MERCEDES-BENZ ML430 1997 Complete Repair Manual

AR54.21-P-1200GH
Remove/install Extended-Activity-Module (EAM)
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

P54.21-2098-06

1
Lock

2
Extended-Activity-Module (EAM)


Remove/install

1.1
Read out coding of Extended-Activity-Module

(EAM)

Only

when replacing the EAM and if it can

still be read out using STAR DIAGNOSIS.

2
Remove cover under the instrument panel (left)

AR68.10-P-1500GH

3
Loosen the lock (1) which secures the EAM in

the bracket

4
Remove the Extended-Activity-Module (EAM)

(2) downwards out of the bracket

5
Disconnect connectors

6
Remove drive authorization module

AR54.21-P-1300GH

7
Install in the reverse order

8.1
Code the EAM

Only

when installing a new EAM.

AR54.21-P-1200-01GH

9
Turn ignition key into position 1 and wait for

40 seconds before first starting the engine.

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Page 1

AP18.00-P-0101-02Z
Extract engine oil

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e. g.)
Order number

WH58.30-Z-1007-16A
Engine oil extractor
Deutsche Tecalemit

Am Metallwerk 11

33659 Bielefeld

1.386950.2

P18.00-0019-01

Shown on Engine 104

1
Extract engine oil through the dipstick guide tube.

Perform only when engine is at normal operating temperature.

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Page 1

BT27.35-P-0002-01A
Installation of a pressure feed valve

P27.35-0212-09

Production breakpoint data/Modifications/New features

Transmission/

steering gear

Transmission ident.

end no. as of
Type of and reason for modification

722.6
0027083

A pressure feed valve (146) has been installed in the 2-3 shift group

to prevent harsh 3-2 downshifts and roll-out shifts.

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1

AP82.10-P-8260-04A
Set or inspect fog lamps

P82.10-0205-01

1
The light-dark boundary must be as horizontal as possible at the height of the appropriate
dividing line (4), correct if necessary.

2
For model 140 sedan as of approx. 03.94, 168 and 202: Check seat of bulb.

P82.10-3633-01

Model 163.113 /154 #A as of 289565,

163.113 #X as of 754620,

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

Arrow:
Position of adjusting screw

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

AR82.10-P-5103GI
Remove/install fog lamp
27.2.01

MODELS
163.113 /154 #A as of 289565,

163.113 /154 #X as of 754620,

163.128 /157 /175

P82.10-2778-06

1
Lever

2
Fog lamp

3
Electrical connector

4
Grommets


Remove/install

1
Press lever (1) to release the fog lamp (2)

Pulling hook

*140589023300

2
Disconnect fog lamp (2) from front bumper

Exercise caution when pulling at the

edges of the fog lamp.


Installation:
First notch in the fog lamp at

the edges. Ensure that the lever (1) securely

holds the fog lamp in place.

Pulling hook

*140589023300

3
Disconnect electrical connector (3) from fog

lamp

4
Pull off grommets (4)


Installation:
Ensure that the grommets

are installed loosely and without kinks.

5
Install in the reverse order

6
Check fog lamp adjustment and adjust if

necessary

e

Check and correct headlamp adjustment

AP82.10-P-8260GH

Pulling hooks
140 589 02 33 00

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

AR68.30-P-4010GHRemove/install paneling in footwell
9.4.97

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

P68.30-2266-01

1
Door sill molding cover

2
Door seal

3
Driver-side paneling

4
Passenger side paneling

5
Bolt

6
Engine hood release lever

7
Arresting mechanism

8
Fuse and relay box cover

9
Nut

P68.30-2267-01


Remove/install

1
Remove front door sill molding cover (1)

2
Unscrew screws from door sill molding on

rocker panel

Only two front screws.

3
Pull off door seal (2) in the area of driver's

side paneling (3) or front passenger's side

paneling (4)

4
Unscrew screw (5) for engine hood release

lever (6) on A-pillar

Driver's side only.

5
Unhook engine hood cable and remove

engine hood release lever (6)

Driver's side only.

6.1
Rotate locks (7) on the cover of the fuse and

relay box (8) 1/4 revolution counterclockwise

into the vertical position

As of 09.99. Passenger side only.

7.1
Pull back cover of fuse and relay box (8)

(arrow) and remove

As of 09.99. Passenger side only.

8.1
Unscrew nut (9)

As of 09.99. Passenger side only.

9
Unclip driver's side paneling (3) and front

passenger's side paneling (4) and remove

Lift door sill molding slightly to allow

removal.

10
Install in the reverse order

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1

AR68.30-P-4470GH
Remove/install rear roof frame paneling
24.2.97

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

P68.30-0507-06

1
Belt end fitting in 3rd seat row

2
Center paneling of roof frame

3
Side paneling of roof frame

4
Expanding anchor

5
Screw


Remove, Install

1.1
Remove belt end fitting at bottom of 3rd seat

row (1)
Only with 3rd seat row, code 847.

*BA91.40-P-1001-01D

2
Unclip center roof frame covering (2)

Installation:
Install paneling in door

rubber seal.

Long wedge

*115589035900

3.1
Remove expanding anchor (4) from side roof

frame covering (3)

up to 31.08.01

Installation:
Replace expanding anchor.

3.2
Remove screw (5) from side roof frame

paneling (3)

4.1Unclip side roof frame paneling in upper outer

corner

As of 01.09.01

4.2
Remove side roof frame paneling (3) upward
Only on 3rd seat row, code 847: remove

seatbelt and remove paneling


Installation:
Install paneling in door

rubber seal.

5.1
Disconnect connector from loudspeaker

As of 01.09.01 and with sound system,

code 810.

6
Install in the reverse order


Seat belts/belt tensioners

Number

Designation
Model 163 up to

08/99
Model 163 as of

09/99

BA91.40-P-1001-01D
Screw on belt end fitting
Nm
3535

Copyright DaimlerChrysler AG 12.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1

Assembly wedge

115 589 03 59 00

Copyright DaimlerChrysler AG 12.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 2

BT27.50-P-0011-01A
Friction bearing in sun wheel of rear planet

gear set converted to anti-friction bearing
Transmission 722.6
k

TRANSMISSION
722.60# /61# /660 /662 /664 /665 /69# ## as of 1572721 as of 1.6.99,
722.62# /63# /650 /654 /661 /663 /666 /669 ## as of 1574575 as of 2.6.99

P27.50-2046-11

1
Anti-friction bearing

45d
Freewheel

45e
Sun gear with inner plate carrier K3, rear planet set

The friction bearing bush in the sun gear (45e) has been replaced

with an anti-friction bearing (1).

This improves the bearing of the hollow shaft and the freewheel (45d)

is no longer worn away by the friction bearing bush.

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1

1998-2005 DRIVELINE/AXLES
Front Axle - 163 Chassis
TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: FRONT AXLE - AR33.00-Z-9163AA
MODEL 163
ATTACH ENGINE SUPPORT BRACKET AND RAISE ENGINE - AR33.10-P-0100-01BV
Workshop equipment
Removing and installing front axleMODELS
163.113 /128 /136 /154 /157 /172 /174 /175AR33.10-P-
0100GH
Remove/install rubber bushes of front
axle transmission mountingMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.10-P-
0120GH
Remove/install front axle halfMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.10-P-
0200GH
Remove/install front axle shaft flange
and double-row angular ball bearingMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0315GH
Checking follower joint of steering
knuckle mount (installed)MODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0426GH
Replace supporting jointMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0440GH
Removing and installing upper
wishboneMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0500GH
Remove/install lower wishboneMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0510GH
Replace front bearing of lower
wishboneMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0526GH
Removing and installing steering
knuckleMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.25-P-
0400GH
Remove/install front axle gearMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.30-P-
0525GH
Replace shaft seal on drive pinionMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.30-P-
0530GH
Remove/install radial shaft seal at front
axle gear of front axle shaftMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.30-P-
0545GH
Remove/install front axle shaftsMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.30-P-
0620GH
Replace rubber boots on front axle shaftMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.30-P-
0660GH
WE58.40-Z-1007-11AEngine lifting fixture

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:21 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.
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Saturday, October 02, 2010 3:38:25 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.