fuel cap MERCEDES-BENZ ML320 1997 Complete Service Manual

1.1
Unscrew bolts at rear of 2/3 seat bench and

raise rear of seat bench

Up to VIN A145272, X708318.

1.2
Remove covers at seat frame of 60% bench

seat

As of VIN A145273, X708319.

AR91.12-P-1100GH

Only remove the covers which are
identified in the document with A, D and E.

2.1
Fold 60% bench seat forward into footwell

As of VIN A145273, X708319. See

operator's manual.

3.1
Pull floor covering below rear seat mounting

bracket (1) of 60% seat forward

Carefully pull floor covering forward under

the seat console to prevent it from tearing.

As of VIN A145273, X708319.

4.1
Pull the floor covering forward under the front

corner of the left C-pillar cover (2)

Carefully pull the floor covering forward

under the cover to prevent it from tearing.

As of VIN A145273, X708319.

5
Cut into floor covering directly behind seat

retaining cable (3)

Ensure that the wiring harness (4) is not

damaged when cutting the floor covering.

As of VIN A145273, X708319. Broken

line marks the cut.

6
Fold floor mat back

Do not crease floor mat!

Fold floor mat back far enough to provide

access to cap (84) between body and fuel

pump.

7
Remove end cover (84) of body


Installation:
Replace cap and insert with

new sealing compound.


Cap (84) is sealed in with body sealer.

Heat with hot air blower to make it easier to

remove.

8
Seal fuel return line (90/11)

Pliers

*163589003700

9
Connect extraction hose (90/14) with adapter
hose to connection for fuel return line (90/11)

Extraction hose

*168589009000


Adapter hose

*163589009100

10
Connect ground cable (90/10) of extraction

pump ground terminal vehicle battery

Pumping out

11
Pump fuel out into safety container using

extraction pump


*BF47.10-P-1001-01A


*WH58.30-Z-1001-16A

12
Install in the reverse order


Fuel tank

Number

Designation
Models

163.113/
136/154/

172 up to

31.08.01
Models

163.113/
136/154/

172 as of

01.09.01


Models

163.157/

175
Model

163.128
Model

163.174

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liter
72838393

Reserve capacity
Liter
10121212

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Page 2

AP18.00-P-0101AR
Engine - oil and filter change
20.1.99

ENGINE
612

Modification notes

12.9.02

Engine oil level modified
Step 9:

Only Model 203:

Up to engine end number: 134 163 oil level
MAX. 135
mm,
MIN 110
mm.

As of engine end number: 134 164 oil level

MAX. 124,5
mm,
MIN 99,5
mm.


Remove

Danger!

Risk of death
cased 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


Danger!

Risk of accident
caused by vehicle starting

off by itself when engine is running.
Risk of

injury
caused by contusions and burns when

working in engine during starting procedure
Secure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.

Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A


Change the engine oil only when the engine

is at operating temperature

1
Remove trim panel of cylinder head cover

AR01.20-P-5014-02B

2
Replace oil filter element, drain oil filter

Model 203: Remove clamp attaching fuel

line in order to insert wrench socket.

AP18.00-P-0101-06EG

*BA18.20-P-1002-01G

Socket wrench bit

*103589020900

3.1
Suction off engine oil

AP18.00-P-0101-02Z
4.1
Remove rear left frame cross brace

Only necessary when draining engine oil

at oil drain plug.

MODEL 163

f

Model 203 except 203.018/218/718, 209
AR94.30-P-5300P

Model 210

AR94.30-P-5300AB

4.2
Detach lower engine compartment paneling

Only necessary when draining engine oil

at oil drain plug.

f

Only Model 203.018/218/718

AR61.20-P-1105P

5.1
Unscrew oil drain plug, drain engine oil


Install

6.1
Screw in oil drain plug

Replace sealing ring, in order to avoid

leakage.


*BA01.45-P-1003-01A

7
Pour in engine oil
Note specified and approved quality

grades and viscosity classes conforming to

SAE at enduring ambient temperatures.

*BE18.00-P-1001-02B


*BF18.00-P-1001-01A

g

Viscosity classes of engine oils (car engines)
Sheet 224.1

BB00.40-P-0224-01A

8
Run engine and inspect for leaks

9
Switch off engine

10.1
Fit on bottom part of noise encapsulation

Only necessary when draining engine oil

at oil drain plug.

f

Model 210

AR94.30-P-5300AB

MODEL 203, 209

AR94.30-P-5300P

MODEL 163

10.2
Install lower engine compartment paneling.

Only necessary when draining engine oil

at oil drain plug.

f

Only Model 203.018/218/718

AR61.20-P-1105P

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d by Modification services.
Page 1

AR07.16-P-1100MM
Remove, install fuel cooler
5.11.99

ENGINE
612.963 in MODELS 163.113

P47.00-2042-12

1
Fuel feed hose

2
Fuel drain hose

3
Coolant feed hose

4
Coolant return flow hose

5
Fuel cooler

7
Bolts of fuel cooler

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

Op. no.
Operation text

P
075890
REMOVING AND INSTALLING FUEL COOLER

P
075895
REPLACE FUEL COOLER


Remove, Install


Danger!
Risk of injury
to
fingers being jammed or

squeezed
when removing and installing or

aligning hoods, doors, tailgate/tailgate and

sliding roof.
When moving components ensure that no

body parts or limbs are in the area of motion.

AS00.00-Z-0011-01A


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


Danger!
Risk of explosion
from fuel igniting,
risk of

poisoning
from inhaling and swallowing fuel

as well as
risk of injury
to eyes and skin

from contact with fuel.
No fire, sparks, naked flames or smoking.

Pour fuels only into suitable and appropriately

marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1
Open engine hood and raise to vertical position


Have second person secure hood.

AR88.40-P-1000GI

2
Remove trim panel of cylinder head cover

AR01.20-P-5014-02B


*BA01.20-P-1002-01A
*BA01.20-P-1003-01A

3
Drain coolant

At radiator.

AR20.00-P-1142M

4
Close fuel feed hose (1) at the fuel cooler (5)

Set of plugs

*129589009100

*WH58.30-Z-1001-06A
*WH58.30-Z-1002-06A

5
Detach fuel outlet hose (2)

Clamp

*000589543700

Set of plugs

*129589009100

*WH58.30-Z-1001-06A
*WH58.30-Z-1002-06A

6
Disconnect coolant return flow hose (4) to

thermostat housing

Hose clamp pliers (length 210 mm;

adjustment range 80 mm)

*WH58.30-Z-1026-02A

7
Unscrew bolts (7) at fuel cooler

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d by Modification services.
Page 1

8
Disconnect coolant feed hose (3) to fuel cooler

Raise fuel cooler.

Hose clamp pliers (length 210 mm;

adjustment range 80 mm)

*WH58.30-Z-1026-02A

9
Install in the reverse order


Danger!
Risk of accident
as vehicle may start off by

itself with the engine running.
Risk of injury


as working around the engine during start-up

or while running may result in contusions and

burns
Secure vehicle to prevent it from moving off

by itself.

Wear closed and tight-fitting work clothes.

Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

10
Pour in coolant
*BF20.00-P-1001-02E

Switch heater to maximum and warm up

engine at moderate revs. Top up coolant

constantly at coolant expansion reservoir.

Close coolant expansion reservoir once

coolant temperature is 60-70 °C.


Note on coolant level
Models 124, 129, 140, 168, 170, 202, 208,

210, 220, 463

AH20.00-P-1142-01A

11
Inspect cooling system for leaks

AR20.00-P-1010HA

12
Run engine and inspect fuel system for leaks

Crankcase ventilation, cylinder head cover

Number

Designation
Engine

612.963

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

to cylinder head cover
NM
10

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

distribution pipe
NM
10


Cooling system

Number

Designation
Engine

612.963

BF20.00-P-1001-02E
Cooling system
Total capacity
Liter
Y
11,0

Capacity of anticorrosion/

antifreeze agent down to -37 °C
Liter
Y
5,5

Capacity of anticorrosion/

antifreeze agent down to -45 °C
Liter
Y
6,25

Specifications for Service

Products
SheetBB00.40-P-0310-01A
SheetBB00.40-P-0325-02A

129 589 00 91 00

Set of closure plugs

Circuit

000 589 54 37 00

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e.g.) g.)
Order number

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d by Modification services.
Page 2

AP47.20-P-0780BB
Replace fuel filter
2.3.99

ENGINE
611.960 in MODEL 202.133 /134 /193 /194

ENGINE
611.961 in MODEL 210.006 /007 /206 /606

ENGINE
612.961 in MODEL 210.016 /216 /616

ENGINE
612.963 in MODEL 163.113

ENGINE
613.961 in MODEL 210.026 /226

ENGINE
613.960 in MODEL 220.026 /126

P47.20-0289-01

Shown on engine 611.960

70
Fuel filter housing

70/1
Fuel filter input

70/2
Fuel filter output

70/3
Threaded ring

70/4
Cap

70/5
Seal

70/6
Filter element

P07.16-2101-01

Shown on engine 612.961

70/1
Fuel line input

70/2
Fuel line output

70/3
Threaded ring

70/4
Cap

70/5
Seal

70/6
Filter element

70/7
Fuel return line

70/8
Fuel feed line


Remove/install and replacing


Danger!
Risk of death.
Death may result if vehicle

slips or topples from the lifting platform.
Align vehicle between the columns of the

lifting platform and position the four support

plates
at the lifting platform support points

specified by the vehicle manufacturer.

AS00.00-Z-0010-01A


Danger!
Risk of explosion
from fuel igniting,
risk of

poisoning
from inhaling and swallowing fuel

as well as
risk of injury
to eyes and skin

from contact with fuel.
No fire, sparks, naked flames or smoking.

Pour fuels only into suitable and appropriately

marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1
Remove trim panel of charge air distribution

pipe

2
Disconnect fuel return line (70/7) and fuel

feed line (70/8 )

3
Unscrew threaded ring (70/3) and remove

together with cover (70/4).

If the fuel filter housing is soiled inside,
it must be removed and cleaned (against
separate order):

#
f

Remove/install fuel full-flow filter

AR47.20-P-1070HB

4
Replace filter insert (70/6)

After inserting the filter element

Fill fuel filter housing with fuel.

5
Replace sealing ring (70/5)

6
Mount threaded ring with cover so that the

groove latches at the fuel filter housing

Tighten threaded ring by hand.

7
Mount fuel return line (70/7) and fuel feed line

(70/8 )

8
Install trim panel of charge air distribution pipe


*BA01.20-P-1003-01A


Danger!
Risk of accident.
Accidents may result if the

vehicle starts off unintentionally with the

engine running.
Risk of injury.
Crushing and

burn injuries may result while working on

engine during when it is being started or when

it is in operation.
Secure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.

Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

9
Run engine and inspect fuel filter for leaks

Crankcase ventilation, cylinder head cover

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Page 1

2.1
Disconnect fuel lines (1,2) at main fuel filter

(70)
Engine 611


Collect escaping fuel.

Pay attention to use of locking arm. Refer

to:

#

Separate fuel lines from engine, reconnect

AR47.25-P-1000-01A

2.2
Disconnect fuel lines (1,2,3,4) at main fuel

filter (70)
Engine 612, 613


Collect escaping fuel.

Pay attention to use of locking arm. Refer

to:

#

Disconnect, connect fuel lines at engine.

AR47.25-P-1000-01A

3
Remove main fuel filter (70)


If the main fuel filter has been emptied, it

must be filled with fuel after being installed

before starting, the engine starts more easily.

*BA47.20-P-1001-02A

4
Install in the reverse order


Danger!

Risk of accident
due to automatic starting-off

when engine is running.
Injury hazard
due to

crimped connection and combustion when

meshing during starting procedure or when

engine is running
Secure vehicle to prevent it from moving off

by itself.

Wear closed and close-fitting work clothes.

Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

5
Run engine and inspect fuel system for leaks

Crankcase ventilation, cylinder head cover

Number

Designation
Engine

611.960/

961/962
Engine

612.961/

962/967
Engine

612.963
Engine

613.960/

961

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

distribution pipe
Nm
10101010


Fuel filter

Number

Designation
Engine

611.960/

961
Engine

611.962
Engine

612.961/

963
Engine

613.960/

961

BA47.20-P-1001-02A
Bolt of fuel filter to charge air distribution pipe
Nm
14141414

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Page 2

AR47.10-P-7000GI
Remove/install fuel level sensor
21.2.01

MODEL
163.113 with ENGINE 612.963

MODEL
163.128 with ENGINE 628.963

P47.10-2128-06

1
Rear seat console

2
Left C-pillar cover

4
Wiring harness

5
Seat retaining cable

P47.10-2083-09

3
Housing

84
Closing cover

89
Union nut

6
Seal

90/10
Fuel intake line
90/11

Fuel-return line

90/12
Fuel feed line

90/13
Stationary heater connection

B4
Fuel level gage sensor


Remove, Install

Danger!

Risk of explosion
from fuel igniting,
risk of

poisoning
from inhaling and swallowing fuel

as well as
risk of injury
to eyes and skin

from contact with fuel.
Fire, sparks, naked flame and smoking

prohibited.

Pour fuels only into suitable and appropriately

marked containers

Wear protective clothing when handling fuel

AS47.00-Z-0001-01A

1
Drain fuel

Fuel tank must not be filled to more than

3/4. If fuel tank is full, drain at least

23 liters of fuel.

AR47.10-P-4000GH

Pay attention to filling capacity of fuel tank.

*BF47.10-P-1001-01A

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Page 1

2
Remove covers at seat frame of 60% bench

seat

As of VIN A145273, X708319.

AR91.12-P-1100GH

Only remove the covers which are
identified in the document with A, D and E.

3
Fold 60% bench seat forward into footwell

As of VIN A145273, X708319. See

operator's manual.

4
Pull floor covering below rear seat mounting

bracket (1) of 60% seat forward

Ensure that the floor covering is not torn

when pulled forward.

As of VIN A145273, X708319.

5
Pull floor covering below front corner of trim

panel of C-pillar (2) forward

Ensure that the floor covering is not torn

when pulled forward.

As of VIN A145273, X708319.

6
Cut into floor covering directly behind seat

retaining cable (5)

Ensure that the wiring harness (4) is not

damaged when cutting into floor covering.

As of VIN A145273, X708319. broken line

marks cut-in.

7
Turn back floor covering to gain access to

cap (84)


Do not kink floor covering.

8
Remove cap (84)


Cap (84) is sealed in with body sealer.

Heat with hot air blower to make it easier to

remove.


Installation:
Replace cap and install with

new sealing compound.

9
Detach fuel feed line (90/12) and fuel return

line (90/11) and, if fitted, the fuel line at

connection (90/13)


Do not kink the fuel lines.


If no stationary heater is fitted to vehicle,

do not remove connection (90/13) otherwise

housing will be damaged.

*163589003700

10
Remove nut (89)

*163589010700


*BA47.20-P-1006-01B

11
Remove housing (3)

Fuel lever sensor and housing are a

single part and cannot be removed separately.


Installation:
Re-install nut (89) together

with seal (89/2).

Apply a thin film of oil to seal.

12
Install in the reverse order


Fuel pump

Number

Designation
Engine 612Engine 628

BA47.20-P-1006-01B
Union nut for fuel tank sensor on fuel

tank
Nm
6565


Fuel tank

Number

Designation
Models

163.113/
136/154/

172 up to

31.08.01
Model

163.113/
136/154/

172 as of

01.09.01


Model

163.157/

175
Model

163.128

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liter
728383

Reserve capacity
Liter
101212

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

1.1
Unscrew bolts at rear of 2/3 seat bench and

raise rear of seat bench

Up to VIN A145272, X708318.

1.2
Remove covers at seat frame of 60% bench

seat

As of VIN A145273, X708319.

AR91.12-P-1100GH

Only remove the covers which are
identified in the document with A, D and E.

2.1
Fold 60% bench seat forward into footwell

As of VIN A145273, X708319. See

operator's manual.

3.1
Pull floor covering below rear seat mounting

bracket (1) of 60% seat forward

Carefully pull floor covering forward under

the seat console to prevent it from tearing.

As of VIN A145273, X708319.

4.1
Pull the floor covering forward under the front

corner of the left C-pillar cover (2)

Carefully pull the floor covering forward

under the cover to prevent it from tearing.

As of VIN A145273, X708319.

5
Cut into floor covering directly behind seat

retaining cable (3)

Ensure that the wiring harness (4) is not

damaged when cutting the floor covering.

As of VIN A145273, X708319. Broken

line marks the cut.

6
Fold floor mat back

Do not crease floor mat!

Fold floor mat back far enough to provide

access to cap (84) between body and fuel

pump.

7
Remove end cover (84) of body


Installation:
Replace cap and insert with

new sealing compound.


Cap (84) is sealed in with body sealer.

Heat with hot air blower to make it easier to

remove.

8
Seal fuel return line (90/11)

Pliers

*163589003700

9
Connect extraction hose (90/14) with adapter
hose to connection for fuel return line (90/11)

Extraction hose

*168589009000


Adapter hose

*163589009100

10
Connect ground cable (90/10) of extraction

pump ground terminal vehicle battery

Pumping out

11
Pump fuel out into safety container using

extraction pump


*BF47.10-P-1001-01A


*WH58.30-Z-1001-16A

12
Install in the reverse order


Fuel tank

Number

Designation
Models

163.113/
136/154/

172 up to

31.08.01
Models

163.113/
136/154/

172 as of

01.09.01


Models

163.157/

175
Model

163.128
Model

163.174

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liter
72838393

Reserve capacity
Liter
10121212

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

BF47.10-P-1000-01A
Fuel tank capacity
Model 124, 129, 140, 163, 168, 170,

171, 199, 202, 203, 208, 209, 210, 211,
215, 220, 230, 240,

414, 463

i

Modification notes

26.4.04

Value modified from 87.6 Nm to 97 Nm
Value modified in series 1001 for model 199


Fuel tank

Number

Designation
Model

124.008/019/

022/028/
029/032/040/

042/052
Model

124.07/

08/09
Model

124.034/

036
Model

124 with

increased tank

capacity code

915

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liters
70729090

Reserve capacity
Liters
99
11
11.5


Fuel tank

Number

Designation
Model

124.06
Model

129
Model

140

without

code

282a or

code 308
Model

140 with code

282a
or

code 308
Model

163.113/
136/154/

172 up to

31.08.01

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liters
70801009072

Reserve capacity
Liters
1110
12.512.5
10


Fuel tank

Number

Designation
Model

163.113/
136/154/

172 as of

01.09.01


Model

163.157/

175
Model

163.128
Model

163.174
Model

168.006/

007/ 008/

009/131/

132/133
Model

168.031/

032/033

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liters
8383935454

Reserve capacity
Liters
121212
88

Designation
Model

170.43/

445/447/46
Model

170.444/

449
Model

171
Model

199
Model

202.018/020/023/

024/025/026 /
029/033/078 /
080/082/083 /

085/086/089/093

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liters
536070
87,6
62

Reserve capacity
Liters
789
10
8

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Page 1