MERCEDES-BENZ ML430 1997 Complete Repair Manual

AR54.65-P-0002GH
Remove/install Parktronic system (PTS) sensors in rear bumper
19.4.01

MODEL
163.113 /128 /154 /157 /174 /175 with CODE (220a) Parktronic System (PTS)

P54.65-2412-06

1
Plug connection

2
Parktronic system sensor

3
Retaining clamps


Remove/install

1
Remove rear bumper

with styling package, code U49.

AR88.20-P-2200GJ

As of 01.09.01.

AR88.20-P-2200GK

2
Put down bumper safely in a suitable place

Do not damage paintwork.

3
Disconnect connector (1) from Parktronic

system sensor(2)

4
Remove Parktronic system sensor (2) from

the bumper

Bo not brake off the retaining clamps (3).

Release tool

*168589023100

5
Install in the reverse order

Release tool

168 589 02 31 00

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR88.20-P-2200GJ
Remove/install rear bumper
6.4.99

MODEL
163.113 /128 /136 /154 /157 /172 /175 with CODE (U49) Styling package

MODEL
163.174

P88.20-2090-09


Remove/install

1.1
Separate antenna of emergency call system

E-Call connector

Only with E-call emergency call system,

code 349. The connector is located behind

the side flap of the right C-pillar paneling at

the jack socket point.

2
Unscrew screws (A) on energy absorber

retaining straps at bottom of cross member

2 each.


*BA88.20-P-1005-01B

3
Pull cover strip off of screws (B) at top of

bumper

Velcro strips

4
Unscrew screws (B) at top of bumper


*BA88.20-P-1005-01B

5
Pull bumper to the rear and remove

Do not damage paintwork/wiring harness.


Installation:
Align bumper at tailgate and

at taillamps.

6.1
Remove rubber seal of antenna of emergency

call system E-Call on right at body

Only with emergency call system E-Call,

Code 349.

7.1
Disconnect connector from Parktronic system

Only with Parktronic system (PTS), code

220a. Remove left rubber seal at body.

8
Install in the reverse order


Bumper
Number

Designation
Model 163

BA88.20-P-1005-01B
Screws, rear bumper to frame
Nm
8

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR88.20-P-2200GJ
Remove/install rear bumper
6.4.99

MODEL
163.113 /128 /136 /154 /157 /172 /175 with CODE (U49) Styling package

MODEL
163.174

P88.20-2090-09


Remove/install

1.1
Separate antenna of emergency call system

E-Call connector

Only with E-call emergency call system,

code 349. The connector is located behind

the side flap of the right C-pillar paneling at

the jack socket point.

2
Unscrew screws (A) on energy absorber

retaining straps at bottom of cross member

2 each.


*BA88.20-P-1005-01B

3
Pull cover strip off of screws (B) at top of

bumper

Velcro strips

4
Unscrew screws (B) at top of bumper


*BA88.20-P-1005-01B

5
Pull bumper to the rear and remove

Do not damage paintwork/wiring harness.


Installation:
Align bumper at tailgate and

at taillamps.

6.1
Remove rubber seal of antenna of emergency

call system E-Call on right at body

Only with emergency call system E-Call,

Code 349.

7.1
Disconnect connector from Parktronic system

Only with Parktronic system (PTS), code

220a. Remove left rubber seal at body.

8
Install in the reverse order


Bumper
Number

Designation
Model 163

BA88.20-P-1005-01B
Screws, rear bumper to frame
Nm
8

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR88.20-P-2000GH
Remove/install front bumper
14.3.97

MODEL
163.113 /154 #A up to 289564,

163.113 #X up to 754619,
163.154 #X up to 716524,

163.136 /172 except CODE (U49) Styling package

P88.20-0375-09

1
Nut
2
Nuts

1a
Screw


Remove/Install

1.1
Remove brush guard together with underride

guard

If installed.

AR88.30-P-2000-01GH


*BA88.30-P-1002-01A


*BA88.30-P-1003-01A


*BA88.30-P-1011-01A


*BA88.30-P-1015-01A


*BA88.30-P-1016-01A

2
Unscrew nut (1)

Left and right at inside.


*BA88.20-P-1001-01B

3
Unscrew bolt (1a)

Left and right at inside.


*BA88.20-P-1002-01B

4
Remove front bumper grille.


Carefully remove front bumper grille so

that bumper grille and bumper grille mount

cannot be damaged.

Loosen retainers and pull to outside

Pulling hook

*140589023300

5.1
Remove outside temperature sensor from

front bumper.

If installed.

6
Unscrew nuts (2)


*BA88.20-P-1003-01B

7
Remove bumper toward front.

Do not damage paint.

8
Install in the reverse order


Detachable body components, underride guard

Number

Designation
Model 163

up to

31.8.01

BA88.30-P-1002-01A
Nut, spacer tube on brush guard
Nm
86

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

BA88.30-P-1003-01A
Screw, mount on brush guard
Nm
49

BA88.30-P-1011-01A
Bolt, underride guard to brush guard
Nm
25

BA88.30-P-1015-01A
Nut, underride guard to bracket
Nm
49

BA88.30-P-1016-01A
Bolt, front section of underride guard to rear

section of underride guard
Nm
49


Bumper
Number

Designation
Model 163

BA88.20-P-1001-01B
Nut, front bumper on outer mount
Nm
8

BA88.20-P-1002-01B
Screw for front bumper on inner mount
Nm
1.5

BA88.20-P-1003-01B
Nut, front bumper on frame
Nm
8

Pulling hook

140 589 02 33 00

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

AR88.20-P-2000GJ
Remove/install front bumper
26.2.01

MODEL
163.113 /154 #A as of 289565,

163.113 #X as of 754620,

163.128 /154 /157 /175 except CODE (U49) Styling package

P88.20-2203-09


Remove/install

1.1
Remove brush guard together with underride

guard

If installed.

AR88.30-P-2000-01GI


*BA88.30-P-1003-01A


*BA88.30-P-1015-01A


*BA88.30-P-1016-01A

2
Remove fog lamps

AR82.10-P-5103GI

3
Remove front bumper grille.

Carefully remove bumper grille so that

bumper grille and mounts cannot be damaged.

Remove with correspondingly formed hook.

Pulling hook

*140589023300

4
Remove outdoor temperature sensor from

bumper.

5
Unscrew screws (1)

At front side of bumper.


*BA88.20-P-1009-01B

6
Unscrew bolt (2)

At inner bumper corners.


*BA88.20-P-1002-01B

7
Unscrew nuts (3).

At inner sides of bumper.


*BA88.20-P-1001-01B

8
Loosen side mount on bumper from body.

Loosen only one side. Move mount

toward inside.

9
Remove bumper toward front.

Do not damage paint. Do not damage
Parktronic connection cable if present.


Installation:
Observe correct installation

position of fog lamps.

10.1
Disconnect connector from Parktronic system

Only with Parktronic system (PTS), code

220a.

11
Install in the reverse order


Detachable body components, underride guard

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

Number
Designation
Model 163

as of

1.9.01

BA88.30-P-1003-01A
Screw, mount on brush guard
Nm
25

BA88.30-P-1015-01A
Nut, underride guard to bracket
Nm
49

BA88.30-P-1016-01A
Bolt, front section of underride guard to rear

section of underride guard
Nm
49


Bumper
Number

Designation
Model 163

BA88.20-P-1001-01B
Nut, front bumper on outer mount
Nm
8

BA88.20-P-1002-01B
Screw for front bumper on inner mount
Nm
1.5

BA88.20-P-1009-01B
Screw for front bumper on mountNm
8

Pulling hook

140 589 02 33 00

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

AR88.20-P-2200GJ
Remove/install rear bumper
6.4.99

MODEL
163.113 /128 /136 /154 /157 /172 /175 with CODE (U49) Styling package

MODEL
163.174

P88.20-2090-09


Remove/install

1.1
Separate antenna of emergency call system

E-Call connector

Only with E-call emergency call system,

code 349. The connector is located behind

the side flap of the right C-pillar paneling at

the jack socket point.

2
Unscrew screws (A) on energy absorber

retaining straps at bottom of cross member

2 each.


*BA88.20-P-1005-01B

3
Pull cover strip off of screws (B) at top of

bumper

Velcro strips

4
Unscrew screws (B) at top of bumper


*BA88.20-P-1005-01B

5
Pull bumper to the rear and remove

Do not damage paintwork/wiring harness.


Installation:
Align bumper at tailgate and

at taillamps.

6.1
Remove rubber seal of antenna of emergency

call system E-Call on right at body

Only with emergency call system E-Call,

Code 349.

7.1
Disconnect connector from Parktronic system

Only with Parktronic system (PTS), code

220a. Remove left rubber seal at body.

8
Install in the reverse order


Bumper
Number

Designation
Model 163

BA88.20-P-1005-01B
Screws, rear bumper to frame
Nm
8

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR88.20-P-2200GI
Remove/install rear bumper
11.4.97

MODEL
163.113 #A up to 289564,

163.113 #X up to 754619,

163.154 #A up to 289564,

163.154 #X up to 716524,

163.136 /172 with CODE (849) Spare wheel carrier/spare wheel

P88.20-0369-09

A
Nuts

B
Nut
E

Nuts

C
Screws

D
Spare wheel carrier consoles


Remove/Install

1.1
Disconnect antenna connector of E-call

emergency call system

Only with emergency call system E-Call,

code 349.

Connector is located behind side flap of right

C-pillar paneling at jack mounting point.

2
Unscrew nuts (A)

On vehicle underbody behind cross

member

3
Unscrew nut (B)

On vehicle underbody behind cross

member

4
Unscrew bolts from spare wheel carrier

console

Do not damage bolt thread


Bolts fastened with nuts (A) can be driven

out from the rear of the cross member.

5
Remove spare wheel carrier consoles (D)

6
Remove 3 panels from bumper

Do not damage paint. Do not break off

clips.

Long wedge

*115589035900

7
Unscrew bolts (C) from bumper


*BA88.20-P-1007-01B

8
Unscrew nuts (E) from bumper


*BA88.20-P-1006-01B

9.1
Remove nut from rear mud guard

Only if present


*BA88.30-P-1004-01A

10
Remove bumper

Do not damage paintwork on vehicle and

bumper.


Completely turn spare wheel carrier to

rear (maximum clearance for bumper). Pull

bumper to rear and then lift out upward

between spare wheel carrier and vehicle.


Installation:
Align bumper at tailgate and
at taillamps
Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

11.1
Remove rubber seal for E-call emergency call

system antenna from body at right

Only with emergency call system E-Call,

code 349.

12
Install in the reverse order


Bumper
Number

Designation
Model 163

BA88.20-P-1006-01B
Nuts for rear bumper on cross member
Nm
8

BA88.20-P-1007-01B
Screws for rear bumper on cross member,

rear
Nm
8

Designation
Model 163

up to

31.8.01

BA88.30-P-1004-01A
Nut for retaining strap on mud guard on vehicle

underbody
Nm
6

Long wedge

115 589 03 59 00

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2