MERCEDES-BENZ ML350 1997 Complete Repair Manual
Manufacturer: MERCEDES-BENZ, Model Year: 1997, Model line: ML350, Model: MERCEDES-BENZ ML350 1997Pages: 4133, PDF Size: 88.89 MB
Page 3191 of 4133
Valve seal not okay :
#
3
Remove/install/replace valve seal.
AR05.30-P-3500B
Cause 6:
Remedy 6:
00 001 70
1.5 mm hole missing on individual right
cylinder head covers at connection to
crankcase ventilation.
1
Check cylinder head cover
Up to production 06/1999.
Crankcase ventilation out of order, engine can
sludge up and consume oil as a result
Cylinder head cover not okay:
#
2
Remove/install/replace cylinder head
cover.
ENGINE
112
Air cleaner positioned on engine
side.
ENGINE
113
Air cleaner positioned on engine
side.
AR01.20-P-5014BV
ENGINE
112
Air cleaner positioned on engine side
ENGINE
113
Air cleaner positioned on engine side
AR01.20-P-5014B
Cause 7:
Remedy 7:
00 001 70
Engine oil sludging due to excessively long
engine oil change intervals
Service information: Oil sludge
SI18.00-P-0010A
If the service interval according to
ASSYST is exceeded, the engine oil sludges
up sooner or later depending on the oil
quality, type of operation and operating time.
Engine consumes oil.
See Service Information.
1
Print out ASSYST printout.
2
Check oil change intervals
3
Inform vehicle owner.
4
Remove/install/replace piston rings.
AR03.10-P-7311BV
Disassemble and clean sludged engines
completely because dirty oil usually gets into
clean-oil side due to clogged oil filter.
Cause 8:
Remedy 8:
00 001 70
Piston rings sticky or have coke deposits from
engine oils (e.g. API-S in USA) in connection
with regionally poor fuel quality.
Always use engine oils according to
Specifications for Operating Fluids 229.3, do
not add special additives to engine oil and fuel
BB00.40-P-0229-03A
1
Remove/install/replace piston rings.
AR03.10-P-7311BV
Cause 9:
Remedy 9:
00 001 70
Piston ring wear due to excessive
contamination/dust (model 163) through air
intake system.
1
Remove/install/replace gaskets on air
intake line and distribution element of
partial load ventilation.
e.g. due to incorrect assembly after
workshop visit or embrittlement of gaskets
The distribution element with optimized
material will be available as of 11/ 2000 as a
standard feature.
2
Remove/install/replace intake module.
Exterior oil loss, e.g. due to cast iron
porosity on left side of crankcase in area of
engine support is not considered to be oil
consumption
In the event of a customer complaint
regarding the engine oil consumption, always
determine the oil consumption definitely
because the oil indicator lamp can come on
due to other causes (e.g. defective oil sensor).
Commercially available tools
(see Workshop Equipment Manual)
Number
Designation
Make (e. g.)
Order number
WH58.30-Z-1009-05A
Flexible inspection light
Scope of supply 1 (complete unit):
-glass fiber optical fiber
-light projector
-230 V, storage case
-operating instructions
-graphics protocol
Richard Wolf GmbH
Pforzheimerstr. 32
D-75438 Knittlingen
Karl Storz GmbH
Mittelstr. 8
D-78532 Tuttlingen
1.00565.00
80902
WH58.30-Z-1010-05A
Flexible inspection light
Scope of delivery 2 (for workshops which already have an approved
Wolf or Storz inspection light):
-storage case
-operating instructions
-pictures protocol
Richard Wolf GmbH
Pforzheimerstr. 32
D-75438 Knittlingen
Karl Storz GmbH
Mittelstr. 8
D-78532 Tuttlingen
7.05065.00
K03506AJ
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Page 3192 of 4133
WH58.30-Z-1027-05A
Cylinder inspection light
Motoskop MB (cold light) with 560 mm and 200 mm lens probes
Karl Storz GmbH
D-78512 Tuttlingen
80 900
Parts ordering notes
Part no.
Designation
Quantity
112 141 01 80
Gaskets
As required
112 141 02 80
Gaskets
As required
112 018 02 09
Distributor fitting
As required
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Page 3193 of 4133
AR88.40-P-3020GH
Adjust engine hood
8.4.99
MODEL
163.113 /128 /136 /154 /157 /172 /174 /175
P88.40-2067-09
1
Bolts
2
Engine hood
3
Engine hood hinge
7
Locknut
8
Nuts
4
Bolts
5
Engine hood catch upper section
6
Stop buffer
Longitudinal, height and transverse
adjustment
Danger!
Risk of injury
to
fingers being jammed or
pinched
when Remove/install or aligning
hoods, doors, trunk lid/tailgate or sliding roof.
When moving components, ensure that no
body parts or limbs are within the operating
range of moving parts.
AS00.00-Z-0011-01A
1
Open engine hood (2)
For slight range of adjustments for
longitudinal and height adjustment
2
Loosen bolts (1) on engine hood hinge (3)
and adjust engine hood (2)
3
Tighten bolts (1)
*BA88.40-P-1001-01C
For larger range of adjustments for
longitudinal and height adjustment
4.1
Remove gas-operated strut from engine hood
(2) and put down in engine compartment
Risk of breakage. Do not remove the
retainer otherwise the preload will be lost.
AR88.40-P-3010GH
As of VIN A145273, X708319.
5
Remove cover on air intake
AR83.25-P-1405GH
6
Remove rubber cover from engine hood hinge
Installation:
Replace rubber cover.
7
Cut seam sealing along engine hood hinge so
that hinge can be moved
Installation:
Replace seam sealing. Paint
sealant after curing.
*BR00.45-Z-1004-01A
8
Loosen nuts (8) on engine hood hinge (3)
9
Adjust engine hood (2) so that front edges of
front fenders are flush with engine hood and
top edges are aligned
For larger range of adjustment in
longitudinal direction loosen engine hood
catch upper section (5) and tighten.
*BA88.40-P-1004-01C
10
Tighten nuts (8) for engine hood hinge (3)
*BA88.40-P-1002-01C
11.1
Install gas-operated strut
As of VIN A145273, X708319.
AR88.40-P-3010GH
12
Adjust stop buffer (6)
Unscrew locknut (7). Adjust height of stop
buffer so that top edges of front fenders and
engine hood are flush If required, place
spacer plates below engine hood catch upper
section.
13
Fasten stop buffer (6)
Tighten locknut (7).
Transverse adjustment
14
Loosen bolts (4) from engine hood catch
upper section (5)
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Page 3194 of 4133
15
Adjust gap dimensions
Gap dimensions
*BE60.00-P-1001-01D
Feeler gage
*129589032100
16
Align engine hood catch upper section (5)
centered in longitudinal and transverse
direction to engine hood catch lower section
and tighten
*BA88.40-P-1004-01C
17
Ensure that engine hood catch catches
properly
For this purpose, close engine hood and
pull upward with a jerk.
18
Release engine hood and ensure that safety
hook catches on radiator crossmember
19
Close engine hood (2)
Test and adjustment values, gap dimensions at hoods, doors and covers
Number
Designation
Model 163
BE60.00-P-1001-01D
Gap
dimension
Engine hood to fender
Dimension "A"
mm
5.0 (
F
0.5)
Engine hood to headlamp
Dimension "R"
mm
5.0 (
F
0.5)
Engine hood to radiator grille
Dimension "O"
mm
5.0 (
F
0.5)
Radiator grill to headlamp
Dimension "N"
mm
-
Fig., see
AR60.00-P-0700-
01GH
Engine hood
Number
Designation
Model 163
BA88.40-P-1001-01C
Bolt, engine hood hinge on engine hood
Nm
10
BA88.40-P-1002-01C
Nut, engine hood hinge to body
Nm
18
BA88.40-P-1004-01C
Bolt, engine hood catch upper section to engine
hood
Nm
12
129 589 03 21 00
Feeler gage
Auxiliary repair materials
Number
Designation
Order number
BR00.45-Z-1004-01A
MB body sealant for sealing seams (suitable for painting)
001 989 63 20
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Page 3195 of 4133
AR88.40-P-3020GH
Adjust engine hood
8.4.99
MODEL
163.113 /128 /136 /154 /157 /172 /174 /175
P88.40-2067-09
1
Bolts
2
Engine hood
3
Engine hood hinge
7
Locknut
8
Nuts
4
Bolts
5
Engine hood catch upper section
6
Stop buffer
Longitudinal, height and transverse
adjustment
Danger!
Risk of injury
to
fingers being jammed or
pinched
when Remove/install or aligning
hoods, doors, trunk lid/tailgate or sliding roof.
When moving components, ensure that no
body parts or limbs are within the operating
range of moving parts.
AS00.00-Z-0011-01A
1
Open engine hood (2)
For slight range of adjustments for
longitudinal and height adjustment
2
Loosen bolts (1) on engine hood hinge (3)
and adjust engine hood (2)
3
Tighten bolts (1)
*BA88.40-P-1001-01C
For larger range of adjustments for
longitudinal and height adjustment
4.1
Remove gas-operated strut from engine hood
(2) and put down in engine compartment
Risk of breakage. Do not remove the
retainer otherwise the preload will be lost.
AR88.40-P-3010GH
As of VIN A145273, X708319.
5
Remove cover on air intake
AR83.25-P-1405GH
6
Remove rubber cover from engine hood hinge
Installation:
Replace rubber cover.
7
Cut seam sealing along engine hood hinge so
that hinge can be moved
Installation:
Replace seam sealing. Paint
sealant after curing.
*BR00.45-Z-1004-01A
8
Loosen nuts (8) on engine hood hinge (3)
9
Adjust engine hood (2) so that front edges of
front fenders are flush with engine hood and
top edges are aligned
For larger range of adjustment in
longitudinal direction loosen engine hood
catch upper section (5) and tighten.
*BA88.40-P-1004-01C
10
Tighten nuts (8) for engine hood hinge (3)
*BA88.40-P-1002-01C
11.1
Install gas-operated strut
As of VIN A145273, X708319.
AR88.40-P-3010GH
12
Adjust stop buffer (6)
Unscrew locknut (7). Adjust height of stop
buffer so that top edges of front fenders and
engine hood are flush If required, place
spacer plates below engine hood catch upper
section.
13
Fasten stop buffer (6)
Tighten locknut (7).
Transverse adjustment
14
Loosen bolts (4) from engine hood catch
upper section (5)
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Page 3196 of 4133
15
Adjust gap dimensions
Gap dimensions
*BE60.00-P-1001-01D
Feeler gage
*129589032100
16
Align engine hood catch upper section (5)
centered in longitudinal and transverse
direction to engine hood catch lower section
and tighten
*BA88.40-P-1004-01C
17
Ensure that engine hood catch catches
properly
For this purpose, close engine hood and
pull upward with a jerk.
18
Release engine hood and ensure that safety
hook catches on radiator crossmember
19
Close engine hood (2)
Test and adjustment values, gap dimensions at hoods, doors and covers
Number
Designation
Model 163
BE60.00-P-1001-01D
Gap
dimension
Engine hood to fender
Dimension "A"
mm
5.0 (
F
0.5)
Engine hood to headlamp
Dimension "R"
mm
5.0 (
F
0.5)
Engine hood to radiator grille
Dimension "O"
mm
5.0 (
F
0.5)
Radiator grill to headlamp
Dimension "N"
mm
-
Fig., see
AR60.00-P-0700-
01GH
Engine hood
Number
Designation
Model 163
BA88.40-P-1001-01C
Bolt, engine hood hinge on engine hood
Nm
10
BA88.40-P-1002-01C
Nut, engine hood hinge to body
Nm
18
BA88.40-P-1004-01C
Bolt, engine hood catch upper section to engine
hood
Nm
12
129 589 03 21 00
Feeler gage
Auxiliary repair materials
Number
Designation
Order number
BR00.45-Z-1004-01A
MB body sealant for sealing seams (suitable for painting)
001 989 63 20
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Page 3197 of 4133
AR88.40-P-3100GH
Remove/install control cable for engine hood
5.5.00
MODEL
163.113 /128 /136 /154 /157 /172 /174 /175
P88.40-2140-06
Illustrated up to VIN A145272, X708318
1
Clips
2
Rubber grommet
3
Engine hood control cable
Removing and installing
1
Open engine hood and raise to vertical position
Up to VIN A145272, X708318.
AR88.40-P-1000GH
As of VIN A145273, X708319.
AR88.40-P-1000GI
2.1
Remove upper frame cross member
Only up to VIN A145272, X708318
AR62.30-P-2300GH
2.2Remove engine hood lock
Only as of VIN A145273, X708319.
AR88.40-P-3200GI
3.1
Unhook engine hood control cable from clip at
bottom of radiator cross member
Only as of VIN A145273, X708319.
4
Remove cover from fuse and relay box
5 screws.
5
Unhook clips (1) from body
6
Remove left cover below instrument panel
Left hand drive vehicle.
AR68.10-P-1500GH
Vehicles with right-hand steering up to
VIN A145272, X708318.
AR68.10-P-1520GH
Vehicles with right-hand steering as of
VIN A145273, X708319.
AR68.10-P-1520GI
7
Remove paneling in left footwell
AR68.30-P-4010GH
8
Unhook engine hood control cable at side at
clip in footwell
9
Remove rubber grommet (2) from fuse and
relay box
10
Pull out engine hood control cable (3) through
firewall on engine side and remove
Installation:
Ensure that engine hood
control cable is routed cleanly along fuse and
relay box.
11
Install in the reverse order
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Page 3198 of 4133
AR88.40-P-4050R
Remove/install Mercedes star
30.3.01
MODEL
163, 203.7, 215, 230.467 /474 /475 /476 /479
P88.40-2291-11
Shown on model 230
1
Mercedes star
2
Grommets
Remove/Install
1
Remove Mercedes star (1) from engine hood
upward with long wedge (1)
Protect engine hood around Mercedes
star (1) with adhesive tape to avoid damaging
paint.
Long wedge
*115589035900
2
Remove grommets (2)
Check grommets (2) and replace if
required.
3
Install in the reverse order
Long wedge
115 589 03 59 00
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Page 3199 of 4133
AR88.40-P-3060GH
Remove/install engine hood hinge
16.4.97
MODEL
163.113 /128 /136 /154 /157 /172 /174 /175
P88.40-0365-01
P88.40-0364-01
1
Screws
2
Engine hood hinge
3
Nuts
Removing and installing
Danger!
Risk of injury
to
fingers being jammed or
squeezed
when removing and installing or
aligning hoods, doors, trunk lid/tailgate or
sliding roof.
When moving components, ensure that no
body parts or limbs are within the operating
range of moving parts.
AS00.00-Z-0011-01A
1.1
Remove engine hood
Only when both engine hood hinges are
removed.
AR88.40-P-3000GH
1.2
Open engine hood and raise to vertical position
Up to VIN A145272, X708318.
AR88.40-P-1000GH
As of VIN A145273, X708319.
AR88.40-P-1000GI
2
Remove cover on air intake
AR83.25-P-1405GH
3
Remove rubber cover from engine hood hinge
Installation:
Replace rubber cover.
4
Cut joint seal along engine hood hinge so that
hinge can be moved
Installation:
Replace seam sealing. Paint
sealant after curing.
*BR00.45-Z-1004-01A
5
Mark installation position of engine hood
hinge (2)
Facilitates installation.
6.1
Remove gas strut
As of VIN A145273, X708319.
AR88.40-P-3010GH
Danger of breaking!
Do not remove the
retainer otherwise the preload will be lost.
7
Remove screws (1)
Support engine hood at rear to prevent
damage.
*BA88.40-P-1001-01C
8
Unscrew nuts (3)
*BA88.40-P-1002-01C
9
Remove engine hood hinge (2)
Installation:
Align engine hood hinge at
marks made previously.
10
Install in the reverse order
11
Check alignment of engine hood
If necessary:
#
Adjust engine hood
AR88.40-P-3020GH
Engine hood
Number
Designation
Model 163
BA88.40-P-1001-01C
Screw for engine hood hinge on engine hood
Nm
10
BA88.40-P-1002-01C
Nut for engine hood hinge on body
Nm
18
Repair products
Number
Designation
Order number
BR00.45-Z-1004-01A
MB body sealant for sealing seams (suitable for painting)
001 989 63 20
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Page 3200 of 4133
SM63.20-P-0002GH
Reinforce engine hood hinge support on front left
16.1.02
MODELS
163.136 /154 /172 #A as of 145273,
163.136 /154 /172 #X as of 708319,
163.113 /128 /174 /175
P63.20-3439-12
The template shown is for the left side
(turn over for the right side)
6
Template
7
Hole, hinge assembly bolt, rear
8
Hole, hinge assembly bolt, front
9
Center punch position
10
Center punch position
11
Center punch position
a
80 mm
b
100 mm
P63.20-3435-06
1
Hinge assembly bolt, front
2
Hinge assembly bolt, rear
3
Center punch mark
4
Center punch mark
5
Center punch mark
Operation no. of operation texts or standard texts and flat rates
Range
Op. no.
Operation text
Time
Acc. no.
Code
P
023540
REINFORCE LEFT ENGINE HOOD HINGE SUPPORT
037 WU/3.1 h
88 237 36
---
P
023541
REINFORCE RIGHT ENGINE HOOD HINGE SUPPORT
040 WU/3.3 hrs.
88 237 36
---
P
023542
REINFORCE (BOTH) ENGINE HOOD HINGE SUPPORTS
053 WU/4.4 hrs.
88 237 36
---
Remove/install
1
Remove engine hood
AR88.40-P-3000GH
2
Remove wiper system
AR82.30-P-6400GH
3
Remove engine hood hinge on driver side
AR88.40-P-3060GH
*BR00.45-Z-1004-01A
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