suspension MERCEDES-BENZ ML350 1997 Complete Repair Manual

204 OperationDriving instructions

Switch off the exterior lamps as well as
the climate control.


Select gear range1 on the automatic
transmission (
page 121).


Enter the water only at a shallow spot,
driving at walking speed.


Do not stop vehicle while immersed in
water, and do not shut off the engine.
There is a very high level of driving re-
sistance in water. The surface is slip-
pery and may not be firm, making
pulling away in water difficult and dan-
gerous.


Clean mud off the tire tread after driv-
ing through water.


To dry the brakes, apply pressure to the
brake pedal several times after leaving
the water.
Crossing obstacles
!Never accelerate before driving into
the water. The bow wave could force
water into the engine and auxiliary
equipment, thus damaging them.
!Obstacles can damage the vehicle
undercarriage or suspension compo-
nents. If possible use the assistance of
a second person outside the vehicle to
scout the path you intend to take and
check for adequate ground clearance
when you cross obstacles with your ve-
hicle. The person assisting you outside
the vehicle should always be a safe dis-
tance away from the vehicle and posi-
tioned so that he or she cannot get hurt
in case of any unexpected vehicle
movement.
After off-road driving or crossing obsta-
cles, inspect vehicle for any damage,
especially vehicle undercarriage and
suspension components. Failure to do
so can adversely affect the vehicle's fu-
ture performance, including increased
chance of an accident.

226 OperationTires and wheels
Tires and wheelsSee your authorized Mercedes-Benz Light
Truck Center for information on tested and
recommended rims and tires for summer
and winter operation. They can also offer
advice concerning tire service and pur-
chase.
Retreaded tires are not tested or recom-
mended by Mercedes-Benz, since previous
damage cannot always be recognized on
retreads. Mercedes-Benz can therefore
not assure the operating safety of the vehi-
cle when such tires are used.
See your authorized Mercedes-Benz Light
Truck Center for information on tested and
recommended rims and tires for summer
and winter operation.
Important guidelines

Use only sets of tires and rims of the
same type and make.


Tires must be of the correct size for the
rim.


Break in new tires for approximately
60 miles (100 km) at moderate
speeds.


Regularly check the tires and rims for
damage. Dented or bent rims can
cause tire pressure loss or damage to
the tire beads.


If vehicle is heavily loaded, check tire
pressure and correct as required.


Do not allow your tires to wear down
too far. Adhesion properties on wet
roads are sharply reduced at tread
depths under
1/8in (3 mm).


When replacing individual tires, you
should mount new tires on the front
wheels first.
Warning!
G
Replace rims or tires with the same designa-
tion, manufacturer and type as shown on the
original part. See your authorized
Mercedes-Benz Light Truck Center for fur-
ther information. If incorrectly sized rims
and tires are mounted:

The wheel brakes or suspension compo-
nents can be damaged.


The correct operating clearance of the
wheels and the tires are no longer guar-
anteed.
Warning!
G
Worn, old tires can cause accidents. If the
tire tread is badly worn, or if the tires have
sustained damage, replace them.
When replacing rims, use only genuine
Mercedes-Benz wheel bolts specified for the
particular rim type. Failure to do so can re-
sult in the bolts loosening and possibly an
accident.

283 Practical hints
Towing the vehicle
Towing the vehicle
Mercedes-Benz recommends that the vehi-
cle be transported with all wheels off the
ground using flatbed or appropriate wheel
lift / dolly equipment. This method is pref-
erable to other types of towing.When circumstances do not permit the
recommended towing methods, the vehi-
cle may be towed with all wheels on the
ground only so far as necessary to have the
vehicle moved to a safe location where the
recommended towing methods can be em-
ployed.
!Use flatbed or wheel lift / dolly equip-
ment, with key in steering lock turned
to position0.
Do not tow with sling-type equipment.
Towing with sling-type equipment over
bumpy roads will damage radiator and
supports.
To prevent damage during transport,
do not tie down vehicle by its chassis or
suspension parts. Use the towing eyes.
Switch off the ESP (
page 81),
tow-away alarm (
page 85) and the
automatic central locking (
page 93).
!When towing the vehicle with all wheels
on the ground, the gear selector lever
must be in positionN and the key must
be in steering lock position2.
When towing the vehicle with all wheels
on the ground, the vehicle may be
towed only for distances up to 30 miles
(50 km) and at a speed not to exceed
30 mph (50 km / h).
If the vehicle is towed with the front
axle raised (observe instructions re-
garding flexible drive shaft), the engine
must be shut off (key in steering lock
position1). Otherwise, the 4-ETS may
become engaged which may cause loss
of towing control.
!To be certain to avoid additional dam-
age to the vehicle powertrain, however
you should observe the following:

With damage to the front axle

raise front axle


remove flexible drive shaft be-
tween rear axle and transfer
case


With damage to the rear axle

raise rear axle


tow vehicle with wheel lift or
dolly placed under front wheels


With damage to the transfer case

remove flexible drive shaft to
the drive axles
Always install new self-locking nuts
when reinstalling flexible drive shaft.

284 Practical hintsTowing the vehicleWarning!
G
If circumstances require towing the vehicle
with all wheels on the ground, always tow
with a tow bar if:

the engine will not run


there is a malfunction in the power sup-
ply or in the vehicle’s electrical system
Prior to towing the vehicle with all wheels on
the ground, make certain that the key is in
steering lock position2.
If the key is left in steering lock position0
for an extended period of time, it can no
longer be turned in the switch. In this case,
the steering is locked. To unlock, remove
key from steering lock and reinsert.
Warning!
G
With the engine not running, there is no
power assistance for the brake and steering
systems. In this case, it is important to keep
in mind that a considerably higher degree of
effort is necessary to brake and steer the ve-
hicle. Adapt your driving accordingly.iTo signal turns while being towed with
hazard warning flasher in use, turn key
in steering lock to position2 and acti-
vate combination switch for left or right
turn signal in usual manner – only the
selected turn signal will operate.
Upon canceling the turn signal, the haz-
ard warning flasher will operate again.iThe vehicle cannot be started via
tow-start.
!When towing the vehicle with all wheels
on the ground, note the following:
With the automatic central locking acti-
vated and the key in steering lock
position2, the vehicle doors lock if the
left front wheel is turning at vehicle
speeds of approx. 9 mph (15 km / h) or
more.
To prevent the vehicle doors from lock-
ing, deactivate the automatic central
locking (
page 93).
Towing of the vehicle should only be
done using the towing eye. Never at-
tach tow cable, tow rope or tow rod to
vehicle chassis, frame or suspension
parts.

Torque Specifications; Engine Mounts, Engine Supports
Torque Specifications; Engine Suspension, Engine Mounts, Engine Supports
Torque Specifications; Engine Suspension, Engine Mounts, Engine Supports
Torque Specifications; Transfer Case, Complete Unit
Fig. 167: Commercially Available Tools (See Workshop Equipment Manual)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/Install Noise Encapsulation
Self-locking screw, propeller shaft to transfer case (to front axle)Nm50
DesignationEngine 112.942/970 113.942/965/ in model 163.154/157/
172/174/175
Bolt of rear engine crossmember to bodyNm40
Bolt or nut, rear engine mount to
transmissionM8Nm-
M10Nm40
DesignationEngine 612.963 in model
163.113Engine 628.963 in model
163
Bolt/nut, rear engine crossmember to
bodyNm4040
Bolt or nut, rear engine mount to
transmissionNm4040
DesignationEngine 111 in model 163
Bolt of rear engine crossmember to bodyNm40
Bolt or nut, rear engine mount to transmissionNm35
DesignationModel 163
Threaded plug in transfer caseNm30
Bolt, transfer case to automatic transmissionNm20
Bolt, transfer case to manual transmissionNm20

2001 Mercedes-Benz ML320
1998-03 AUTOMATIC TRANSMISSIONS Complete Transmissions - ML 320 - 722.662
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Shown on engine 112
Fig. 108: Identifying Bottom Part Of Oil Pan Remove/Install Components
- Shown On Engine 112
Remove/install
External torx setFig. 49
1Remove engine trim panel
2Remove viscous fan (4) Right-hand thread!AR20.40-P-5660C
3.1Remove fan shroud (5) Only engine
112.942 /970.
Unscrew bolts (8) at
bottom of fan shroud.
4.1Remove air guide (9) Engine 113.942 only.
5Drain and collect engine oil *BA01.45-P-1003-01B
*BF18.00-P-1001-01H
6Unscrew nuts (7) at front
suspension carrier Before unbolting the
left engine mount, press
oil line of power steering
out of fixture.

*BA22.10-P-1001-01L
7Remove resonance tube (3)
with resonance unit (2) Do not damage the
plastic strap.
The resonance pipe is
attached at the rear at the

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Fig. 109: Identifying External Torx Set (001 589 76 09 00)
Workshop equipment
Repair materials
REMOVE/INSTALL BOTTOM PART OF OIL PAN - AR01.45-P-7555VE
ENGINE 113.965 in MODEL 1
ENGINE 113.981 in MODEL 1
Fig. 110: Identifying Bottom Part Of Oil Pan Remove/Install Components

WE58.40-Z-1007-11AEngine lifting fixture
NumberDesignationOrder number
BR00.45-Z-1013-01ASealantA 003 989 98 20
Remove/install
External torx setFig. 49
1Remove engine trim panel
2Drain and collect engine oil *BA01.45-P-1003-01B
*BF18.00-P-1001-01H
3Unscrew nuts (7) at front
suspension carrier Before unscrewing the

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
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The engine support bracket (1) is positioned with its support surfaces resting on the left and right-side
fenders' inside seams (arrows).
During installation it is important to proceed with caution to avoid damage to the vehicle paintwork.
1. Lift engine by the front suspension hook.
Shown on model 163 with engine 112.942
Fig. 1: Identifying Engine Support Bracket
- Shown On Model 163 With Engine 112.942
SUPPORTING FRONT AXLE CARRIER WITH INSPECTION PIT OR ASSEMBLY LIFT - AR33.10-P-0100-03GH
Workshop equipment
1. Support front axle with axle removal device (070) and inspection pit or assembly lift. Ensure that the
guide pin (arrow) is inserted in the front axle carrier.
Lower the front axle carefull
y; ensure that no cables and lines are trapped in between.
WE58.40-Z-1019-11ARemoval fixture for axles

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
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Front axle torsion strut
Wheel location, hub
REPLACE FRONT BEARING OF LOWER WISHBONE - AR33.20-P-0526GH
MODEL 163.113 /128 /136 /154 /157 /172 /174 /175
3.1
Remove linkage rod for suspension-
control module (95b) from lower
right control arm
Vehicles with xenon headlamps.
4Detach torsion bar (28) from lower
control arm *BA32.20-P-
1002-02G
5Detach lower control arm (4) from
front subframe
Installation: Tighten new nuts slightly.
Tighten bolt fully only when vehicle is on
its wheels and ready to drive.

*BA33.20-P-
1004-01D
6
Loosen clamped joint at rear of
lower wishbone (4) and fold down
bearing shell (4d)
Installation: Tighten new nuts slightly.
Tighten bolt fully only when vehicle is on
its wheels and ready to drive.

*BA33.20-P-
1005-01D
Inspect
7Inspect lower control arm for signs
of distortion and corrosion
8Install in the reverse order
9Perform chassis alignment check AR40.20-P-
0200GH
NumberDesignationModel Series 163
BA32.20-P-1002-02GBolt, torsion bar to wishboneNM68
NumberDesignationModel Series 163
BA33.20-P-1004-01DBolt, lower wishbone at front to front axle carrierNM135
BA33.20-P-1005-01DBolt, lower wishbone at rear to front axle carrierNM30

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
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GENERAL NOTES: PASSENGER CARS - AH00.01-Z-0998AZ
MODEL all
Notes on TowingMODEL 461, 463AH00.60-P-0100-
02GA
Overall vehicle
Overall vehicleFG00AH00.00-Z-9999AZ
Engine
Complete engine,
crankcase ventilation,
cylinder head, crankcaseFG01AH01.00-Z-9999AZ
Crank assemblyFG03AH03.00-Z-9999AZ
Engine timingFG05AH05.00-Z-9999AZ
Mixture formationFG07AH07.00-Z-9999AZ
Air intake, superchargingFG09AH09.00-Z-9999AZ
Electrical system - engineFG15AH15.00-Z-9999AZ
Engine lubrication,
engine oil coolingFG18AH18.00-Z-9999AZ
Engine cooling systemFG20AH20.00-Z-9999AZ
Engine suspensionFG22AH22.00-Z-9999AZ
Throttle control, cruise
control systemFG30AH30.00-Z-9999AZ
Fuel systemFG47AH47.00-Z-9999AZ
Exhaust systemFG49AH49.00-Z-9999AZ
Chassis
Manual transmissionFG26AH26.00-Z-9999AZ
Automatic transmissionFG27AH27.00-Z-9999AZ
Frame, trailer operationFG31AH31.00-Z-9999AZ
SuspensionFG32AH32.00-Z-9999AZ
Rear axleFG35AH35.00-Z-9999AZ
Wheels, chassis
alignment checkFG40AH40.00-Z-9999AZ
Brakes - hydraulic and
mechanical systemsFG42AH42.00-Z-9999AZ
Brakes - pneumatic
system and auxiliary
brakesFG43AH43.00-Z-9999AZ
SteeringFG46AH46.00-Z-9999AZ
Electrical system,
equipment and
instrumentsFG54AH54.00-Z-9999AZ

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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