MERCEDES-BENZ ML350 1997 Complete Repair Manual

AR63.20-P-2010GH
Remove/install D-pillar paneling
26.1.99

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

P63.20-3336-11

1
D-pillar paneling

2
Bonding material


Remove

1
Remove D-pillar paneling (1)

Separate glue bead with cutting wire.

Additional pull handle for cutting wire

*WH58.30-Z-1017-02A

2
Remove any residual bonding material on the

D-pillar flange

Not more than 2 mm of glue must remain.


Install

3
Clean D-pillar paneling

In order to ensure a good adhesion.

4
Apply primer to damaged paint areas on D-

pillar flange

Use 2K primer
. Allow primer to air for at

least 5 minutes.

5
Prepare D-pillar flange

If the remaining glue (cut glue bead) is

older than 24 hours, also apply
primer
for

paint to body to obtain optimum glued joint.

*BR00.45-Z-1059-02A

If the
body
has been damaged or if there

is no bonding material then apply the
primer

to the bonding first. Allow the primer to flash

off for at least 10 minutes, but not for longer

than 15 minutes.

6
Prepare D-pillar paneling (1)

Apply primer to bonding. Allow the primer

to flash off for at least 10 minutes, but not for

longer than 15 minutes.

*BR00.45-Z-1059-02A

7
Prepare glue cartridge

AR67.10-P-1000-07P

Betapower II (2-component electric

cartridge gun)

*WH58.30-Z-1015-20A

2-component glue kit

*BR00.45-Z-1055-02A

8
Apply glue (2) as glue bead to D-pillar

paneling (1)


The paneling must be put on within 5

minutes, otherwise the adhesion quality of the

bonding material will be impaired.

Height of adhesive bead approx. 13 mm

Use reference points on inside of D-pillar

paneling.

Betapower II (2-component electric

cartridge gun)

*WH58.30-Z-1015-20A

9
Align D-pillar paneling (1)

10
Install D-pillar paneling (1)

Firmly press D-pillar paneling to D-pillar

flange.

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e. g.)
Order number

WH58.30-Z-1017-02A
Additional handle for cutting wire
Stahlwille

Eduard Wille GmbH &

Co.Lindenallee 27

D-42331 Wuppertal

10351/1

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WH58.30-Z-1015-20A
Betapower II (2-component electric cartridge gun)
DOW Automotive

(Deutschland) GmbH

Am Güterbahnhof

D-35683 Dillenburg

Tel.: +49 (0)

39484/8714-0

995.182

Repair products

Number

Designation
Order number

BR00.45-Z-1059-02A
Primer BETAPRIME 5404

100ml

Item no. 940.870

Felt ring

Tech. Großhandels GbR

D-37242

Bad Sooden-Allendorf

BR00.45-Z-1055-02A
2K glue kit
168 670 00 93

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AR47.10-P-4000GH
Empty fuel tank if fuel pump is faulty
28.10.97

MODEL
163.113 with ENGINE 612.963

MODEL
163.128 with ENGINE 628.963

MODEL
163.136 with ENGINE 111.977

MODEL
163.154 with ENGINE 112.942

MODEL
163.157 with ENGINE 112.970

MODEL
163.172 with ENGINE 113.942

MODEL
163.174 with ENGINE 113.981

MODEL
163.175 with ENGINE 113.965

P47.20-2076-06

1
Fondsitzkonsole

2
Cover of left C-pillar

3
Seat retaining cable

4
Wiring harness

P47.10-2077-09

84
Closing cover

90/10
Ground line (vacuum unit)

90/11
Fuel return line
90/12

Fuel feed line

90/13
Stationary heater connection

90/14
Extraction hose


Remove, Install


Danger!
Risk of explosion
from fuel igniting,
risk of

poisoning
from inhaling and swallowing fuel

as well as
risk of injury
to eyes and skin

from contact with fuel.
Fire, sparks, open flames or smoking

forbidden.

Pour fuels only into suitable and appropriately

marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

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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

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163 589 00 91 00

Extraction hose

Adapter hose

Pliers

163 589 00 37 00 168 589 00 90 00

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e.g.)
Order number

WH58.30-Z-1001-16A
Suction master M2P 20 B
Ecco GmbH

Vonkeln 17

D-42349 Wuppertal
9749 5000 50

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AR40.10-P-1080A
Draining TIREFIT sealant out of tires
18.6.96

MODEL
163.174

MODEL
168, 170, 171, 203, 209, 211, 230, 240

P40.10-0309-02

1
Tire sealant container

2
Hose

3
Tire sealant

Draining


Danger!
Risk of death
cased by vehicle slipping or

toppling off of the lifting platform.
Align vehicle between the columns of the

hydraulic hoist and position the four support

plates below the hoist support points specified

by the vehicle manufacturer.

AS00.00-Z-0010-01A

1
Remove wheel.

e

Remove/install wheels, rotate if necessary
Model 163.174

AP40.10-P-4050GH
Model 168, 170, 203, 209, 211, 230, 240

AP40.10-P-4050Z

Type 171

AP40.10-P-4050V

2
Position road wheel upright with valve

pointing downwards for

approx. 10 minutes.

Raise wheel approx. 200 mm to allow tire

sealant (3) to run out.

3
Unscrew valve element from the valve and

allow pressure to escape from the tire

4
Pull valve out of rim.

Press remains of valve remaining in valve

bore of disk wheel into inside of tire.

5
Attach hose (2) to tire sealant container (1).

Replace original hose of tire sealant

container (1) with a hose (2) approx.

400 mm long.

6
Press tire sealant container (1) together and

immerse hose (2) through the valve hole in

the disk wheel, as low as possible into the tire

repair kit (3)

7
Reduce pressure on tire sealant container (1),

the tire sealant (3) is extracted.

This method can be used to remove

approx. 90% of the tire sealant (3).

If the tire sealant container (1) is not

available, drill the tire tread with a twist drill (

4

10mm) and allow the tire repair kit (3) to flow

into a suitable container.


TIREFIT tire sealant
Model 163.174, 168, 170, 171, 203, 209, 211,

230, 240

AH40.10-P-0001-01A

8
Replace tire

Remove the remaining tire repair kit (3)
from the rim using a damp cloth.

AR40.10-P-1030A

9
Place new TIREFIT tire repair kit in the vehicle
See
#
e

TIREFIT tire sealant - check expiration date.

AP40.10-P-4054R

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AR54.21-P-1300GH
Remove/install drive authorization module (FBM)
11.7.00

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

163.136 /154 /172 #X as of 708319,

163.113 /128 /157 /174 /175

P54.21-2099-06

2
Extended-Activity-Module (EAM)

3
Retaining lugs

4
Removal tools

5
DAS control module


Remove/install

1
Remove Extended-Activity-Module (EAM) (2)

AR54.21-P-1200GH

2
Loosen the retaining lugs (3) which hold the

DAS control module (5) in the EAM

Ensure that the retaining lugs do not

break off.

Use radio removal tools (4) for removal.

3
Remove the DAS control module from the EAM

Before installing a new DAS control

module, determine in the old DAS control

module whether keys are banned and code

suitably in the new DAS control module.


Note:
The chassis number must be

stated when ordering a new control module.

4
Install in the reverse order

5
Move ignition key into position 1 for at least

40 seconds

6
Check whether the vehicle can be started

with all keys

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GF54.21-P-4106GH
Extended activity module position/task
23.6.99

MODEL
163

P54.21-2057-11

N10/1
Extended activitiy module
The extended activity module in combination with the new drive

authorization system (DAS (N10/ 1- n1)) represents an extension of

the
A
ll-
A
ctivity
M
odule. In addition, the extended activity module acts

as a diagnosis gateway for the transfer case, the all-activity module

and as of 1.9.00 for the trip computer control module.

Extended activity module position
The extended activity module is located in the

interior of the vehicle on the left side behind

the instrument cluster.

Extended activity module task

GF54.21-P-4106-01GH

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GF54.21-P-4106-01GH
Extended Activity Module - Task

n

The primary tasks of the Extended Activity Module (EAM, N10/1) are

as follows:
D
To control the door sill lights

D
To suppress the auto-dimming mirror function

D
To control the headlight cleaning system (HCS)

D
To control the rear window defroster

D
To control seat heating

D
To control the power supply via control console to tilt/sliding or

louvered sunroof switch

D
To control the PTC heater booster (R22/3)

D
To control the auxiliary fan (M4)

D
To read the cruise control switch (S40) and relay data to control

module (DAS, N73/1)

D
To read the contacts for wiper speed settings 1 and 2 on

combination switch (S4) for diagnosis.

To perform these tasks the Extended Activity Module (EAM, N10/1)

reads various signals and switch settings directly.

The Extended Activity Module (EAM, N10/1) interfaces with other
control modules via the engine compartment CAN.

-----------------------------------------------------------------------------------------
Diagnosis

Diagnosis is performed using the Star diagnostic tool. To facilitate

this task, the Extended Activity Module (EAM, N10/1) is equipped

with its own diagnostics cable.
This cable is also used to diagnose the
All Activity Module (AAM,

N10)
and the
transfer case control module (N78)
.

The Extended Activity Module (EAM, N10/1) is linked to the All

Activity Module (AAM, N10) via the
engine compartment CAN
.

Data communication between the All Activity Module (AAM,

N10) and the Extended Activity Module (EAM, N10/1) is

assumed by the
CAN (N10 - N10/1)
when terminal 15 is off.

The CAN (N10 - N10/1)
is an independent CAN bus located

between the All Activity Module (AAM, N10) and the Extended

Activity Module (EAM, N10/1).
No other
control modules are

connected to the CAN (N10 - N10/1).

-----------------------------------------------------------------------------------------

Details:

Door sill lights

When the front interior light is on and one of the front doors is open,

or when the rear interior light is on and one of the back doors is open,

the door sill lights for the open door will illuminate.

Headlight cleaning system (HCS)

Activating a separate switch causes the EAM to send a turn-on signal

to the HCS pump relay.

EAM will send an additional turn-on signal to the HCS pump relay

only after the cleaning operation is completed and a "rest period" of

approximately 2.5 sec. has passed.

Auto-dimming mirror function

The auto-dimming mirror function is suppressed when the interior

light is on or reverse gear is engaged.

Auto-dimming suppression for the outside rearview mirror (slave) is

activated by the inside rearview mirror (master).

Heater booster/PTC air heater for diesel engines

EAM monitors system voltage and adjusts heater booster capacity to

minimize load on battery.
Rear window defroster

EAM sets maximum ON time for rear window defroster depending

on outdoor temperature and current vehicle speed.
D
Standard ON time:
10 min.

D
Outdoor temperature < 5
o
C:
Additional 5 min.

D
Speed >80 km/h:
Additional 3 min.

Seat heating

Sets maximum seat heating time.
D
Setting 1: max. 20 min.

D
Setting 2: max. 5 min.

Tilt/sliding or louvered sunroofs

Signal via AAM2 allows operation of tilt/sliding or louvered sunroofs

when ignition is on (standard mode) or off (keyless mode).

Ignition authorization via CAN

The EAM issues ignition authorization to AAM2 via the engine

compartment CAN depending on the requirements of the engine

control unit in connection with the FBM.

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AF91.12-P-6003A
Easy-entry seat will not operate
21.3.02

MODEL
163.154 /172 #A as of 145273,

163.136 /154 /172 #X as of 708319,

163.113 /128 /175 with CODE (847) 3rd seat row

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

Sector

Op. no.
Operation text

Time
Acc. no.
Code

P
023612
SECURE BOWDEN CABLE FOR EASY-ENTRY RELEASE

HANDLE
005 AW/0,4 h
92 139 38
---

Damage Code
Cause
Remedy

Release cable disconnected from eyelets at

top of telescoping strut.
1
Slide one piece of shrink-on tubing (1),

approximately 25 mm long, onto release

cable.

2
Reattach right end of release cable to

eyelet at top of telescoping strut (2).

3
Position shrink-on tubing (1) over right

cable connection to eyelet.

4
Reattach left end of release cable to

eyelet at top of telescoping strut (2).

5
Position a second piece of shrink-on

tubing (3), approximately 25 mm long,

over left cable connection eyelet.

6
Carefully heat tubing until they shrink

securely over release cable ends and

eyelets of telescoping strut.

Do not damage seat cover.

Hot air gun

*WE58.40-Z-1007-03A

7
Verify proper function of easy-entry seat.

P91.12-2444-06

1
Shrink-on tubing

2
Telescoping strut

3
Shrink-on tubing

Workshop equipment/MB testers
(refer to Workshop equipment manual)

WE58.40-Z-1007-03A
Hot air gun

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