Mercedes-Benz ML320. Manual — part 641

AR88.40-P-3020GH

Adjust engine hood

8.4.99

MODEL

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

P88.40-2067-09

1

Bolts

2

Engine hood

3

Engine hood hinge

7

Locknut

8

Nuts

4

Bolts

5

Engine hood catch upper section

6

Stop buffer

Longitudinal, height and transverse
adjustment

Danger!

Risk of injury to fingers being jammed or
pinched when Remove/install or aligning
hoods, doors, trunk lid/tailgate or sliding roof.

When moving components, ensure that no
body parts or limbs are within the operating
range of moving parts.

AS00.00-Z-0011-01A

1

Open engine hood (2)

For slight range of adjustments for
longitudinal and height adjustment

2

Loosen bolts (1) on engine hood hinge (3)
and adjust engine hood (2)

3

Tighten bolts (1)

*BA88.40-P-1001-01C

For larger range of adjustments for
longitudinal and height adjustment

4.1

Remove gas-operated strut from engine hood
(2) and put down in engine compartment

Risk of breakage. Do not remove the

retainer otherwise the preload will be lost.

AR88.40-P-3010GH

As of VIN A145273, X708319.

5

Remove cover on air intake

AR83.25-P-1405GH

6

Remove rubber cover from engine hood hinge

Installation: Replace rubber cover.

7

Cut seam sealing along engine hood hinge so
that hinge can be moved

Installation: Replace seam sealing. Paint

sealant after curing.

*BR00.45-Z-1004-01A

8

Loosen nuts (8) on engine hood hinge (3)

9

Adjust engine hood (2) so that front edges of
front fenders are flush with engine hood and
top edges are aligned

For larger range of adjustment in

longitudinal direction loosen engine hood
catch upper section (5) and tighten.

*BA88.40-P-1004-01C

10

Tighten nuts (8) for engine hood hinge (3)

*BA88.40-P-1002-01C

11.1

Install gas-operated strut

As of VIN A145273, X708319.

AR88.40-P-3010GH

12

Adjust stop buffer (6)

Unscrew locknut (7). Adjust height of stop

buffer so that top edges of front fenders and
engine hood are flush If required, place
spacer plates below engine hood catch upper
section.

13

Fasten stop buffer (6)

Tighten locknut (7).

Transverse adjustment

14

Loosen bolts (4) from engine hood catch
upper section (5)

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services.

Page 1

15

Adjust gap dimensions

Gap dimensions

*BE60.00-P-1001-01D

Feeler gage

*129589032100

16

Align engine hood catch upper section (5)
centered in longitudinal and transverse
direction to engine hood catch lower section
and tighten

*BA88.40-P-1004-01C

17

Ensure that engine hood catch catches
properly

For this purpose, close engine hood and

pull upward with a jerk.

18

Release engine hood and ensure that safety
hook catches on radiator crossmember

19

Close engine hood (2)

Test and adjustment values, gap dimensions at hoods, doors and covers

Number

Designation

Model 163

BE60.00-P-1001-01D

Gap
dimension

Engine hood to fender

Dimension "A"

mm

5.0 (

F

0.5)

Engine hood to headlamp

Dimension "R"

mm

5.0 (

F

0.5)

Engine hood to radiator grille

Dimension "O"

mm

5.0 (

F

0.5)

Radiator grill to headlamp

Dimension "N"

mm

-

Fig., see

AR60.00-P-0700-

01GH

Engine hood

Number

Designation

Model 163

BA88.40-P-1001-01C

Bolt, engine hood hinge on engine hood

Nm

10

BA88.40-P-1002-01C

Nut, engine hood hinge to body

Nm

18

BA88.40-P-1004-01C

Bolt, engine hood catch upper section to engine
hood

Nm

12

129 589 03 21 00

Feeler gage

Auxiliary repair materials

Number

Designation

Order number

BR00.45-Z-1004-01A

MB body sealant for sealing seams (suitable for painting)

001 989 63 20

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services.

Page 2

AR88.40-P-3100GH

Remove/install control cable for engine hood

5.5.00

MODEL

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

P88.40-2140-06

Illustrated up to VIN A145272, X708318

1

Clips

2

Rubber grommet

3

Engine hood control cable

Removing and installing

1

Open engine hood and raise to vertical position Up to VIN A145272, X708318.

AR88.40-P-1000GH

As of VIN A145273, X708319.

AR88.40-P-1000GI

2.1

Remove upper frame cross member

Only up to VIN A145272, X708318

AR62.30-P-2300GH

2.2

Remove engine hood lock

Only as of VIN A145273, X708319.

AR88.40-P-3200GI

3.1

Unhook engine hood control cable from clip at
bottom of radiator cross member

Only as of VIN A145273, X708319.

4

Remove cover from fuse and relay box

5 screws.

5

Unhook clips (1) from body

6

Remove left cover below instrument panel

Left hand drive vehicle.

AR68.10-P-1500GH

Vehicles with right-hand steering up to
VIN A145272, X708318.

AR68.10-P-1520GH

Vehicles with right-hand steering as of
VIN A145273, X708319.

AR68.10-P-1520GI

7

Remove paneling in left footwell

AR68.30-P-4010GH

8

Unhook engine hood control cable at side at
clip in footwell

9

Remove rubber grommet (2) from fuse and
relay box

10

Pull out engine hood control cable (3) through
firewall on engine side and remove

Installation: Ensure that engine hood

control cable is routed cleanly along fuse and
relay box.

11

Install in the reverse order

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services.

Page 1

AR88.40-P-4050R

Remove/install Mercedes star

30.3.01

MODEL

163, 203.7, 215, 230.467 /474 /475 /476 /479

P88.40-2291-11

Shown on model 230

1

Mercedes star

2

Grommets

Remove/Install

1

Remove Mercedes star (1) from engine hood
upward with long wedge (1)

Protect engine hood around Mercedes

star (1) with adhesive tape to avoid damaging
paint.

Long wedge

*115589035900

2

Remove grommets (2)

Check grommets (2) and replace if

required.

3

Install in the reverse order

Long wedge

115 589 03 59 00

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services.

Page 1