Mercedes-Benz ML320. Manual — part 643

SM63.20-P-0003GI

Reinforce right front engine hood hinge support

16.1.02

MODELS 163.136 /154 /172 #A as of 145273,
163.136 /154 /172 #X as of 708319,
163.113 /128 /174 /175

P63.20-3439-12

The template shown is for the left side
(turn over for the right side)

6

Template

7

Hole, hinge assembly bolt, rear

8

Hole, hinge assembly bolt, front

9

Center punch position

10

Center punch position

11

Center punch position

a

80 mm

b

100 mm

P63.20-3435-06

1

Hinge assembly bolt, front

2

Hinge assembly bolt, rear

3

Center punch mark

4

Center punch mark

5

Center punch mark

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

Range

Op. no.

Operation text

Time

Acc. no.

Code

P

023540

REINFORCE LEFT ENGINE HOOD HINGE SUPPORT

037 WU/3.1 hrs.

88 237 36

---

P

023541

REINFORCE RIGHT ENGINE HOOD HINGE SUPPORT

040 WU/3.3 hrs.

88 237 36

---

P

023542

REINFORCE (BOTH) ENGINE HOOD HINGE SUPPORTS

053 WU/4.4 hrs.

88 237 36

---

Remove/install

1

Ensure that the recirculated air function is
deactivated

2

Remove engine hood

AR88.40-P-3000GH

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

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3

Remove engine hood hinge on the front
passenger side

AR88.40-P-3060GH

*BR00.45-Z-1004-01A

Danger!

Risk of explosion from explosive gas. Risk
of poisoning and caustic burns from
swallowing battery electrolyte. Risk of injury
through burns to skin and eyes from battery
acid or when handling damaged lead-acid
batteries

No fire, sparks, naked flames or smoking.
Wear protective gloves, acid-resistant
clothing and safety glasses. Pour battery
electrolyte only into suitable and appropriately
marked containers.

AS54.10-Z-0001-01A

4

Remove battery

AR54.10-P-0005GH

5

Remove air conditioning blower motor

AR83.30-P-5560GH

6

Print out template (6) and adapt the size to
the correct dimensions (a, b)

Determine ACTUAL dimension (a) from the
drawing.

Divide the SPECIFIED dimension (a) by the
determined ACTUAL dimension (a) and copy
the template to the original size with the
corresponding factor.

Check dimensions for both axles.

7

Cut out template

8

Cut out holes (7, 8) for engine hood hinge
studs

9

Position template in the engine hood hinge
support using the stud holes

The template is drawn for the left side.

Turn over to obtain the right side.

10

Center the engine hood hinge support on the
template using the markings (9, 10, 11)

11

Remove template

12

Drill a hole at each center punch mark (3, 4, 5)

Only drill through the 2 upper panels. Do

not drill through the reinforcement panel (3rd
panel).

*201589005100

13

Cover windshield, paint surface and adjacent
components adequately in order to avoid
damage due to welding work

Cover apertures in the body in order to

prevent flying sparks: the foam in the
instrument panel burns easily.

c

General information on repairs to body

AH60.00-N-0001-01A

Danger!

The high voltage used for arc welding
presents a lethal hazard. Explosion hazard
when welding in area of materials easily
inflammable. Injury hazard from welding
spatter and UV-light while welding. Risk of
poisoning when inhaling welding vapors.

Use insulating mats. Wear protective clothing,
safety glasses, and protective mask. Remove
highly inflammable materials from the danger
zone. Use air extractor.

AS00.00-Z-0007-01A

14

Plug weld each hole

*WE58.40-Z-1005-02A

15

Plug welds should be flat and ground smooth

16

Remove covers and clean the repair area

17

Prime untreated points in the area of the
engine hood hinge support

18

Prime the underside of the reinforcement
panel of the engine hood hinge

Access to underside of engine hood hinge

support through the recess for the wiper motor.

19

Spray the underside of the reinforcement
panel of the engine hood hinge support with
wax preservative

Access to underside of engine hood hinge

support through the recess for the wiper motor.

20

Install in the reverse order

Weld spot miller

201 589 00 51 00

Workshop equipment/MB testers (see Workshop Equipment Manual)

WE58.40-Z-1005-02A

MIG inert gas welding equipment, aluminum weldable, sold by company Wieländer & Schill

Repair products

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

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Number

Designation

Order number

BR00.45-Z-1004-01A

MB body sealant for sealing seams (suitable for painting)

001 989 63 20

Parts ordering notes

Part no.

Designation

Quantity

000 986 06 50

Priming stick

1

000 986 33 70 10

Wax preservative

1

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

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AR88.40-P-3200GI

Remove/install engine hood lock

9.4.99

MODEL

163.136 /154 /172 #A as of 145273,

163.136 /154 /172 #X as of 708319,
163.113 /128 /157 /174 /175

P88.40-2058-06

1

Screws

2

Engine hood lock bottom section

3

Engine hood control cable

4

Electrical connector

5

Screws

6

Engine hood lock top section

Removing and installing

1

Open engine hood and raise to vertical position

AR88.40-P-1000GI

2

Unscrew screws (1) and remove engine hood
lock bottom section (2) upward

*BA88.40-P-1003-01C

3.1

Disconnect electrical connector (4) from
engine hood lock bottom section (2)

Only when equipped with ATA.

4

Unhook engine hood control cable (3) from
engine hood lock bottom section (2)

Pull out engine hood control cable slightly.

5

Remove engine hood lock bottom
section (2)

Installation: Ensure that engine hood

control cable is routed carefully.

6

Unscrew screws (5) and remove engine hood
lock top section (6)

Mark installation position for engine hood

lock top section on engine hood.

*BA88.40-P-1004-01C

7

Install in the reverse order

8

Check alignment of engine hood

If necessary:

#

Adjust engine hood

AR88.40-P-3020GH

9

Lubricate engine hood lock

e

Lubricate hood lock, safety hook and hinges

AP88.40-P-8821GH

10

Perform function check

11

Check function of safety hook

For this purpose, close engine hood,

unlock and check arrest on radiator cross
member.

Engine hood

Number

Designation

Model 163

BA88.40-P-1003-01C

Screw for engine hood lock on radiator cross
member

Nm

12

BA88.40-P-1004-01C

Screw for engine hood lock top section on engine
hood

Nm

12

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

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