MERCEDES-BENZ ML430 1997 Complete Repair Manual

Fig. 5: Identifying Key To Body Plate
The body plate is screwed onto the cross member above the radiator. The layout differs from one plant to
another, however, always contains the same data.
GENERAL NOTES: PASSENGER CARS: OVERALL VEHICLE - AH00.00-Z-9999AZ
MODEL all
Notes of position of
chassis numberMODEL 452.3 /4AH00.00-P-0002-
01RR
Notes on avoiding
damage through
contamination and
foreign objectsMODEL allAH00.00-P-5000-01A
Notes on bolted
connections with self
tapping screwsMODEL allAH00.00-P-0007-
01SF
Chassis number
breakdownMODEL 452AH00.00-P-2000-
01RR
Measures for preventing
damage to vehicles or
components when
performing arc welding
workMODEL 452.3 /4AH00.00-P-0005-
01RC
Notes on bolted
connections with self
tapping screwsMODEL 452.3 /4AH00.00-P-0007-
01RR
Notes on position of
chassis numberMODEL 454.0AH00.00-P-0002-
01FF
Notes of position of
chassis numberMODEL 450.3 /4AH00.00-P-0002-
01SM
Notes on water entry -
ConvertibleMODEL 450.4AH00.00-P-0004-
01SM
Notes on bolted MODEL 450.3 /4AH00.00-P-0007-

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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connections with self
tapping screws01SM
Key to chassis numberMODEL 107 as of 1.8.83, 124, 126
as of 1.8.83, 129, 140, 201, 202, 210AH00.00-P-2000-01A
Chassis number
breakdownMODEL
163.113/128 /136 /154 /172 /174 /175AH00.00-P-2000-
01GH
Chassis number
breakdownMODEL 450AH00.00-P-2000-
01SM
Chassis number
breakdownMODEL 463.249 /246 /271AH00.00-P-2000-01U
Layout of vehicle data
cardMODEL 100, 107, 108, 109, 111,
112, 113, 114, 115, 116, 123 from
01.01.60 until 31.12.77AH00.00-P-3000-01A
Layout of vehicle data
cardMODEL 123, 124, 126, 129, 140,
163, 168, 170, 201, 202, 208, 210,
215, 220 ab 01.01.78AH00.00-P-3000-01B
Key to body plateMODEL 100, 107, 108, 109, 111,
112, 113, 114, 115, 116, 123, 124,
126, 129, 140, 163, 168, 170, 201,
202, 208, 210...AH00.00-P-4000-01A
Conversion measures
resulting in alteration to
vehicle modelMODEL 100, 107, 108, 109, 111,
112, 113, 114, 115, 116, 123, 124,
126, 129, 140, 163, 168, 170, 201,
202, 208, 210...AH00.10-P-1000-01A
Converting vehicles to
operate on liquefied
petroleum gasMODEL 123.220 /280, 124.020 /080,
126.021, 201.023AH00.10-P-1000-02A
Notes on performance
correctionENGINE 104, 111, 112, 113, 119,
120, 137, 166, 601, 602, 603, 604,
605, 606 ...AH00.10-P-2010-01A
Correction tables for
calculating actual
performance valueENGINE 104, 111, 112, 113, 119,
120, 137, 166, 601, 602, 603, 604,
605, 606 ...AH00.10-P-2010-02A
Notes on replacing
safety-relevant
componentsMODEL allAH00.19-P-1000-02A
Advantages of repairing
wiring harnessesMODEL 124, 126, 129, 140, 163,
164, 168, 169, 170, 171, 199, 202,
203, 208, 209, 210, 211, 215, 216,
219, 220, 221, 230, 240, 245, 251,
414, 461, 463...AH00.19-P-1000-03A
Advantages of repairing
wiring harnessesMODEL 452.3 /4AH00.19-P-1000-
03RC
Advantages of repairing
wiring harnessesMODEL 450.3 /4, 454.0AH00.19-P-1000-
03SM

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Saturday, October 02, 2010 3:47:44 PMPage 7 © 2006 Mitchell Repair Information Company, LLC.

Repair methods for
wiring harnessesMODEL 124, 126, 129, 140, 163,
164, 168, 169, 170, 171, 199, 202,
203, 208, 209, 210, 211, 215, 216,
219, 220, 221, 230, 240, 245, 251,
414, 461, 463 ...AH00.19-P-1000-04A
Methods for repairing
wiring harnessesMODEL 452.3 /4AH00.19-P-1000-
04RC
Repair methods for
wiring harnessesMODEL 450.3 /4, 454.0AH00.19-P-1000-
04SM
Notes regarding plug
connectionsMODEL 124, 126, 129, 140, 163,
164, 168, 169, 170, 171, 199, 202,
203, 208, 209, 210, 211, 215, 216,
219, 220, 221, 230, 240, 245, 251,
414, 461, 463 ...AH00.19-P-1000-06A
Notes on soft solderingMODEL 124, 126, 129, 140, 163,
164, 168, 169, 170, 171, 199, 202,
203, 208, 209, 210, 211, 215, 216,
219, 220, 221, 230, 240, 245, 251,
414, 461, 463 ...AH00.19-P-1000-07A
Notes on crimpingMODEL 452.3 /4 Crimp- and
Stripping PliersAH00.19-P-1000-
09RC
Notes on crimpingMODEL 450.3 /4, 454.0 Crimp- and
Stripping PliersAH00.19-P-1000-
09SM
Notes on solderingMODEL 450.3 /4AH00.19-P-1000-
10SM
Notes on cable
protectionMODEL 124, 126, 129, 140, 163,
164, 168, 169, 170, 171, 199, 202,
203, 208, 209, 210, 211, 215, 216,
219, 220, 221, 230, 240, 245, 251,
414, 461, 463 ...AH00.19-P-1000-11A
Notes on stripping wiresMODEL 452.3 /4 Crimp- and
Stripping PliersAH00.19-P-1000-
12RC
Notes on stripping wiresMODEL 452.3 /4 Stripping PliersAH00.19-P-1000-
12RR
Notes on stripping wiresMODEL 450.3 /4, 454.0 Crimp- and
Stripping PliersAH00.19-P-1000-
12SM
Notes on stripping wiresMODEL 450.3 /4, 454.0 Stripping
PliersAH00.19-P-1000-
12SN
Notes on self-locking
nuts and boltsMODEL allAH00.00-N-0001-
01A
Measures for preventing
damage to vehicles or
components when
performing arc welding
workMODEL 450.3 /4AH00.00-P-0005-
01SM

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Saturday, October 02, 2010 3:47:44 PMPage 8 © 2006 Mitchell Repair Information Company, LLC.

Information on function
and performance test on
roller dynamometerMODEL 460, 461, 463 ...AH00.10-P-1000-03A
Measures for preventing
damage to vehicles or
components when
performing arc welding
workMODEL allAH00.00-N-0005-
01A
Measures for preventing
damage to vehicles or
components when
performing electric
welding workMODEL 451.3/4, 454.0AH00.00-P-0005-
01FF
Notes on thread repairsMODEL 452.3 /4AH00.00-P-0008-
01RR
Notes on thread repairsMODEL 450.3 /4AH00.00-P-0008-
01SM
Notes on removing glue
residues and foils on
paint and metal surfaces
with eraser discMODEL 169.0 /3, 216.3, 219.3,
221.0/1, 245.2AH00.00-P-0013-
01AK
Assessment of damage
in wiring harnessesMODEL 124, 126, 129, 140, 163,
164, 168, 169, 170, 171, 199, 202,
203, 208, 209, 210, 211, 215, 216,
219, 220, 221, 230, 240, 245, 251,
414, 461, 463...AH00.19-P-1000-05A
Assessment of damage
to cable harnessesMODEL 452.3 /4AH00.19-P-1000-
05RC
Assessment of damage
in wiring harnessesMODEL 450.3 /4, 454.0AH00.19-P-1000-
05SM
Notes on replacement of
safety-relevant and
special componentsMODEL 124, 126, 129, 140, 163,
164, 168, 169, 170, 171, 199, 202,
203, 208, 209, 210, 211, 215, 216,
219, 220, 221, 230, 240, 245, 251,
414, 461, 463...AH00.19-P-1000-08A
Notes on crimpingMODEL 124, 126, 129, 140, 163,
164, 168, 169, 170, 171, 199, 202,
203, 208, 209, 210, 211, 215, 216,
219, 220, 221, 230, 240, 245, 251,
414, 461, 463...AH00.19-P-1000-09A
Notes on solderingMODEL 124, 126, 129, 140, 163,
164, 168, 169, 170, 171, 199, 202,
203, 208, 209, 210, 211, 215, 216,
219, 220, 221, 230, 240, 245, 251,
414, 461, 463...AH00.19-P-1000-10A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 9 © 2006 Mitchell Repair Information Company, LLC.

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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Saturday, October 02, 2010 3:47:44 PMPage 10 © 2006 Mitchell Repair Information Company, LLC.

CONVERSION MEASURES RESULTING IN ALTERATION TO VEHICLE MODEL - AH00.10-P-1000-01A
Model 100, 107, 108, 109, 111, 112, 113, 114, 115, 116, 123, 124, 126, 129, 140, 163, 168, 170, 201, 202, 208,
210
We disapprove of all vehicle conversions resulting in an alteration to the model. A standard production vehicle
is a design entity which, upon installation of parts alien to the model, usually changes in a detrimental way.
Changes to important components influence the homogeneity of the vehicle in its entirety. For this reason we
have not investigated the details to be observed when performing such conversions. Such conversions can also
lead to changes on the vehicle which require new proof that the vehicle complies with legal requirements.
The main reasons for our disapproval are:
1. Subsequent installation of a component such as a more powerful engine may overload the remaining
components such as the transmission, brakes, axles, etc.
Body
Body - generalFG60AH60.00-Z-9999AZ
Front end and fire wallFG62AH62.00-Z-9999AZ
Side wallFG63AH63.00-Z-9999AZ
Rear wall and rear endFG64AH64.00-Z-9999AZ
RoofFG65AH65.00-Z-9999AZ
WindowsFG67AH67.00-Z-9999AZ
Interior equipmentFG68AH68.00-Z-9999AZ
DoorsFG72AH72.00-Z-9999AZ
Sliding roof, soft top, top
attachmentsFG77AH77.00-Z-9999AZ
Central locking,
convenience feature,
drive authorization
systemFG80AH80.00-Z-9999AZ
Electrical system bodyFG82AH82.00-Z-9999AZ
Climate controlFG83AH83.00-Z-9999AZ
Emergency equipment,
sanitary equipment,
galleyFG86AH86.00-Z-9999AZ
Detachable body
components, exterior
flapsFG88AH88.00-Z-9999AZ
Seats, bunks, restraint
systemsFG91AH91.00-Z-9999AZ
Body sealing, corrosion
protectionFG97AH97.00-Z-9999AZ
PaintworkFG98AH98.00-Z-9999AZ

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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2. Changes to the standard condition may decisively influence the new vehicle warranty, since our warranty
obligation does not cover damage resulting from a change to the original Daimler Benz delivery
condition.
3. Proper supply of parts is no longer ensured when major components are replaced.
4. The exchange procedure is based on the "Identical unit exchange" principle. For example, an identical
model reconditioned unit will be supplied in return for a damaged engine. Only then is it possible to be
credited for the returned damaged engine.
Customer inquiries and requests of this type should be answered along these lines in order to ensure that the
quality standard of our vehicles is not impaired.
NOTES ON PERFORMANCE CORRECTION - AH00.10-P-2010-01A
Engine 104, 111, 112, 113, 119, 120, 137, 166, 601, 602, 603, 604, 605, 606
General
The weather station's barometer must be calibrated to the air pressure specified by the local meteorological
office.
The measured performance value must be corrected with correction factors.
There are two 2 correction factors:
Altitude correction factor
Performance correction factor
Performance correction formula N
eo = Ne x KH
Neo = Performance in reference to normal operating conditions in kW.
Ne = Performance measured on the output dynamometer in kW.
K
H = Correction for intake air temperature, barometer level and altitude of the relevant test location.
Calculation example
1. Read air pressure, altitude and intake air temperature of the test location off at the weather station. NOTE: In addition, vehicles registered in the Federal Republic of Germany are subject
to the law which revokes the operating permit as a result of conversions which
change the model. We cannot issue a Certificate of non-objection for individual
approval by the technical motor vehicle testing authority in each case.

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Saturday, October 02, 2010 3:47:44 PMPage 12 © 2006 Mitchell Repair Information Company, LLC.

In the example:
Air pressure of the test location =955 hPa (mbar)
Altitude of the test location = 400 m
Intake air temperature of the test location =+20°C
2. Determine the performance on the output dynamometer =100 kW
3. In the altitude correction Table, the altitude value of the test location = 400 m, results in a height
correction factor of 46 hPa (mbar).
4. The air pressure of the test location minus the height correction factor results in an air pressure value (p)
of:
955 hPa (mbar) - 46 hPa (mbar) = 909 hPa (mbar)
In order to be able to insert the air pressure (p) into the Table, it must be rounded. In the example, to 910
hPa.
5. On the basis of the air pressure (p) = 910 hPa, we read a correction factor (KH) of 1.0787 off from the
performance correction Table with an intake air temperature (t) of 20°C.
6. The performance data in relation to normal operating conditions results in the following:
N
eo = Ne x KH
N
eo = 100 kW x 1.0787 = 108 kW
Output on the dynamometer: Ne = 100 kW
Air pressure value of the test location: P= 955 hPa (955 mbar)
Air-charge temperature of the test location: t =+20°C
Altitude of the test location: 400 m above sea level
Units: hPa = Hecto Pascal
1 hPa = 1 mbar
1 Pa = 0.01 mbar
CORRECTION TABLES FOR CALCULATING ACTUAL PERFORMANCE VALUE - AH00.10-P-2010-02A
Engine 104, 111, 112, 113, 119, 120, 137, 166, 601, 602, 603, 604, 605, 606

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Saturday, October 02, 2010 3:47:44 PMPage 13 © 2006 Mitchell Repair Information Company, LLC.

Performance correction formula Neo = Nex KH
Neo = Performance in reference to normal operating conditions (sea level, temperature 25°C) in kW.
Ne = Performance measured on the output dynamometer in kW.
K
H = Correction factor n
Correction factor (K
H ): n
Determine air pressure and altitude of the test location
Use subsequent altitude correction Table to correct air pressure
Determine air-charge temperature.
Using these values and the subsequent performance correction Table read off the correction factor (K H )
Altitude correction
If the air pressure is read off in relation to the sea level (weather station), the following air pressure in the
correction Table must be subtracted.
Performance correction Table
mhPamhPamhPamhPamhPa
0
0 30036 60069 900104 2000221
50
6 35041 635075 950109 2100230
100
12 40046 70081 1000115 2200239
150
18 45052 75086 1100126 2300250
200
24 50058 80092 1200137 2400259
250
30 55063 85098 1300148 2500268
hPa
(mbar)
0°C5°C10°C15°C20°C25°C30°C35°C40°C45°C50°C
10400.91110.91940.92770.93580.90.90.990.96780.97560.98330.9910
10350.91550.92390.93210.94030.96450.95650.96450.97240.98030.98810.9958
10300.92000.92840.93670.94490.95310.9920.9920.97720.992910.99291.0007
10250.92450.93290.94120.94950.95770.98990.90.98990.990.99771.0056
10200.92900.93750.94580.95420.96241.00260.99470.99470.99471.00261.0105
10150.93360.94210.95050.9990.96720.97540.98350.99160.99961.00761.0155
10100.93820.94670.95520.96360.90.95520.98840.951.01261.01261.0205
10050.94280.95140.96000.96840.97680.9510.99331.00156000.961.01761.0256
10000.94760.95620.96480.97320.98170.964800.9731.00651.01461.02271.0307
9950.95230.96100.96100.96027810.98660.99501.00331.01151.01971.02781.0359

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Saturday, October 02, 2010 3:47:44 PMPage 14 © 2006 Mitchell Repair Information Company, LLC.

9900.95710.96590.97450.98311.01661.00001.00841.01661.02491.03301.0411
9850.96200.97080.97950.98810.99661.00511.01351.02181.038311.03831.0464
9000.96690.97570.98450.99311.00171.01021.01861.01.03531.04361.0517
9750.97190.98070.98950.99821.00681.01541.02391.03231.04061.04891.0571
9700.97690.98580.99461.00331.01201.02061.046011.061.04601.05431.0626
9650.98190.98190.90.99981.00851.01731.02591.03451.04301.05141.05981.0681
9600.98700.99601.00501.01381.02261.07361.03991.04841.05691.06531.0736
9550.99221.00131.01021.070911.02791.03661.04531.05391.0701.07931.0793
9500.99741.00651.01551.02451.03331.076511.05081.08491.0241.07651.0849
9451.00271.01191.091.02091.03881.04761.05641.082211.09071.08221.0907
9401.00801.01721.02631.0441.04431.05321.05321.01.071.07941.08801.0965
9351.01341.02271.03181.091.0491.05881.06771.07641.11.09381.1023
9301.01891.02821.03741.05551.0551.06451.07341.08221.01891.01.09971.1083
9251.02441.03371.03371.01.05221.06131.0431.07921.105611.09691.10561.1143
9201.03001.03931.04871.05791.101.067011.057911.09401.10281.11161.1203
9151.03561.04501.0541.06371.07291.10001.101.101.10891.11771.1264
9101.04131.05081.06021.06951.07871.08791.07871.01.11501.11501.12381.1326
9051.04701.05661.05661.01.07541.08471.09391.11.11.11.13001.1389
9001.05281.06241.07201.06241.09071.101.14521.13631.13631.13631.1452
8951.05871.06841.07791.06841.09681.068411.11541.12461.13361.14271.1516
8901.06471.07441.08401.09351.101.11241.12171.13091.14001.15811.1581
8851.07071.08051.09011.09971.10921.11861.12801.13731.14651.16461.1646
8801.07681.08551.09631.101.11551.12501.13441.14371.15301.17121.1712
8751.08291.09281.10261.11231.12191.13141.14091.15031.15961.16881.1779
8701.08921.09911.10891.18471.12831.13791.14741.15691.16621.17551.1847
8651.09541.10541.11531.12511.13491.14451.105411.16361.17301.18231.1915
8601.10181.191.19851.13171.14151.15121.16081.17031.17981.18921.1985
8551.10831.11841.12841.13831.128411.15791.16761.17721.18671.19611.2055
8501.11481.12491.13501.13501.15491.16471.17441.124911.19371.21261.2126
8451.12141.13161.14171.15181.14171.17161.18141.211.20071.21031.2198
8401.12811.13831.14851.17861.16861.17861.18841.21.20791.21751.2270
8351.13481.14521.15541.16561.17561.18561.19551.23441.224811.22481.2344
8301.14161.15211.16241.17261.18271.19281.20271.21261.22241.23211.2418
8251.14861.15901.16941.17971.1691.20001.21001.22001.22981.23961.2493
8201.15561.16611.17651.18691.197111.20731.21741.21741.23731.24721.2569
8151.16271.17331.18381.21.20451.21471.22491.23491.24491.25481.2647
8101.16981.18051.16981.11.20151.21191.221.23241.24261.26261.26261.2725
8051.17711.18781.19851.20901.21951.22981.270411.25031.26041.27041.2804
8001.18451.19531.20601.21661.2784111.23751.28841.278411.26831.27841.2884
7951.19201.20281.21351.28641.21.23481.24531.25571.26601.28641.21.28641.2956
7901.19941.30471.21.23201.26361.28431.21.261.27401.28431.29451.3047

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 15 © 2006 Mitchell Repair Information Company, LLC.