06B
Service date reminder AP00.20-P-0000-07B
Service card for units AP00.20-P-0000-08A
Service Information:
Engine oil changeModels 129, 163, 168, 170,
203, 208, 209, 210, 215,
220, 230SI 18.00-P-0011A
SERVICE SHEET for
Active Service System
(ASSYST)Model 129 as of 1.6.97AP00.20-P-0001D
Model 140 as of 1.6.97AP00.20-P-0001E
Model 163AP00.20-P-0001A
Model 168AP00.20-P-0001B
Model 170 as of 1.6.97AP00.20-P-0001C
Model 202 as of 1.6.97AP00.20-P-0001F
Model 203AP00.20-P-0001K
Model 208AP00.20-P-0001G
Model 209AP00.20-P-0001M
Model 210 as of 1.3.97AP00.20-P-0001H
Model 215AP00.20-P-0001J
Model 220 except code
Z04/Z07AP00.20-P-0001I
Model 220.175/176/178 AP00.20-P-0001IG

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