fuel filter MERCEDES-BENZ ML320 1997 Complete Repair Manual

2 Contents
Fog lamp switch
(except Canada) ........................... 92
Fog lamp switch
(Canada only) .............................. 93
Hazard warning flasher
switch ............................................ 94
Headlamp cleaning system ............ 94
Windshield wiper/washer
switch ............................................ 95
Rear window wiper/washer ........... 96
Climate control ................................. 98
Basic setting – Heater ............... 100
Basic setting –
Air conditioner ........................... 100
Special setting ............................ 101
Dust filter .................................... 102
Air recirculation ......................... 102
Rear window defroster .............. 103
Power windows ............................... 104
Rear quarter windows ................... 106
Sliding/pop-up roof ....................... 107
Skyview Top .................................... 109
Interior lighting ..............................110
Sun visors ........................................113Illuminated vanity mirrors ........... 113
Interior ............................................. 114
Storage compartments,
armrest and cup holder ............ 114
Glove box ...................................... 115
Armrest in rear bench seat ........... 117
Ashtrays ........................................... 118
Lighter .............................................. 119
Split rear seat bench ..................... 120
Easy entry/exit feature ............. 123
Rear seat head restraints ......... 124
Third row seats .............................. 126
Removable cargo floor plates ...... 129
Enlarged cargo area .......................131
Cargo tie-down rings .....................132
Hooks ...............................................133
Partition net ....................................133
Loading instructions ......................136
Cargo area cover blind ..................137
Telephone, general .........................139
Cellular telephone ..........................139
Garage door opener ....................... 140
DrivingControl and operation of
radio transmitters ..................... 146
The first 1 000 miles
(1 500 km) ................................. 147
Maintenance ................................... 147
Tele Aid ........................................... 148
Catalytic converter ........................ 160
Emission control ............................ 161
Steering lock ................................... 162
Starting and turning off
the engine .................................. 164
Automatic transmission ............... 165
Parking brake ................................. 173
Driving instructions ...................... 174
Drive sensibly – save fuel ......... 174
Drinking and driving ................. 174
Pedals ........................................... 174
Power assistance ........................ 175
Brakes .......................................... 175
Driving off ................................... 176
Parking ........................................ 176
Tires ............................................. 177

292 Fuels, coolants, lubricants etc. - capacities
Te ch n ica l
data Instruments
and controlsOperation DrivingInstrument
cluster displayPractical hints Car care Index
Fuels, coolants, lubricants etc. – capacities
Vehicle components and their respective lubricants must match. Therefore use only brands tested and recommended
by us. Please refer to the Factory Approved Service Products pamphlet, or inquire at your Mercedes-Benz Light Truck
Center.
Fuels, coolants, lubricants etc. Model Capacity
Engine with oil filter
(recommended engine oils)ML 320 / ML 430
ML 55 AMG8.5 US qt (8.0 l)
8.0 US qt (7.5 l)
Automatic transmission
(automatic transmission fluid)9.0 US qt (8.5 l)
Transfer case
(Dexron 3 or Dexron 2E)1. 6 U S q t (1. 5 l )
Rear axle
(Hypoid gear oil SAE 90, 85 W 90)1.3 US qt (1.25 l)
Front axle
(Hypoid gear oil SAE 90)1. 2 U S q t (1. 1 l )
Power steering
(MB Power steering fluid)approx. 0.65 US qt (0.6 l)
Front wheel hubs
(high temperature roller bearing grease)approx. 1.5 oz (43 g) each

301 Index
Te ch n ica l
data Instruments
and controlsOperation DrivingInstrument
cluster displayPractical hints Car careIndex Brake fluid ............................................................. 175, 294
Brake warning lamp ................................................. 219
Capacity ......................................................................293
Brake pad wear indicator .............................................225
Brake warning lamp ...................................................... 219
Brake fluid low .......................................................... 219
Brakes ....................................................173, 175, 293, 294
CCapacities
Fuels, coolants, lubricants etc. ...............................292
Cargo area ....................................................................... 131
Hooks .......................................................................... 133
Loading instructions ................................................ 136
Cargo area cover blind .................................................. 137
Cargo compartment lamp .............................................. 111
Cargo floor plates
Removable .................................................................. 129
Storage ........................................................................ 130
Cargo tie-down rings ..................................................... 132
Catalytic converter ........................................................ 160
Cellular telephone ......................................................... 139
Center console .................................................................. 20
Central locking switch .................................................... 32Central locking system .................................................... 26
Automatic central locking .........................................32
Locking and unlocking ............................................... 27
Mechanical keys ..........................................................29
Panic button .................................................................28
Remote control ............................................................26
Unlocking the liftgate ................................................. 28
Vehicle keys .................................................................24
Changing wheels ........................................................... 245
Inflating the space-saver tire ................................. 249
Charge indicator lamp .................................................. 223
CHECK ENGINE malfunction indicator lamp ............ 218
Check regularly and before a long trip ....................... 215
Checking engine oil level
Via engine oil level indicator ....................................89
Via oil dipstick .......................................................... 233
Child restraint ..............................................38, 46, 53, 65
Cleaning and care of the vehicle ................................ 278
Climate control .................................................................98
Air recirculation ........................................................102
Basic setting ...............................................................100
Defogging windows ................................................... 101
Defrosting windshield .............................................. 101
Dust filter ...................................................................102
Rear window defroster ............................................. 103
Special settings ......................................................... 101

2
Contents
Fog lamp switch (except Canada) ........................... 92
Fog lamp switch (Canada only) .............................. 93
Hazard warning flasher switch ............................................ 94
Headlamp cleaning system ............ 94
Windshield wiper/washer switch ............................................ 95
Rear window wiper/washer ........... 96
Climate control ................................. 98 Basic setting – Heater ............... 100
Basic setting –
Air conditioner ........................... 100
Special setting ............................ 101
Dust filter .................................... 102
Air recirculation ......................... 102
Rear window defroster .............. 103
Power windows ............................... 104
Rear quarter windows ................... 106
Sliding/pop-up roof ....................... 107
Skyview Top .................................... 109
Interior lighting ..............................110
Sun visors ........................................113 Illuminated vanity mirrors ........... 113
Interior ............................................. 114
Storage compartments, armrest and cup holder ............ 114
Glove box ...................................... 115
Armrest in rear bench seat ........... 117
Ashtrays ........................................... 118
Lighter .............................................. 119
Split rear seat bench ..................... 120 Easy entry/exit feature ............. 123
Rear seat head restraints ......... 124
Third row seats .............................. 126
Removable cargo floor plates ...... 129
Enlarged cargo area .......................131
Cargo tie-down rings .....................132
Hooks ...............................................133
Partition net ....................................133
Loading instructions ......................136
Cargo area cover blind ..................137
Telephone, general .........................139
Cellular telephone ..........................139
Garage door opener ....................... 140
DrivingControl and operation of radio transmitters ..................... 146
The first 1 000 miles (1 500 km) ................................. 147
Maintenance ................................... 147
Tele Aid ........................................... 148
Catalytic converter ........................ 160
Emission control ............................ 161
Steering lock ................................... 162
Starting and turning off the engine .................................. 164
Automatic transmission ............... 165
Parking brake ................................. 173
Driving instructions ...................... 174 Drive sensibly – save fuel ......... 174
Drinking and driving ................. 174
Pedals ........................................... 174
Power assistance ........................ 175
Brakes .......................................... 175
Driving off ................................... 176
Parking ........................................ 176
Tires ............................................. 177

292
Fuels, coolants, lubricants etc. - capacities
Te ch n ica l
data
Instruments
and controls Operation Driving
Instrument
cluster display Practical hints Car care Index
Fuels, coolants, lubricants etc. – capacities
Vehicle components and their respective lubricants must match. Therefore use only brands tested and recommended
by us. Please refer to the Factory Approved Service Products pamphlet, or inquire at your Mercedes-Benz Light Truck
Center.
Fuels, coolants, lubricants etc. Model Capacity
Engine with oil filter
(recommended engine oils) ML 320 / ML 430
ML 55 AMG 8.5 US qt (8.0 l)
8.0 US qt (7.5 l)
Automatic transmission
(automatic transmission fluid) 9.0 US qt (8.5 l)
Transfer case
(Dexron 3 or Dexron 2E) 1. 6 U S q t (1. 5 l )
Rear axle
(Hypoid gear oil SAE 90, 85 W 90) 1.3 US qt (1.25 l)
Front axle
(Hypoid gear oil SAE 90) 1. 2 U S q t (1. 1 l )
Power steering
(MB Power steering fluid) approx. 0.65 US qt (0.6 l)
Front wheel hubs
(high temperature roller bearing grease) approx. 1.5 oz (43 g) each

301
Index
Te ch n ica l
data
Instruments
and controls Operation Driving
Instrument
cluster display Practical hints Car care
Index
Brake fluid ............................................................. 175, 294
Brake warning lamp ................................................. 219
Capacity ......................................................................293
Brake pad wear indicator .............................................225
Brake warning lamp ...................................................... 219 Brake fluid low .......................................................... 219
Brakes ....................................................173, 175, 293, 294
CCapacities Fuels, coolants, lubricants etc. ...............................292
Cargo area ....................................................................... 131 Hooks .......................................................................... 133
Loading instructions ................................................ 136
Cargo area cover blind .................................................. 137
Cargo compartment lamp .............................................. 111
Cargo floor plates
Removable .................................................................. 129
Storage ........................................................................ 130
Cargo tie-down rings ..................................................... 132
Catalytic converter ........................................................ 160
Cellular telephone ......................................................... 139
Center console .................................................................. 20
Central locking switch .................................................... 32 Central locking system .................................................... 26
Automatic central locking .........................................32
Locking and unlocking ............................................... 27
Mechanical keys ..........................................................29
Panic button .................................................................28
Remote control ............................................................26
Unlocking the liftgate ................................................. 28
Vehicle keys .................................................................24
Changing wheels ........................................................... 245 Inflating the space-saver tire ................................. 249
Charge indicator lamp .................................................. 223
CHECK ENGINE malfunction indicator lamp ............ 218
Check regularly and before a long trip ....................... 215
Checking engine oil level Via engine oil level indicator ....................................89
Via oil dipstick .......................................................... 233
Child restraint ..............................................38, 46, 53, 65
Cleaning and care of the vehicle ................................ 278
Climate control .................................................................98 Air recirculation ........................................................102
Basic setting ...............................................................100
Defogging windows ................................................... 101
Defrosting windshield .............................................. 101
Dust filter ...................................................................102
Rear window defroster ............................................. 103
Special settings ......................................................... 101

300 Technical dataFuels, coolants, lubricants etc.
Fuels, coolants, lubricants etc.Capacities
Vehicle components and their respective
lubricants must match.Therefore use only brands tested and
approved by Mercedes-Benz.Please refer to the Factory Approved
Service Products pamphlet, or inquire at
your Mercedes-Benz Light Truck Center.
Model
Capacity
Fuels, coolants, lubricants etc.
Engine with oil filter
ML 350, ML 500
8.5 US qt (8.0 l)
Approved engine oils
Automatic transmis-
sion
9.0 US qt (8.5 l)
MB Automatic Transmission Oil
Transfer case
1.6 US qt (1.5 l)
(Dexron 3 or Dexron 2E)
Rear axle
1.3 US qt (1.25 l)
(Hypoid gear oil SAE 90, 85 W 90)
Front axle
1.2 US qt (1.1 l)
(Hypoid gear oil SAE 90)
Power steering
approx. 0.65 US qt (0.6 l)
MB Power Steering Fluid
Front wheel hubs
approx. 1.5oz (43g) each
High temperature roller bearing grease

and skin caused
by contact with
fuel
1
Remove key
from electronic
ignition switchOnly on vehicles with electronic ignition switch.
Vehicles with Keyless Go code 889: Switch off engine, remove Keyless
Go-Cards out of vehicle and store outside of the sender range.

2
Remove cover
on front side of
engine
Model 129, 211, 215, 220, 230 only
3.1
Remove engine
cover with
integrated air
filterExcept model 171.473, 203.076 /276, , 209.376 /476 from 24.4.04
The air filter is integrated in the engine cover. Remove engine cover or air
filter by pulling it vertically up and off the cylinder head covers.

3.2Remove air
filter housingModel 171.473
Model 203.076/ 276
Model 209.376/ 476 as of 24.4.04AR09.10-
P-1150AC
4
Remove hot
film mass air
flow sensor
with air intake
pipe
Engine 112.910/ 920/ 921/940/ 941/ 942/ 970
Engine 113.940AR07.07-
P-1454A
Engine 112.922 /944 /972 /973 /975
Engine 113.941/ 948/ 960/ 961/ 963/ 966AR07.07-
P-1454AA
Engine 112.912 /913 /916 /917 /946 /947 /949 /954 /953 /955
Engine 113.968 /967 /969 /987 /988 /989AR07.07-
P-1454SV
Engine 112.923 /943
Engine 113.943 /944 /980 /984AR07.07-
P-1454AG
Engine 113.942 /965/981
AR07.07-
P-
1454MV
5
Disconnect
lead line (17/2)
at the fuel
distributor
Release fuel pressure via service valve and collect fuel.

*BA07.52
P-1001-
01A
Fig. 12
6
Removing fuel
rail with
injection valvesEngine 112.910 /920 /921 /923 /940 /941 /942 /943 /970
Engine 113.940 /942 /943 /944 /961 /965 /980 /981 /984AR07.03-
P-1451A

Engine
112.912/913 /916 /917 /922 /944 /946 /947 /949 /953 /954 /955 /972 /973 /975
Engine 113.941 /948 /960 /963 /966 /967 /968 /969 /987 /988 /989AR07.03-
P-1451AA
Unscrew

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:57 PMPage 11 © 2006 Mitchell Repair Information Company, LLC.

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

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AF07.00-P-9000B
Engine runs rough, surges or does not turn over
29.4.02

ENGINE
611 in MODEL 203, 202, 210

ENGINE
612 in MODEL 163, 203, 210, 209

ENGINE
613 in MODEL 210, 220

ENGINE
628 in MODEL 163, 220, 211

ENGINE
646 in MODEL 203, 211

ENGINE
647 in MODEL 211

ENGINE
648 in MODEL 220, 211

ENGINE
668 in MODEL 168

ENGINE
612, 628 in MODEL 463

Modification notes

23.3.01

Supersedes STIP 07.16-014 dated 11.12.00

Damage code
Cause
Remedy

07 206 D5
High-pressure pump

To verify whether high pressure pump is

damaged.

#

High pressure pump of common rail

injection system is damaged mechanically.

1
Remove/install/replace high pressure

pump.

When the high pressure pump of the common

rail injection system is damaged metal chips

and/or damage to the pump drive (timing

drive) can occur due to contamination of the

injection system components.
2
Turn high pressure pump by hand with

driver.

If mechanical resistance can be felt,

perform the following tests. Clarify additional

work with ESKULAB by specifying repair work:

#
3
Check driver of high pressure pump or

mount in sprocket for damage (visual

check).

If high pressure pump is locked:
#
4
Check timing

5
Check timing drive for damage.

In each case:
#
6
Remove/install/replace timing chain.

If timing deviates by a crankshaft angle of

more than 20 degrees (corresponding to one

tooth skipped):

#
7
Check pressure loss.

8
Open low pressure connection on high

pressure pump return (plastic line in

area of pressure regulator valve) and

check connection point in rail for chips.

If chips are present when checking

injection system:

#
9
Thoroughly clean all fuel low pressure

lines as well as feed and return lines.

Flush and blow out with compressed air.

10
Remove fuel preheater and fuel filter

with filter housing, replace.

Fuel preheater is only installed in models

202, 203 and 163.

11
Remove/install/replace fuel cooler at

vehicle and engine end.

Not installed in model 210 up to 6/99 and

model 168.

12
Remove fuel tank, replace.

On engine 628:
#

13
Remove/install/replace electric supply

pump.

14
Remove/install/replace injectors, rail

(including pressure regulation valve and

rail pressure sensor), high pressure

lines and injector leak oil rail.*

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1