MERCEDES-BENZ ML430 1997 Complete Repair Manual

1.1
Unscrew bolts at rear of 2/3 seat bench and

raise rear of seat bench

Up to VIN A145272, X708318.

1.2
Remove covers at seat frame of 60% bench

seat

As of VIN A145273, X708319.

AR91.12-P-1100GH

Only remove the covers which are
identified in the document with A, D and E.

2.1
Fold 60% bench seat forward into footwell

As of VIN A145273, X708319. See

operator's manual.

3.1
Pull floor covering below rear seat mounting

bracket (1) of 60% seat forward

Carefully pull floor covering forward under

the seat console to prevent it from tearing.

As of VIN A145273, X708319.

4.1
Pull the floor covering forward under the front

corner of the left C-pillar cover (2)

Carefully pull the floor covering forward

under the cover to prevent it from tearing.

As of VIN A145273, X708319.

5
Cut into floor covering directly behind seat

retaining cable (3)

Ensure that the wiring harness (4) is not

damaged when cutting the floor covering.

As of VIN A145273, X708319. Broken

line marks the cut.

6
Fold floor mat back

Do not crease floor mat!

Fold floor mat back far enough to provide

access to cap (84) between body and fuel

pump.

7
Remove end cover (84) of body


Installation:
Replace cap and insert with

new sealing compound.


Cap (84) is sealed in with body sealer.

Heat with hot air blower to make it easier to

remove.

8
Seal fuel return line (90/11)

Pliers

*163589003700

9
Connect extraction hose (90/14) with adapter
hose to connection for fuel return line (90/11)

Extraction hose

*168589009000


Adapter hose

*163589009100

10
Connect ground cable (90/10) of extraction

pump ground terminal vehicle battery

Pumping out

11
Pump fuel out into safety container using

extraction pump


*BF47.10-P-1001-01A


*WH58.30-Z-1001-16A

12
Install in the reverse order


Fuel tank

Number

Designation
Models

163.113/
136/154/

172 up to

31.08.01
Models

163.113/
136/154/

172 as of

01.09.01


Models

163.157/

175
Model

163.128
Model

163.174

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liter
72838393

Reserve capacity
Liter
10121212

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

163 589 00 91 00

Extraction hose

Adapter hose

Pliers

163 589 00 37 00 168 589 00 90 00

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e.g.)
Order number

WH58.30-Z-1001-16A
Suction master M2P 20 B
Ecco GmbH

Vonkeln 17

D-42349 Wuppertal
9749 5000 50

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 3

BF47.10-P-1000-01A
Fuel tank capacity
Model 124, 129, 140, 163, 168, 170,

171, 199, 202, 203, 208, 209, 210, 211,
215, 220, 230, 240,

414, 463

i

Modification notes

26.4.04

Value modified from 87.6 Nm to 97 Nm
Value modified in series 1001 for model 199


Fuel tank

Number

Designation
Model

124.008/019/

022/028/
029/032/040/

042/052
Model

124.07/

08/09
Model

124.034/

036
Model

124 with

increased tank

capacity code

915

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liters
70729090

Reserve capacity
Liters
99
11
11.5


Fuel tank

Number

Designation
Model

124.06
Model

129
Model

140

without

code

282a or

code 308
Model

140 with code

282a
or

code 308
Model

163.113/
136/154/

172 up to

31.08.01

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liters
70801009072

Reserve capacity
Liters
1110
12.512.5
10


Fuel tank

Number

Designation
Model

163.113/
136/154/

172 as of

01.09.01


Model

163.157/

175
Model

163.128
Model

163.174
Model

168.006/

007/ 008/

009/131/

132/133
Model

168.031/

032/033

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liters
8383935454

Reserve capacity
Liters
121212
88

Designation
Model

170.43/

445/447/46
Model

170.444/

449
Model

171
Model

199
Model

202.018/020/023/

024/025/026 /
029/033/078 /
080/082/083 /

085/086/089/093

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liters
536070
87,6
62

Reserve capacity
Liters
789
10
8

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

Fuel tank

Number

Designation
Model

202.121/122/128/

133/180/182/

188/193
Model

203
Model

208
Model

209

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liters
62626262

Reserve capacity
Liters
7888

Designation
Model

210 with

code 282a

or

code 308
Model

210.0

without code

915
Model

210.0

with code

915
Models

210.2/6

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liters
70658070

Reserve capacity
Liters
98
10
9

Designation
Model

211.004/006/042/606

without code 915 (fuel

tank with increased

capacity)
Model

211.004/006/016/042/
061/080/206/216/242/

261/280/606/616

with code 915 (fuel

tank with increased

capacity)

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liters
6580

Reserve capacity
Liters
8...98...9


Fuel tank

Number

Designation
Model

211.016/061/080/616

without code

915 (fuel tank with

increased capacity),

954a (Avantgarde),

955a (Elegance)
Model

211.016/061/080/
216/261/280 /616

with code 954a

(Avantgarde),

955a (Elegance)
Model

211.023/026/
028/065/070/
076/082/083/
223/226/265/
270/276/282/

283

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liters
658080

Reserve capacity
Liters
8...98...98...9


Fuel tank

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

Number
Designation
Model

211.206

without code 915 (fuel

tank with increased

capacity)
Model

211.216/242/

261/280

without code 915 (fuel

tank with increased

capacity),

954a (Avantgarde),

955a (Elegance)

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liters
7070

Reserve capacity
Liters
8...98...9


Fuel tank

Number

Designation
Model

215 with

code 282a

or

code 308
Model

215

without

code

282a or

code 308
Model

220 with

code 282a

or

code 308

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liters
788878

Reserve capacity
Liters
101110


Fuel tank

Number

Designation
Model

220

without

code

282a or

code 308
Model

230
Model

240
Model

414
Model

461, 463

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liters
88801105496

Reserve capacity
Liters
111014
8
20

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 3

AR47.10-P-4001GH
Emptying, filling the fuel tank
11.3.97

Model
163.136 with engine 111.977

Model
163.154 with engine 112.942

Model
163.157 with engine 112.970

Model
163.172 with engine 113.942

Model
163.174 with engine 113.981

Model
163.175 with engine 113.965

P47.10-0411-06

1/1
Service valve

17
Fuel rail

17/2
Fuel feed line

80/9
Fuel hose

F1K3
Fuel pump relay

Draining or pumping out

Danger!

Risk of explosion
if ignition takes place,
risk

of poisoning
caused by inhaling fuel vapors

or swallowing fuel as well as
risk of injury
to

skin and eyes exposed to fuel.
No fire, sparks, open flames or smoking.

Only pour fuels into suitable and appropriately

marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1
Release fuel pressure through service valve

(1/1)

Collect fuel.

Pressure hose

*119589046300

2
Unscrew fuel feed line (17/2) at fuel distributor

(17)


*BA07.52-P-1001-01A

3
Connect fuel hose (80/9) to fuel feed line (17/2)

Use 10 mm diameter fuel hose.

4
Insert fuel hose (80/9) into safety reservoir

5
Pull fuel pump relay (F1k3) out of relay holder

n

Assignment and cable connections of fuse

blocks

GF54.15-P-1255GH

6
Bridge fuel pump

Connect slot 30 (battery positive) to slot

87 (relay contact input).


*220589009900

7
Switch on ignition

8
Pump fuel out into safety canister


*BF47.10-P-1001-01A


Fuel rail

Number

Designation
Engine

112 except

112.945/951/

960/961

BA07.52-P-1001-01A
Fuel feed line on fuel distributor
Nm
38

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

Fuel rail

Number

Designation
Engines

113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/988/

BA07.52-P-1001-01A
Fuel feed line on fuel distributor
Nm
38


Fuel tank

Number

Designation
Models

163.113/
136/154/

172 up to

31.08.01
Models

163.113/
136/154/

172 as of

01.09.01


Models

163.157/

175
Model

163.174

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liters
728393

Reserve capacity
Liters
101212

220 589 00 99 00

Electrical connection set

Pressure hose

119 589 04 63 00

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

AR47.10-P-4100GH
Remove fuel tank
10.3.97

MODEL
163.113 with ENGINE 612.963

MODEL
163.128 with ENGINE 628.963

MODEL
163.136 with ENGINE 111.977

MODEL
163.154 with ENGINE 112.942

MODEL
163.157 with ENGINE 112.970

MODEL
163.172 with ENGINE 113.942

MODEL
163.175 with ENGINE 113.965

P47.10-0407-06

1
Left side paneling cover

2
Filler cap

3
Bayonet lock

4
Filler cap attachment

5
Rubber seal

B4/3 Fuel tank pressure sensor

X36/4
Fuel tank filler neck/ground screw

connection

P47.10-0413-09

77
Activated charcoal canister

77/1
Fine venting connection

77/2
Regeneration connection

77/3
Spring chamber venting connection
80/19

Mounting screw

90/11
Fuel return line

90/12
Fuel feed line

B4/3 Fuel tank pressure sensor

77/4

Frischluftanschluss

80
Fuel tank

80/2
Tensioning straps

80/18
Longitudinal strut for tensioning

straps

Modification notes
7.11.00

Figure modified from 170 Nm auf 200 Nm
Value in BA35.10-P-1001-01C changed for

model 163

*BA35.10-P-1001-01C

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

Remove, Install


Danger!
Risk of explosion
from fuel igniting,
risk of

poisoning
from inhaling and swallowing fuel

as well as
risk of injury
to eyes and skin

from contact with fuel.
Fire, sparks, open flames or smoking

forbidden.

Pour fuels only into suitable and appropriately

marked containers.

Wear protective clothing when handling fuel.
AS47.00-Z-0001-01A

1
Drain fuel tank

Via fuel pump. NOT for model 163.113/128.

AR47.10-P-4001GH

If fuel pump faulty, and model 163.113/128.

AR47.10-P-4000GH


*BF47.10-P-1001-01A

2
Unscrew filler cap (2) and detach from filler

cap attachment (4)

3.1
Remove left seat of 3rd seat row

If installed. See owner's manual

4
Unclip cover of left-hand side panel (1)

5.1
Detach fuel lines of expansion reservoir and

separate from filler neck

As of VIN A289565. NOT for model

163.113/128.

6
Detach fuel filler neck from guide funnel


Installation:
Check O-ring and replace if

necessary. Ensure that the bayonet-lock
remains above
the pressure sensor.

Ensure it is correctly located when installed.

Open bayonet lock (3) to do this.

7
Pull filler neck through toward interior

Screw on cap again in order to avoid fuel

flowing out.

8.1
Remove fuel tank pressure sensor (B4/3)

Only USA version

AR47.10-P-8022GH
9.1
Detach bolted connection of fuel tank filler

neck/ground (X36/4) from filler neck

NOT for model 163.113/128.

10.1
Cut cable strap for retaining clips of fuel lines
at filler neck and remove retaining clips

As of VIN A289565. NOT for model

163.113/128.


Danger!
Risk of fatal accident
from vehicle slipping

or toppling off the lift platform
Align vehicle between the columns of lifting
platform and position the four support plates


below the support strongpoints specified by

the vehicle manufacturer.

AS00.00-Z-0010-01A

11
Place the vehicle on lifting platform

AR00.60-P-1000GH

12
Separate rubber seal (5) from underside of

vehicle and remove filler neck from interior

Do not damage fuel lines at filler neck.

13
Remove left rear wheel

e

Removing and installing wheels, rotating if

necessary

AP40.10-P-4050GH

14
Remove spare wheel and spare wheel carrier

complete

NOT in the case of spare wheel

holder/spare wheel, code 849.

15
Cut a large safety cable strap for filler neck at

bracket on longitudinal frame member

16
Remove bracket from longitudinal frame

member

17
Disconnect connection for regeneration (77/2)

and fresh air connection (77/4) on activated

charcoal canister (77)


Installation
: Connect up lines as per

connection diagram:

#

Engine 111

AR47.30-P-8212-01GJ

Engines 112, 113

AR47.30-P-8212-01GI

Engines 112, 113 version
I

AR47.30-P-8212-01GH

Charcoal canister and fuel tank form a

single unit.

NOT for model 163.113/128.

18
Detach vent hose

At rear differential to rear of activated

charcoal reservoir.

19
Remove rear exhaust system heat shield.

Do not damage boot at rear axle shaft.

20
Disconnect rear propeller shaft at differential


Installation:
Install new self-locking bolts.


Tie up propeller shaft e.g. using welding

wire

Heat bolts with hot air fan to facilitate

removing. Mark propeller shaft and differential

gear flange for correct installed position.


*BA41.10-P-1002-01C

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

21
Detach rear brake cables

Unclip at underfloor of vehicle and

unscrew brake cable holder on right and left

at frame.

22.1
Unbolt check strap of rear axle carrier from

underfloor of vehicle

As of VIN A145273, X708319.

23
Remove left rear stone shield

24
Remove lower tensioning straps (80/2) and

loosen the upper tensioning straps

Tensioning straps are color-coded and

cannot be mixed up.

Support fuel tank using assembly jack.


*BA47.10-P-1001-01D

25
Remove longitudinal strut for tensioning

straps (80/18)


*BA47.10-P-1002-01D

26.1
Unscrew linkage for headlamp range

adjustment
at the top

If installed.

27
Unscrew nuts on bottom of the shock
absorbers at the transverse control arm


Installation:
Install new self-locking nuts.


*BA32.25-P-1001-03D

28
Unscrew rear axle carrier from floor of vehicle

and lower as far as possible

Support rear axle carrier.


Installation:
Install new self-locking bolts.


*BA35.10-P-1001-01C

29
Lower fuel tank

Support fuel tank.

30
Remove upper tensioning strap
at the rear
The tensioning strap at the top at the front.

31.1
Unclip lines from side of fuel tank

As of VIN A289565, X754620.


Installation:
The lines must not be

damaged.

32
Disconnect fuel pump electrical plug

connection

33
Disconnect fuel feed line (90/12) and fuel

return line (90/11)

Fuel lines must not be bent.

Pliers

*163589003700

34
Remove fuel tank (80)


Installation:
Ensure that the sealing

rubbers (5) seat correctly in the body floor to

prevent water entry.

Do not damage fuel lines at filler neck.

Guide filler neck with its chamfered side

(arrow) through between frame and body.

Filler neck and fuel tank cannot be separated

from each other.

35
Install in the reverse order

36.1
Dispose of fuel tank

Ony when replacing the fuel tank.

o

Disposal of fuel tanks

OS47.10-P-0001-01A


Rear axle carrier

Number

Designation
Model

Series 163

BA35.10-P-1001-01C
Self-locking bolt, rear axle carrier at front and rear

to frame floor
Nm
200


Propeller shaft

Number

Designation
Model

Series 163

BA41.10-P-1002-01C
Self-locking bolt, rear propsharft

at rear axle center section
Nm
50

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 3