MERCEDES-BENZ ML430 1997 Complete Repair Manual

AR94.30-P-5400GH
Remove/install noise encapsulation
16.8.01

MODEL
163.113 /128

P94.30-2011-12

1
Noise encapsulation, front section

2
Headless setscrew

3
Plastic clip

4
Noise encapsulation, center section

5
Noise encapsulation, rear section


Remove, install


Installation

Inspect headless setscrews and plastic clips,

replace if necessary.

1
Remove headless setscrews (2) and plastic

clips (3) from noise encapsulation front
section (4)
6 headless setscrews and plastic clips.

2
Remove noise encapsulation front section (1)

3
Remove headless setscrews (2) and plastic

clips (3) from noise encapsulation center

section (4)
4 headless setscrews and plastic clips.

4
Remove (4) noise encapsulation center section

5
Remove headless setscrews (2) and plastic

clips (3) from noise encapsulation rear section

(5)

8 headless setscrews and plastic clips.

6
Remove noise encapsulation rear section (5)

7
Install in reverse order

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AR94.30-P-5500GH
Modify noise encapsulation
12.9.01

MODEL
163.113

P94.30-2012-11

1
Noise encapsulation, front section

2
Insulation cubes

3
Scribe line, horizontal

4
Scribe line, vertical

5
Area to be removed

r
10 mm


Remove

1
Remove noise encapsulation
front
section (1)

Do NOT remove other encapsulation

sections.

AR94.30-P-5400GH

Modify

2
Flatten insulation cubes (2)

3
Scribe two 38 mm
vertical
lines (4) forward

from rear edge of encapsulation

Vertical scribe lines should be flush with

outside edges of rear cutout in encapsulation.

4
Scribe a straight, horizontal line (3) between

vertical lines

5
Radius forward corners of scribe lines to 10

mm (r)

6
Remove area (5) of encapsulation bordered

by scribe lines


Install

7
Reinstall noise encapslation
front
section (1)

AR94.30-P-5400GH

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AR94.30-P-5400GH
Remove/install noise encapsulation
16.8.01

MODEL
163.113 /128

P94.30-2011-12

1
Noise encapsulation, front section

2
Headless setscrew

3
Plastic clip

4
Noise encapsulation, center section

5
Noise encapsulation, rear section


Remove, install


Installation

Inspect headless setscrews and plastic clips,

replace if necessary.

1
Remove headless setscrews (2) and plastic

clips (3) from noise encapsulation front
section (4)
6 headless setscrews and plastic clips.

2
Remove noise encapsulation front section (1)

3
Remove headless setscrews (2) and plastic

clips (3) from noise encapsulation center

section (4)
4 headless setscrews and plastic clips.

4
Remove (4) noise encapsulation center section

5
Remove headless setscrews (2) and plastic

clips (3) from noise encapsulation rear section

(5)

8 headless setscrews and plastic clips.

6
Remove noise encapsulation rear section (5)

7
Install in reverse order

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AH00.00-N-0001-01A
Notes on self-locking nuts and bolts
All models


Important repair information


Bolts with locking splines, micro-encapsulated bolts and self-

locking nuts must always be replaced after being used once.

There is an increased risk of injury when unscrewing micro-

encapsulated bolts due to the sudden breakaway torque.
Before new micro-encapsulated bolts are screwed in, the mating

thread must be re-cut in order to remove all the residue of the old bolt

locking compound.

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AD00.00-P-2000-02C
Assignment of data link connector

P07.00-0323-10

X11/22
Data link connector

1
Electronic ignition/starter switch control module (model

168)

2 -
3
TNA signal (gasoline)

3
TD signal (diesel)

4
Circuit 31 (ground)

5
Circuit 31 (electronics ground)

6
CAN interior bus (H)

7
ME
Motor electronics (ME-SFI)

8
Circuit 87 voltage

9
ABS
Anti-lock brake system (model 168)

9
ETS
Electronic traction system (model 163)

9
ASR
Acceleration slip regulation (model 168)

9
ESP
Electronic Stability Program

10
-

11 ETC
Electronic transmission control

11
FTC
Front transmission control (model 168)

11
Automatic clutch (model 168)

12
AAM
All activity module
12

RD
Radio Audio 10, Audio 30, and Audio 30 APS with D2B

(model 168)

13
AB
Airbag/emergency tensioning retractor

14
CAN interior bus (L)

15 IC
Instrument cluster

16
Circuit 30 voltage 30

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AF07.07-P-2700A
Oil consumption too high
28.1.03

ENGINE
112, 113 in MODEL 163.1## ## up to 357786

ENGINE
112 in MODEL 202.02

ENGINE
112 in MODEL 202.08

ENGINE
112 in MODEL 210.06

ENGINE
113 in MODEL 210.07

ENGINE
112 in MODEL 210.663

ENGINE
112 in MODEL 210.26# ## up to 276396

ENGINE
113 in MODEL 210.27# ## up to 276396

ENGINE
112, 113 in MODEL 210.08# ## up to 084039

ENGINE
112, 113 in MODEL 210.28# ## up to 084039

Operation no. of operation texts or standard texts and flat rates

Category

Op. no.
Operation text

Time
Acc. no.
Code

P
023813
Remove/install/replace gasket between intake pipe and throttle

valve
006 WU/0.5 h
------

Damage code
Cause
Remedy

14 034 04
Gasket (B) between intake pipe (A) and

throttle valve defective.

High oil consumption of more than 0.8

liters per 1000 km.

In order to avoid erroneous removal the

following documents
must
be processed

before starting the work:

#

High oil consumption

AF18.00-P-8044D

Measure oil consumption

AR18.00-P-0025AV

1
Remove,/install/replace gasket (B)

between intake pipe (A) and throttle

valve.

AR07.07-P-1454A

Use new gasket according to parts

ordering notes Old gasket with part number

112 141 01 80 should no longer be used.

P07.07-2038-01

A
Intake pipe

B
Gasket

Parts ordering notes
Part no.

Designation
Quantity

A 112 141 18 80
Gasket
1

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BT27.20-P-0001-01A
Oil drain plug on torque converter deleted
Transmission 722.6
k

TRANSMISSION
722.6## /6## ## as of 1772285 as of 22.9.99

For reasons of cost, the oil drain plug on the torque converter has

been deleted for all transmission variants.

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AP18.00-P-0101-06GH
Replacing oil filter element, draining oil filter


Oil filter

Number

Designation
Engines

112.910/911/
912/913/914/
915/916/917/
920/921/922/
923/940/941/
942/943/944/
945/946/947/
949/951/953/
954/955/960/
961/970/972/

973/975
Engines

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

984/986
Engines

113.990/

991/993

BA18.20-P-1001-01D
Screw cap on oil filter
Nm
252525

103 589 02 09 00

Socket wrench bit

1
Unscrew screw cap (2) using the
socket wrench bit and remove together with the oil

filter element (4).

2
Release oil filter element (4) by shortly turning up the middle rod from the screw cap (2).

Use a suitable container for this operation.

3
Replace seal (3).

4
Insert new oil filter element (4) into oil filter housing (5).

5
Screw on screw cap (2) using the

socket wrench bit
.

P18.00-0308-01

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AP18.00-P-0101-06EG
Replace oil filter element, drain oil filter

Crankcase ventilation, cylinder head cover

Number

Designation
Engine

611.960/

961/962
Engine

612.961/

962/967
Engine

612.963
Engine

612.965/

966
Engine

613.960/

961

BA01.20-P-1002-01A
Screw of trim panel of cylinder head cover

to cylinder head cover
Nm
1010101010

BA01.20-P-1003-01A
Screw attaching cover panel to charge air

distribution pipe
Nm
1010101010

Crankcase ventilation, cylinder head cover

Number

Designation
Engine

646.951/961,

647
Engine

646.962/963
Engine

648

BA01.20-P-1002-01G
Bolt, trim panel of cylinder

head cover to cylinder head
Nm
999

BA01.20-P-1003-01G
Bolt, cover to charge air

distribution pipe.
Nm
999

Designation
Engine

611.960/

961/962
Engine

612.961/962/

963/990,

613.960/961
Engine

612.965/

966
Engine

646.951/961/
962/963/982/
983/984,
647, 648

BA18.20-P-1002-01G
Screw cap at oil filter
Nm
25252525

Socket wrench bit

103 589 02 09 00

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P18.20-2022-01

1
Engine 611.961 as of 07.99, 611.962, 612, 613, 646, 647, 648:

Remove trim panel of cylinder head cover and trim panel of charge air distribution pipe.

2
Model 203, 211:

Remove fastening clamp (arrow) of fuel line.

3
Remove screw cap (1) with wrench socket

and take off together with oil filter element
(3).

4
Replace seal (2).

5
Insert new oil filter element (3) into oil filter housing.

6
Fasten the screw cap (1) with bolts using a socket wrench bit

.
7
Model 203, 211:

Install the fastening clamp (arrow) of the fuel line.

8
Engine 611.961 as of 07.99, 611.962, 612, 613, 646, 647, 648:

Install the cylinder head cover trim panel and the charge air distribution pipe trim panel

.

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