drain bolt MERCEDES-BENZ ML500 1997 Complete Repair Manual
[x] Cancel search | Manufacturer: MERCEDES-BENZ, Model Year: 1997, Model line: ML500, Model: MERCEDES-BENZ ML500 1997Pages: 4133, PDF Size: 88.89 MB
Page 1177 of 4133
Fig. 4: Removing & Installing Transmission With Torque Converter
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/Install -
1 - Disconnect ground cable of battery. See DISCONNECT GROUND LEAD FROM BATTERY
.
2 - Remove transfer case. See TRANSFER CASE .
3 - Unbolt oil filler pipe (3) from crankcase. See Fig. 4
.
4 - Remove heat shield (5) and disconnect 13-pin plug connector (2).
5 - Remove locking clips (21) and remove shift.
6 - Unscrew oil drain screw on oil pan (14).
7.1 - Unscrew oil drain screw for torque converter (15).
8.1 - Detach wire for park lock interlock (7) at transmission.
9 - Lambda sensors for primary catalytic converters remove.
10 - Unscrew oil lines (4) to oil cooler from transmission.
11 - Remove cover in oil pan (18) and disconnect torque converter from driven plate at flange.
12 - Unscrew bolts of transmission (19) at crankcase and take out transmission downwards at an angle
using a lifting device. NOTE: Code radio, set clock, normalize power windows and set timer in vehicles
with stationary heater.
NOTE: Adjust shift rod using pliers. See Fig. 10
.
NOTE: If the transmission fluid is burnt or contains wear particles, the oil cooler
lines and oil cooler must be flushed out: Flush oil cooler and oil cooler
lines.
NOTE: Only up to A145272,X708318. For installation and removal, position
selector lever or range selector lever in position "P" and leave in position
"P" when cable/transmission is removed. See REMOVING & INSTALLING
WIRE CABLE/TRANSMISSION FOR PARKING SHIFT LOCK ON
TRANSMISSION.
NOTE: Only up to A145272, X708318.
Upon Installation: Adjust cables for parking shift lock. See ADJUSTING
WIRE CABLES FOR PARKING LOCK INTERLOCK.
NOTE: Upon Installation: Check function of parking shift lock.
2001 Mercedes-Benz ML320
1998-03 AUTOMATIC TRANSMISSIONS Complete Transmissions - ML 320 - 722.662
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Page 1780 of 4133
Fig. 188: Identifying Air Conditioning System Hose And Clip
Remove/Install
1Remove upper frame cross
member AR62.30-P-2300GH
2Drain the washer fluid
reservoir Manual pumpFig. 189
3Disconnect connectors
and hoses from pumps (5)Loosen wiring harness
from the side of the
washer fluid reservoir. If
fitted, disconnect plug
from washer fluid level
indicator switch.
4Unscrew bolt (2)
5Loosen air conditioning
hose (3) from clip (4)
6.1Remove covers and
locking clips from fuse
and relay module Only Model 163.128.
7Detach cooling module
(10) from lower grommets
8Remove washer fluid
reservoir (1) Loosen washer fluid
reservoir (1)from lower
grommets (6). Lift up
2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
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Page 2071 of 4133
1
Open cooling system cap (2) on coolant
expansion reservoir (1)
Cap with detent:
Turn cap carefully as far as the first detent,
release pressure, and then unscrew cap.
2-stage and 1-stage cap: Rotate cap half
a revolution in a counterclockwise direction,
release overpressure, then unscrew cap.
2.1Remove engine compartment paneling
Models 129, 202, 208, 210
AR61.20-P-1105AB
Models 163.172/ 174/ 175
AR61.20-P-1105GH
Models 163.113/ 128
AR94.30-P-5400GH
Model 211
AR61.20-P-1105T
Models 215, 220
AR61.20-P-1105M
Model 230
AR61.20-P-1105R
2.2Remove underride guard
Only on model 463
3.1
Remove air guide
Only on model 163 with engine 113.942
4
Drain coolant
Model 163: For draining coolant, detach
bottom coolant line at radiator or at coolant
pump.
Collect coolant Observe regulations for
disposal of coolant.
Installation:
On model 163 replace
radiator connection of hose clamps to coolant
hose, otherwise this can cause a damage to
the bolt/thread.
Hose clamp
*BA20.20-P-1004-01A
Pouring in
5
Pour in coolant
All except engine 137
*BF20.00-P-1001-02K
Engine 137
*BF20.00-P-1001-02M
Notes on coolant level
Engines 112, 113, 137, 275, 285
AH20.00-P-1142-01V
Notes on coolant level
Model 163 with engines 111, 112, 113
AH20.00-P-1142-01GH
6
Bleed cooling system
Let engine run, put heater on full heat
output.
Except stationary heater, code 228
AR20.00-P-1142-06GA
With stationary heater code 228
7
Inspect cooling system for leaks
AR20.00-P-1010HA
Radiator, coolant hoses
Number
Designation
Engines
112.942/
970,
113.942/
965/981
BA20.20-P-1004-01A
Hose clamp
Nm
3
Designation
Engines
112.910 /920
in model 202,
112.940
in model 208
Engines
112.911/921/941
in model 210
Engines
112.922/944/972
in model 220
BF20.00-P-1001-02K
Cooling system
Total capacity
Liters
Y
9.5
Y
10.0
Y
10.5
Capacity of
anticorrosion/antifreeze agent
down to -37°C
Liters
Y
4.75
Y
5.0
Y
5.0
Capacity of anticorrosion/
antifreeze agent down
to -45°C
Liters
Y
5.25
Y
5.5
Y
5.5
Specifications for Operating
Fluids
SheetBB00.40-P-0310-01ABB00.40-P-0310-01ABB00.40-P-0310-01A
SheetBB00.40-P-0325-00ABB00.40-P-0325-00ABB00.40-P-0325-00A
Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2
Page 2086 of 4133
P01.30-0299-06
20
Bolts cylinder head
!
timing case cover
21
Cylinder head bolts
22
Cylinder head left
23
Cylinder head right
24
Left cylinder head gasket
25
Right cylinder head gasket
26
Dowel sleeves
Remove/Install
Notes on self-locking nuts and bolts
All models
AH00.00-N-0001-01A
External torx set
*001589760900
Torx bit set
*000589011000
Danger!
Risk of explosion
caused by oxyhydrogen
gas.
Risk of poisoning and caustic burns
caused by swallowing battery acid.
Risk of
injury caused by burns to skin and eyes from
battery acid or when handling damaged lead-
acid batteries
No fire, sparks, open flames or smoking.
Wear acid-resistant gloves, clothing and
safety glasses. Pour battery acid only into
suitable and appropriately marked containers.
AS54.10-Z-0001-01A
1
Disconnect battery ground cable
Installation:
After connecting, read out
fault memory, encode radio and normalize
power windows.
Vehicles with stationary heater: Set time on
timer for stationary heater
AR54.10-P-0003A
Notes on battery
All models
AH54.10-P-0001-01A
Danger!
Risk of death
caused by vehicle slipping or
toppling off of the lifting platform.
Align vehicle between the columns of the
hydraulic hoist and position the four support
plates below the hoist support points specified
by the vehicle manufacturer.
AS00.00-Z-0010-01A
2
Place the vehicle on lifting platform
AR00.60-P-1000GH
3.1
Remove air guide (1)
Only with engine 113.942
Danger!
Risk of injury
to skin and eyes suffering
scalding from contact with hot coolant spray.
Risk of poisoning
from swallowing coolant.
Do not open cooling system unless coolant
temperature is below 90 °C. Open cap slowly
and release the pressure. Do not pour coolant
into beverage bottles.
Wear protective gloves, protective clothing
and eye protection.
AS20.00-Z-0001-01A
4
Drain coolant
Remove coolant hose at bottom on
radiator.
AR20.00-P-1142HA
5
Remove engine cover
6.1
Remove viscous fan (2)
All except model 163.174 /175 with
engine 113.981 /965.
Right-hand thread!
AR20.40-P-5660C
7.1
Remove the fan shroud (3).
Only model 163.154 /157 /172. Unscrew
bolts (4) from bottom of fan shroud
7.2
Remove electric fan
Only model 163.174/ 175.
AR20.40-P-5000GH
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
Page 2094 of 4133
P01.30-0299-06
20
Bolts cylinder head
!
timing case cover
21
Cylinder head bolts
22
Cylinder head left
23
Cylinder head right
24
Left cylinder head gasket
25
Right cylinder head gasket
26
Dowel sleeves
Remove/Install
Notes on self-locking nuts and bolts
All models
AH00.00-N-0001-01A
External torx set
*001589760900
Torx bit set
*000589011000
Danger!
Risk of explosion
caused by oxyhydrogen
gas.
Risk of poisoning and caustic burns
caused by swallowing battery acid.
Risk of
injury caused by burns to skin and eyes from
battery acid or when handling damaged lead-
acid batteries
No fire, sparks, open flames or smoking.
Wear acid-resistant gloves, clothing and
safety glasses. Pour battery acid only into
suitable and appropriately marked containers.
AS54.10-Z-0001-01A
1
Disconnect battery ground cable
Installation:
After connecting, read out
fault memory, encode radio and normalize
power windows.
Vehicles with stationary heater: Set time on
timer for stationary heater
AR54.10-P-0003A
Notes on battery
All models
AH54.10-P-0001-01A
Danger!
Risk of death
caused by vehicle slipping or
toppling off of the lifting platform.
Align vehicle between the columns of the
hydraulic hoist and position the four support
plates below the hoist support points specified
by the vehicle manufacturer.
AS00.00-Z-0010-01A
2
Place the vehicle on lifting platform
AR00.60-P-1000GH
3.1
Remove air guide (1)
Only with engine 113.942
Danger!
Risk of injury
to skin and eyes suffering
scalding from contact with hot coolant spray.
Risk of poisoning
from swallowing coolant.
Do not open cooling system unless coolant
temperature is below 90 °C. Open cap slowly
and release the pressure. Do not pour coolant
into beverage bottles.
Wear protective gloves, protective clothing
and eye protection.
AS20.00-Z-0001-01A
4
Drain coolant
Remove coolant hose at bottom on
radiator.
AR20.00-P-1142HA
5
Remove engine cover
6.1
Remove viscous fan (2)
All except model 163.174 /175 with
engine 113.981 /965.
Right-hand thread!
AR20.40-P-5660C
7.1
Remove the fan shroud (3).
Only model 163.154 /157 /172. Unscrew
bolts (4) from bottom of fan shroud
7.2
Remove electric fan
Only model 163.174/ 175.
AR20.40-P-5000GH
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
Page 2288 of 4133
Oil pan
Oil pan
Model 220 except 220.074 /174
with engine 113
Do not remove top part of oil
pan!
Model 463AR01.40-P-8000GV
Do not remove top part of oil
pan!
Model 210 with 4MATICAR01.40-P-8000GV
Models
203.061 /064 /065 /081 /084 /261/
264 /265 /281 /284 /076 /276AR01.40-P-8000V
Models 209.361/365/ 375/ 376/
461/ 465/ 475/ 476AR01.40-P-8000PV
Models 211.061 / 065/ 070/ 080/
082/ 083/ 280/ 282/ 283
Models 220.074/174AR01.40-P-8000RVK
Model 215.374
Model 203.764
Models 210.062/262
Models 215.373/375
8Remove slide rails (1) At the same time detach slide
rails (1) toward front from the
retaining bolts.
9Install in the reverse
order
NumberDesignationEngines
112.910/911/
912/913/914/
915/917/920/
921/922/923/
940/941/942/
943/944/945/
946/947/949/
951/954/955/
960/961/970/
972/973/976Engines
113.940/941/
942/943/944/
945/946/960/
961/962/963/
965/967/968/
969/980/981/
982/984/986/
992/995
BA01.45-P-1003-
01BOil drain screw
to oil panM14Nm3030
NumberDesignationEngine
112.916/953/975, Engine 113.987/
988/991
2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
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Page 2409 of 4133
swallowing battery
acid. Risk of injury
caused by burns to
skin and eyes from
battery acid or when
handling damaged
lead-acid batteries
3Disconnect battery
ground cable The battery is located in the right of the
engine compartment.AR54.10-P-
0003A
Notes on batteryAll modelsAH54.10-P-0001-
01A
Installation: After connecting, read out
fault memory, encode radio and normalize
power windows.Vehicles with
stationary heater:
adjust time
display on
stationary heater.
4.1Remove air guide
(23) Engine 113.942 only.
Risk of injury to
skin and eyes caused
by scalding from
contact with hot
coolant spray. Risk
of poisoning caused
by swallowing
coolant.Do not open cooling system unless coolant
temperature is below 90° C. Open cap slowly
and release the pressure. Do not pour coolant
into beverage containers.
Wear protective gloves, pr otective clothing and
safety glasses.AS20.00-Z-0001-
01A
5Drain coolant from
radiator Remove coolant pump line --> (16) from
coolant pump.AR20.00-P-
1142HA
6Drain and collect
engine oil *BA01.45-P-
1003-01B
*BF18.00-P-
1001-01H
7.1Remove viscous fan
(1)All except model 163.174 with engine 113.981
and 163.175 with engine 113.965.
Right-hand thread!AR20.40-P-
5660C
8.1Remove fan shroud
(2). Unscrew bolts at bottom of fan shroud
8.2Remove electric fan Only model 163.174 with engine 113.981
and 163.175 with engine 113.965.AR20.40-P-
5000GH
9Attach guard plate
for radiator /
condenser
Guard plate for
radiator / condenserEngine 606 in MODEL 124,
Engine 606.961 in MODEL 140,
Engine 112, 113, 604, 605, 611.960 in MODEL WF58.50-P-0110-
01A
2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 53 © 2006 Mitchell Repair Information Company, LLC.
Page 2490 of 4133
Shown on engine 112
Fig. 108: Identifying Bottom Part Of Oil Pan Remove/Install Components
- Shown On Engine 112
Remove/install
External torx setFig. 49
1Remove engine trim panel
2Remove viscous fan (4) Right-hand thread!AR20.40-P-5660C
3.1Remove fan shroud (5) Only engine
112.942 /970.
Unscrew bolts (8) at
bottom of fan shroud.
4.1Remove air guide (9) Engine 113.942 only.
5Drain and collect engine oil *BA01.45-P-1003-01B
*BF18.00-P-1001-01H
6Unscrew nuts (7) at front
suspension carrier Before unbolting the
left engine mount, press
oil line of power steering
out of fixture.
*BA22.10-P-1001-01L
7Remove resonance tube (3)
with resonance unit (2) Do not damage the
plastic strap.
The resonance pipe is
attached at the rear at the
2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 134 © 2006 Mitchell Repair Information Company, LLC.
Page 2492 of 4133
Engine mounts, engine supports
Engine lubrication
NumberDesignation
951/954/955/
960/961/970/
972/973/976969/980/981/
982/984/986/
992/995
BA01.45-P-
1002-01BSelf-tapping
screw of oil pan
to oil panThread not
pretappedNm1414
Thread pre-
tappedNm1010
BA01.45-P-
1003-01BOil drain screw
to oil panM14Nm3030
NumberDesignation
Engine
112.942/970
113.942/965/981
in model
163.154/157/17
2/174/175
BA22.10-P-1001-01LBolt, front engine mounts
to front axle carrierNm35
NumberDesignation
Engine
112
except
112.916/953/975Engines
113.940/941/
942/943/960/
961/962/969/
982
BF18.00-P-1001-
01HEngine
oil
Filling capacity with oil filterLiters8.08.0
Filling capacity without oil
filterLiters7.5-
Specifications for Operating
Fluids
SheetBB00.40-P-0229-
01A
BB00.40-P-0229-
01A
SheetBB00.40-P-0229-
03A
BB00.40-P-0229-
03A
SheetBB00.40-P-0229-
05A
BB00.40-P-0229-
05A
2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 136 © 2006 Mitchell Repair Information Company, LLC.
Page 2495 of 4133
Engine mounts, engine supports
Engine lubrication
Fig. 111: Identifying External Torx Set (001 589 76 09 00)
NumberDesignation
965/967/968/
969/980/981/
982/984/986/
992/995
BA01.45-P-1002-
01BSelf-tapping screw
of oil pan to oil panThread not pre-
tappedNm14
Thread pre-tappedNm10
BA01.45-P-1003-
01BOil drain screw to
oil panM14Nm30
NumberDesignation
Engine
112.942/970
113.942/965/981
in model
163.154/157/17
2/174/17 5
BA22.10-P-1001-01LBolt, front engine mounts
to front axle carrierNm35
NumberDesignation
Engine
113.944/980/981
/984/986/991Engine
113.963/
963/965
BF18.00-P-
1001-01HEngine oilFilling capacity
with oil filterLiters7.57.5
Filling capacity
without oil filterLiters-7.0
Specifications
for Operating
FluidsSheetBB00.40-P-
0229-01A
BB00.40-P-
0229-01A
SheetBB00.40-P-
0229-03A
BB00.40-P-
0229-03A
SheetBB00.40-P-
0229-05A
BB00.40-P-
0229-05A
2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 139 © 2006 Mitchell Repair Information Company, LLC.