MERCEDES-BENZ ML350 1997 Complete Repair Manual

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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Workshop equipment
MAINTENANCE
PREFACE - AP00.20-P-0000-01C
These "Service Documents" contain all the maintenance operations for the basic and national versions of the
following models:
Model 170, 129, 140, 202 as of 1.6.97
Model 210 as of 1.3.97
Models 163, 168, 203, 208, 209, 215, 220, 230
Type 414
This maintenance manual became necessary with the introduction of the Active Service System (ASSYST). It
contains all maintenance operations for vehicles with the Active Service System (ASSYST) and is divided into
the two volumes 4 and 4.1.
The system for demand-related complete vehicle maintenance is described in the Introduction into Service
manual "Active Service System (ASSYST)".
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
Inspection pit lift.
AR00.60-P-1000-01GH
*WE58.40
-Z-1002-05A
1Forward jacking points
2Rear jacking points
3Side sill covers
011Lifting platform *WE58.40-Z-1001-05A
012Support platesAll four support plates
must be extended to an
equal distance (Dimension
X).
WE58.40-Z-1001-05ATwo-post lifting platform
WE58.40-Z-1002-05APit lift

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These maintenance documents contain instructions relating to carrying out maintenance and repair operations
on Mercedes-Benz passenger cars. They are intended for the exclusive use of workshops affiliated to the
Mercedes-Benz Organization.
The instructions form the basis for proper and competent service and maintenance.
The nature in which the operations are described is based on the training standard of a fitter who has completed
vocational training and has good knowledge of our products. This level of knowledge is essential for carrying
out the described work.
The continuous further development and improvement of our vehicles may lead to deviations between the
actual technical status of the vehicles and the operation descriptions.
DaimlerChrysler AG reserves the right to make alterations and modifications at any time and without prior
notice.
If there are any open questions relating to repair procedures, please take up the matter with the competent
contact person in the relevant national organization (for DCVD refer to valid Service Information Group 99).
Additional information about the breakdown and structure of the work descriptions and the meaning of the
symbols (Logos) can be found in the Workshop Information System WIS.
Each described maintenance operation has a number (operation item) which is stated in the head line. The
operation item in the maintenance manual is identical with that on the SERVICE SHEET for the Active Service
System (ASSYST), enabling the appropriate texts and data to be found straight away if required when
performing maintenance jobs.
Maintenance operations which are not described have no number (operation item) on the SERVICE SHEET.
The group numbers familiar from the workshop literature are used for the first two digits of the 4-digit operation
item numbers. This ensures the assignment of each maintenance operation to the group.
DaimlerChrysler AG
Global Service & Parts
July 2004
SAFETY NOTES/WARNING NOTES - AP00.20-P-0000-02A
Safety information (hazardous situations for persons), warnings (quality of work, property damage).
These notes are identified by the following symbols (logos):
The logo " " represents safety information (dangerous situations for persons).
The lo
go " "represents a warning (work quality, property damage).

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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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Fig. 641: Additional Designation For Models And Components
SERVICE INTERVALS/WORK SHEETS GENERAL INFORMATION - AP00.20-P-0000-04C
The Active Service System (ASSYST) was introduced as of 3/97 first of all on model 210 and as of 1.6.97 on
models 170, 129, 140, 202 and from the start of production on models 163, 168, 203, 208, 209, 215, 220, 230,
414.

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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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SPECIAL SERVICE PROCEDURES - AP00.20-P-0000-06B
Have the brake fluid replaced if more than 2 years have elapsed since the last change; this is best done in the
spring.
The coolant should be inspected for correct anticorrosion/ antifreeze concentration before the beginning of, and
during the cold season of the year. Depending on the model series, the coolant has to be replaced every 3 years
or 15 years (or after 250,000 km).
Refer to the particular valid service sheet for further additional operations based on kilometers or years.
SERVICE DATE REMINDER - AP00.20-P-0000-07B
The confirmation in the service booklet must be filled out completely and signed for every service (A or B).
Confirmation in the service booklet
Fig. 643: Identifying Service Date Reminder

SERVICE CARD FOR UNITS - AP00.20-P-0000-08A
Mercedes-Benz
Service card - major assembly
Maintenance
During the first service after exchanging a Mercedes-Benz genuine major assembly the operations listed in the
maintenance sheet or maintenance manual are to be carried out and confirmed.
Running-in:
The first 1 500 km
WARNING:When vehicles without service display are inspected, the assembly will be
serviced within the scope of the following care and/or maintenance
service.

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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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CHECK ALL VISIBLE PARTS FOR SIGNS OF LEAKS AND DAMAGE - AP00.20-P-0053GH
MODEL 163.113 /128 /136 /154 /157 /172 /174 /175
INSPECTING CHASSIS AND LOAD-BEARING BODY PARTS FOR DAMAGE AND CORROSION - AP00.20-P-0090GH
MODEL 163
with Code Z04/Z07
Model 230AP00.20-P-0001L
Model 414AP00.20-L-0001A
Taxi serviceModels 202, 210AP00.20-P-0007A
Model 203AP00.20-P-0007C
Remove
Detach lower engine
compartment panelingModels 163.172/174/175AR61.20-P-1105GH
Remove noise
encapsulationModel 163.113/128AR94.30-P-5400GH
Check

2If traces of fluid are noted
(e.g. oil), then determine
and correct the cause (on a
separate work order).
Check for leaksEngine:
Transmission
Transfer case
Front axle
Rear axle
Pressure oil pump
3Check for leaks and fixingShock absorbers,
suspension struts
4Inspect for leaks and
conditionRubber boots of front axle
shafts
5Inspect lines and hoses for
leaks and condition, pay
attention to chafing points
and routingRadiator
Fuel system
Exhaust system
Clutch actuation
Automatic transmission
Power steering
Brake system
Install
Install lower engine
compartment paneling.Models 163.172/174/175AR61.20-P-1105GH
Install noise encapsulationModel 163.113/128AR94.30-P-5400GH
1Visual inspectionControl arm mountings and
control arms of front axle

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SAFETY PRECAUTIONS FOR NEW VEHICLES THAT ARE BEING PUT IN STORAGE - AP00.70-P-1000ZZ
MODELS all
and rear axle
Frame
New vehicles in the
context of this description
are vehicles for which no
inspection has been carried
out to date. For other
vehicles, the instructions
in the Specifications for
Service Products apply
In areas in which
extremely high corrosive
attacks can be expected
from experience, the
measures given here are
not always sufficient even
for new vehiclesExport countries
In these cases, proceed in
accordance with
Specifications for Service
products.
Treatment of battery if
vehicle taken out of
service AR54.10-P-0006EA
Treatment of tire inflation
pressure if vehicle taken
out of serviceFor vehicles which will be
stored for longer than 2
months, the tire inflation
pressure should be
increased to approx. 4 bar
to prevent flattening of the
contact surface.
Treatment of break system
if vehicle taken out of
serviceWarm up service brake so
that adhering moisture at
the brake disks and the
brake pads evaporates.
This prevents the brake
pad from becoming stuck
to the brake disks.
Release parking brake.
The vehicle must be
secured by engaging a
gear/park pawl or by using
wedges.
Treatment of fuel system
if vehicle taken out of To protect the fuel tank
from corrosion, we

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