ar91.12-p MERCEDES-BENZ ML320 1997 Complete Repair Manual
[x] Cancel search | Manufacturer: MERCEDES-BENZ, Model Year: 1997, Model line: ML320, Model: MERCEDES-BENZ ML320 1997Pages: 4133, PDF Size: 88.89 MB
Page 1491 of 4133
AR91.12-P-1100GH
Remove and install cover on bottom of rear seat
22.2.00
MODELS
163.136 /154 /172 as of 1.9.99,
163.113 /128 /157 /174 /175
P91.12-2189-09
Arrows
Pushing directions for releasing
the locating tabs
Remove
Risk of breakage! Carefully press covers off
with a short screwdriver or suitable long
wedges.
1
Remove rear cargo space floor flaps
See Operating Instructions
2Remove rear cover (A)
Pull front outer edges of the cover
upwards in order to release the locating tabs
(1). Press outer locating tabs (2) outwards. In
the center of the cover, press locating tab (3)
to the right and locating tab (4) forwards. In
order to release the locating tabs (5), press
the cover down and remove to the rear.
3
Remove curtain at front 40 % bench
4
Remove outer cover (B) from 40 % bench
Press the cover in and pull upwards at
locating tab (6). Pull outwards at locating tabs
(7, 8). Press the cover forwards in order to
release the locating tab (9). At locating tab
(10), press down with a long wedge between
the covers. Guide the cover past the lateral
curtain.
5
Remove inner cover (C) from 40 % bench
Pull the outer rear corners of the cover up
in order to release the rear locating tabs (11).
In order to release the locating tabs (12),
press the cover forwards and remove to the
front.
6
Remove curtain at front 60 % bench
7
Remove outer cover (D) from 60 % bench
Push locating tab (13) up and turn cover
out and up at locating tab (14). Pull outwards
at locating tabs (15). Press the cover
forwards in order to release the locating tabs
(16). At locating tab (17) press down with a
long wedge between the covers. Guide the
cover past the lateral curtain.
8
Remove inner cover (E) from 60 % bench
Press locating tabs (18) in. Pull the outer
rear corners of the cover up in order to
release the rear locating tabs (19). In order to
release the locating tabs (20), press the cover
forwards, rotate counterclockwise and remove
past the springs towards the rear.
Install
Copyright DaimlerChrysler AG 12.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1
Page 1494 of 4133
AR91.12-P-1010GI
Remove and install bench
21.3.00
MODELS
163.136 /154 /172 as of 1.9.99,
163.113 /128 /157 /174 /175
40 % bench seat
P91.12-2126-06
1
Bolts, front of rear seat fastening
2
Bolts, rear of rear seat fastening
4
Seat frame covering
Remove, Install
1
Remove headrest
See Operating Instructions
2.1
Remove covering (4) on bottom of rear seat
On 40 % rear seat only.
AR91.12-P-1100GH
3.1
Disconnect plug to seat belt buckle cable
Only with side airbag in the rear (left and
right), code 293.
4.1
Remove electric lead attached to seat frame
with adhesive tape
Only with side airbag in the rear (left and
right), code 293.
Installation:
Replace adhesive tape.
5
Unscrew bolts (1) on front of rear seat
fastening
Installation:
Replace bolts and nuts with
locking agent applied.
Torx bit set
*000589011000
*BA91.12-P-1005-03A
6
Release backrest and tip forward
See Operating Instructions
7
Release seat bench and fold down
See Operating Instructions
8
Remove bolts (2) on rear of rear seat fastening
Installation:
Replace bolts and nuts with
locking agent applied.
Torx bit set
*000589011000
*BA91.12-P-1005-03A
9
Remove 40 % bench
10
Install in the reverse order
Rear seats
Number
Designation
Model
163 as of
09/99
BA91.12-P-1005-03A
Nuts for rear seat console on vehicle floor
NM
40
Copyright DaimlerChrysler AG 12.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1
Page 1886 of 4133
Remove/install glove
compartment AR68.10-P-1400GI
Torx bit setFig. 309
6Loosen upper section of
right front door rubber
seal
7Remove A-pillar paneling
on right
Remove/install paneling
on A-pillar AR68.30-P-4050GH
Long wedgeFig. 155
8Remove right sun visor
Remove/install sun visor AR68.60-P-5480GH
9Remove right front
handle Open covers for
handles, press down clip
on each side of handle, at
the same time press
handle upward and pull
out.
10Remove edge guard for
tilting/sliding roof cutout
11Release upper right B-
pillar paneling
12Remove covers at lower
rear seat Do NOT remove
center cover for lower
40% seat. Do NOT
reinstall curtain on 60%
front bench seat.
Remove and install cover
on bottom of rear seat AR91.12-P-1100GH
13Release side shade at the
60% bench Fold shade upward so
that the working area is
not obstructed.
14Remove 40% rear seat
Remove and install bench AR91.12-P-1010GI
Torx bit setFig. 309
Install
15Retrofit central interface
module (1) AZ82.60-P-0004-01A
16Insert antenna cable for
FM modulator (6) into
vehicle antenna cable (7)
17Cover connector with
self-adhesive foamed
2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
Saturday, October 02, 2010 3:30:12 PMPage 391 © 2006 Mitchell Repair Information Company, LLC.
Page 1888 of 4133
30.1Plug in plug of additional
interface module and
secure the wiring harness
of the additional interface
module (10) to the clip
(11) together with the
wiring harness of the rear
power windows in the
center console Up to VIN A289564,
X754619.
30.2Insert auxiliary interface
module (13) connector
and route between center
console mount (14) and
center console. As of VIN A289565,
X754620.
31.1Secure auxiliary interface
module plug in the left
rear corner of the ashtray
housing using self-
adhesive foamed material
(12) Up to VIN A289564,
X754619.
32Open ashtray and cup
holder and close to check
correct function
33Attach side shade of the
60% bench
34.1Retrofit video player (3) AZ82.60-P-0004-05A
*BA91.12-P-1005-03A
BA91.12-P-1008-03A
34.2Retrofit DVD player AZ82.60-P-0005-01GH
35Install 40% rear seat
Remove and install bench AR91.12-P-1010GI
Torx bit setFig. 309
36Install remaining covers
under rear seat benchReplace cover under rear
seat bench at rear with
cover from the
conversion kit.
Remove and install cover
on bottom of rear seat AR91.12-P-1100GH
37Disconnect ground lead
from battery
Disconnect ground lead
from battery AR54.10-P-0003A
38Retrofit voltage supply
for central interface
module (1) AZ82.60-P-0004-06A
2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
Saturday, October 02, 2010 3:30:12 PMPage 393 © 2006 Mitchell Repair Information Company, LLC.
Page 2078 of 4133
AR91.12-P-1100GH
Remove and install cover on bottom of rear seat
22.2.00
MODELS
163.136 /154 /172 as of 1.9.99,
163.113 /128 /157 /174 /175
P91.12-2189-09
Arrows
Pushing directions for releasing
the locating tabs
Remove
Risk of breakage! Carefully press covers off
with a short screwdriver or suitable long
wedges.
1
Remove rear cargo space floor flaps
See Operating Instructions
2Remove rear cover (A)
Pull front outer edges of the cover
upwards in order to release the locating tabs
(1). Press outer locating tabs (2) outwards. In
the center of the cover, press locating tab (3)
to the right and locating tab (4) forwards. In
order to release the locating tabs (5), press
the cover down and remove to the rear.
3
Remove curtain at front 40 % bench
4
Remove outer cover (B) from 40 % bench
Press the cover in and pull upwards at
locating tab (6). Pull outwards at locating tabs
(7, 8). Press the cover forwards in order to
release the locating tab (9). At locating tab
(10), press down with a long wedge between
the covers. Guide the cover past the lateral
curtain.
5
Remove inner cover (C) from 40 % bench
Pull the outer rear corners of the cover up
in order to release the rear locating tabs (11).
In order to release the locating tabs (12),
press the cover forwards and remove to the
front.
6
Remove curtain at front 60 % bench
7
Remove outer cover (D) from 60 % bench
Push locating tab (13) up and turn cover
out and up at locating tab (14). Pull outwards
at locating tabs (15). Press the cover
forwards in order to release the locating tabs
(16). At locating tab (17) press down with a
long wedge between the covers. Guide the
cover past the lateral curtain.
8
Remove inner cover (E) from 60 % bench
Press locating tabs (18) in. Pull the outer
rear corners of the cover up in order to
release the rear locating tabs (19). In order to
release the locating tabs (20), press the cover
forwards, rotate counterclockwise and remove
past the springs towards the rear.
Install
Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1
Page 2134 of 4133
1.1
Unscrew bolts at rear of 2/3 seat bench and
raise rear of seat bench
Up to VIN A145272, X708318.
1.2
Remove covers at seat frame of 60% bench
seat
As of VIN A145273, X708319.
AR91.12-P-1100GH
Only remove the covers which are
identified in the document with A, D and E.
2.1
Fold 60% bench seat forward into footwell
As of VIN A145273, X708319. See
operator's manual.
3.1
Pull floor covering below rear seat mounting
bracket (1) of 60% seat forward
Carefully pull floor covering forward under
the seat console to prevent it from tearing.
As of VIN A145273, X708319.
4.1
Pull the floor covering forward under the front
corner of the left C-pillar cover (2)
Carefully pull the floor covering forward
under the cover to prevent it from tearing.
As of VIN A145273, X708319.
5
Cut into floor covering directly behind seat
retaining cable (3)
Ensure that the wiring harness (4) is not
damaged when cutting the floor covering.
As of VIN A145273, X708319. Broken
line marks the cut.
6
Fold floor mat back
Do not crease floor mat!
Fold floor mat back far enough to provide
access to cap (84) between body and fuel
pump.
7
Remove end cover (84) of body
Installation:
Replace cap and insert with
new sealing compound.
Cap (84) is sealed in with body sealer.
Heat with hot air blower to make it easier to
remove.
8
Seal fuel return line (90/11)
Pliers
*163589003700
9
Connect extraction hose (90/14) with adapter
hose to connection for fuel return line (90/11)
Extraction hose
*168589009000
Adapter hose
*163589009100
10
Connect ground cable (90/10) of extraction
pump ground terminal vehicle battery
Pumping out
11
Pump fuel out into safety container using
extraction pump
*BF47.10-P-1001-01A
*WH58.30-Z-1001-16A
12
Install in the reverse order
Fuel tank
Number
Designation
Models
163.113/
136/154/
172 up to
31.08.01
Models
163.113/
136/154/
172 as of
01.09.01
Models
163.157/
175
Model
163.128
Model
163.174
BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liter
72838393
Reserve capacity
Liter
10121212
Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2
Page 2230 of 4133
1.1
Unscrew bolts at rear of 2/3 seat bench and
raise rear of seat bench
Up to VIN A145272, X708318.
1.2
Remove covers at seat frame of 60% bench
seat
As of VIN A145273, X708319.
AR91.12-P-1100GH
Only remove the covers which are
identified in the document with A, D and E.
2.1
Fold 60% bench seat forward into footwell
As of VIN A145273, X708319. See
operator's manual.
3.1
Pull floor covering below rear seat mounting
bracket (1) of 60% seat forward
Carefully pull floor covering forward under
the seat console to prevent it from tearing.
As of VIN A145273, X708319.
4.1
Pull the floor covering forward under the front
corner of the left C-pillar cover (2)
Carefully pull the floor covering forward
under the cover to prevent it from tearing.
As of VIN A145273, X708319.
5
Cut into floor covering directly behind seat
retaining cable (3)
Ensure that the wiring harness (4) is not
damaged when cutting the floor covering.
As of VIN A145273, X708319. Broken
line marks the cut.
6
Fold floor mat back
Do not crease floor mat!
Fold floor mat back far enough to provide
access to cap (84) between body and fuel
pump.
7
Remove end cover (84) of body
Installation:
Replace cap and insert with
new sealing compound.
Cap (84) is sealed in with body sealer.
Heat with hot air blower to make it easier to
remove.
8
Seal fuel return line (90/11)
Pliers
*163589003700
9
Connect extraction hose (90/14) with adapter
hose to connection for fuel return line (90/11)
Extraction hose
*168589009000
Adapter hose
*163589009100
10
Connect ground cable (90/10) of extraction
pump ground terminal vehicle battery
Pumping out
11
Pump fuel out into safety container using
extraction pump
*BF47.10-P-1001-01A
*WH58.30-Z-1001-16A
12
Install in the reverse order
Fuel tank
Number
Designation
Models
163.113/
136/154/
172 up to
31.08.01
Models
163.113/
136/154/
172 as of
01.09.01
Models
163.157/
175
Model
163.128
Model
163.174
BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liter
72838393
Reserve capacity
Liter
10121212
Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2
Page 2597 of 4133
2
Remove covers at seat frame of 60% bench
seat
As of VIN A145273, X708319.
AR91.12-P-1100GH
Only remove the covers which are
identified in the document with A, D and E.
3
Fold 60% bench seat forward into footwell
As of VIN A145273, X708319. See
operator's manual.
4
Pull floor covering below rear seat mounting
bracket (1) of 60% seat forward
Ensure that the floor covering is not torn
when pulled forward.
As of VIN A145273, X708319.
5
Pull floor covering below front corner of trim
panel of C-pillar (2) forward
Ensure that the floor covering is not torn
when pulled forward.
As of VIN A145273, X708319.
6
Cut into floor covering directly behind seat
retaining cable (5)
Ensure that the wiring harness (4) is not
damaged when cutting into floor covering.
As of VIN A145273, X708319. broken line
marks cut-in.
7
Turn back floor covering to gain access to
cap (84)
Do not kink floor covering.
8
Remove cap (84)
Cap (84) is sealed in with body sealer.
Heat with hot air blower to make it easier to
remove.
Installation:
Replace cap and install with
new sealing compound.
9
Detach fuel feed line (90/12) and fuel return
line (90/11) and, if fitted, the fuel line at
connection (90/13)
Do not kink the fuel lines.
If no stationary heater is fitted to vehicle,
do not remove connection (90/13) otherwise
housing will be damaged.
*163589003700
10
Remove nut (89)
*163589010700
*BA47.20-P-1006-01B
11
Remove housing (3)
Fuel lever sensor and housing are a
single part and cannot be removed separately.
Installation:
Re-install nut (89) together
with seal (89/2).
Apply a thin film of oil to seal.
12
Install in the reverse order
Fuel pump
Number
Designation
Engine 612Engine 628
BA47.20-P-1006-01B
Union nut for fuel tank sensor on fuel
tank
Nm
6565
Fuel tank
Number
Designation
Models
163.113/
136/154/
172 up to
31.08.01
Model
163.113/
136/154/
172 as of
01.09.01
Model
163.157/
175
Model
163.128
BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liter
728383
Reserve capacity
Liter
101212
Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2
Page 2601 of 4133
1.1
Unscrew bolts at rear of 2/3 seat bench and
raise rear of seat bench
Up to VIN A145272, X708318.
1.2
Remove covers at seat frame of 60% bench
seat
As of VIN A145273, X708319.
AR91.12-P-1100GH
Only remove the covers which are
identified in the document with A, D and E.
2.1
Fold 60% bench seat forward into footwell
As of VIN A145273, X708319. See
operator's manual.
3.1
Pull floor covering below rear seat mounting
bracket (1) of 60% seat forward
Carefully pull floor covering forward under
the seat console to prevent it from tearing.
As of VIN A145273, X708319.
4.1
Pull the floor covering forward under the front
corner of the left C-pillar cover (2)
Carefully pull the floor covering forward
under the cover to prevent it from tearing.
As of VIN A145273, X708319.
5
Cut into floor covering directly behind seat
retaining cable (3)
Ensure that the wiring harness (4) is not
damaged when cutting the floor covering.
As of VIN A145273, X708319. Broken
line marks the cut.
6
Fold floor mat back
Do not crease floor mat!
Fold floor mat back far enough to provide
access to cap (84) between body and fuel
pump.
7
Remove end cover (84) of body
Installation:
Replace cap and insert with
new sealing compound.
Cap (84) is sealed in with body sealer.
Heat with hot air blower to make it easier to
remove.
8
Seal fuel return line (90/11)
Pliers
*163589003700
9
Connect extraction hose (90/14) with adapter
hose to connection for fuel return line (90/11)
Extraction hose
*168589009000
Adapter hose
*163589009100
10
Connect ground cable (90/10) of extraction
pump ground terminal vehicle battery
Pumping out
11
Pump fuel out into safety container using
extraction pump
*BF47.10-P-1001-01A
*WH58.30-Z-1001-16A
12
Install in the reverse order
Fuel tank
Number
Designation
Models
163.113/
136/154/
172 up to
31.08.01
Models
163.113/
136/154/
172 as of
01.09.01
Models
163.157/
175
Model
163.128
Model
163.174
BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liter
72838393
Reserve capacity
Liter
10121212
Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2
Page 3561 of 4133
1Remove front seats 1000GH
2.1Remove bass module speaker Only with Sound-System, Code 810.AR82.62-P-
7839GH
3.1Remove control module for
emergency call system Only with emergency call system E-Call,
Code 349.AR82.95-P-
0008GH
4Remove bench 1/3 bench seat, up to 31.8.99.AR91.12-P-
1010GH
40% bench seat, as of 01.9.99.AR91.12-P-
1010GI
2/3 bench seat, up to 31.8.99.AR91.12-P-
1010GJ
60% bench seat, as of 01.9.99.AR91.12-P-
1010GK
5Remove rear seat anchors (2) Up to 31.8.99, unscrew internal Torx drive
bolts (3).
Torx bit setFig. 24
6Remove center console (4) AR68.20-P-
2000GH
7Remove cover below instrument
panel on left (6) AR68.10-P-
1500GH
8Remove cover below instrument
panel on right (5) Up to 31.8.99.AR68.10-P-
1520GH
As of 01.9.99.AR68.10-P-
1520GI
9Unscrew plastic nuts (11) in right
footwell
10Remove condensate water drain
hose from heater housing
11
Remove door sill molding on
right (9) and door sill molding on
left (10)
AR68.30-P-
4100GH
12
Remove paneling in footwell on
right (7) and paneling in footwell
on left (8)
AR68.30-P-
4010GH
13Remove insulating mat under the
center console
14Remove air duct for ventilation in
the rear
15Remove radio AR82.60-P-
7502EA
16Disconnect all the electrical
connectors and lay aside
17Detach shift-lock cable at the
electronic selector module
2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Interior Equipment - 163 Chassis
me
Saturday, October 02, 2010 3:35:22 PMPage 43 © 2006 Mitchell Repair Information Company, LLC.