MERCEDES-BENZ ML350 1997 Complete Repair Manual

ENGINES 111.977, 112.942/970, 113.942/965/981, 612.963, 628.963 in MODEL 163
Fig. 31: Identifying Checking For Alternator Charging Current

Modification notes
18.10.05Charging current of
alternatorEngine 111*BE15.40-P-1001-01A
Checking
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 batteriesNo fire, sparks, open flames
or smoking. Wear acid-
resistant gloves, clothing
and goggles. Only pour
battery acid into suitable
and appropriately marked
containers.AS54.10-Z-0001-01A
Notes on battery AH54.10-P-0001-01A
1Check regulation voltage
of alternator AR15.40-P-5010GH
2Connect volt ampere
tester (079) with current
clamp (065) according to Volt ampere tester with
load resistance*WH58.30-Z-1002-09A
Volt ampere tester ETT *WH58.30-Z-1003-09A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 57 © 2006 Mitchell Repair Information Company, LLC.

connection diagram011.00
Risk of accident caused
by vehicle starting off by
itself when engine is
running. Risk of injury
caused by contusions and
burns during starting
procedure or when
working near the running
engineSecure vehicle to prevent it
from moving by itself.
Wear closed and snug-
fitting work clothes.
Do not grasp hot or rotating
parts.AS00.00-Z-0005-01A
3Start engine
4Load battery (G1) with
volt ampere tester (079)
and check charging
current of alternator (G2)
with increased engine
speed Vary load resistance
long enough until the
maximum load current is
achieved; when this is
done, the regulating voltage
must not drop below 12.7
V.
Engines 111, 612*BE15.40-P-1001-01A
Engines 112, 113*BE15.40-P-1001-01K
Engine 628*BE15.40-P-1001-01J
Volt ampere tester with
load resistance*WH58.30-Z-1002-09A
Volt ampere tester ETT
011.00*WH58.30-Z-1003-09A
Charging current below
desired value: ?
Check diodes for
alternator (G2).
AR15.40-P-9301-02EA
Engine tester with
oscilloscope
If diodes are faulty: ?
Replace alternator
(G2)
*WH58.30-Z-1046-13A
Engines 111, 112, 113AR15.40-P-5032GH
Engine 612AR15.40-P-5032GI
Engine 628 with water-
cooled alternator (G2)AR15.40-P-5032IA
Engine 628 with air-cooled
alternator (G2)AR15.40-P-5032GD
5Turn off engine
6Disconnect volt ampere
tester (079) with current Volt ampere tester with
load resistance*WH58.30-Z-1002-09A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 58 © 2006 Mitchell Repair Information Company, LLC.

Check values for alternator
Check values for alternator
Check values for alternator
Commercially available tools
clamp (065) Volt ampere tester ETT
011.00*WH58.30-Z-1003-09A
NumberDesignationEngine 111 in
models 163, 203
Engine 111 in
models 202, 208
with code 910
Bosch/ ValeoEngine 612 in
models 163,203,
209, 210, 463
Delphi
BE15.40-P-1001-
01ACharging current
of alternatormax.A120190
min.A90150
Engine speedrpm25002500
RatioI=2.932.53
NumberDesignationEngine 628.963
in model 163
NF 14V 150AEngine 628.963
in model 163
E10 14V 90-
200A
BE15.40-P-1001-
01JCharging current
of alternatormax.A150200
min.A120160
Engine speedrpm25002500
RatioI=2.82.93
NumberDesignationEngine 112 in
models 163, 170,
202, 203, 208,
209, in model 210
without code 978,
in model 211
without code 910,
Bosch/ValeoEngine 113 in
models
163,171,203,208,
209,210,211,215,
219, 220, 230 except
models 211.076/276,
215.374, 219.376,
220.074/174,
230.472/474 Bosch
BE15.40-P-
1001-01KCharging
current of
alternatormax.A120150
minA90120
Engine speedrpm25002500
RatioI=2.932.93
NumberDesignation
WH58.30-Z-1002-09AVolt-amp(s) tester with load resistance (no longer
available)

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 59 © 2006 Mitchell Repair Information Company, LLC.

REMOVE AND INSTALL GENERATOR - AR15.40-P-5032GH
ENGINE 111.977, 112.942/970, 113.942/965/981 in MODEL 163
Fig. 32: Identifying Generator Remove/Install Components
- Shown On Engine 112
Modification notes
WH58.30-Z-1003-09AVolt ampere tester
WH58.30-Z-1046-13AEngine tester with oscilloscope
14.4.00Specification revised from
15 Nm to 18 NmSpecification in BA15.40-
P-1001-01A revised for
Series 112, 113 engines*BA15.40-P-1001-01A
14.4.00Value modified from 4
Nm to 5 NmSpecification in BA15.40-
P-1002-01A revised for
112, 113 engines*BA15.40-P-1002-01A
Removal/installation
Risk of poisoning caused by
swallowing brake fluid. Risk
of injury caused by brake
fluid coming into contact
with skin and eyes.Fire, sparks, naked flames and
smoking prohibited. Wear acid-
resistant gloves, clothing and
safety glasses. Pour battery acid
only into suitable and
appropriately marked containers.AS54.10-Z-0001-01A
Risk of injury to fingers When moving components, AS00.00-Z-0011-01A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 60 © 2006 Mitchell Repair Information Company, LLC.

being jammed or squeezed
when removing and
installing or aligning hoods,
doors, trunk lid/tailgate or
sliding roof.ensure that no body parts or
limbs are within the operating
range of moving parts.
1Open engine hoodModel 163.136/154 /172 #A up
to 145272,
Model 163.136 /154 /172 #X up
to 708318AR88.40-P-1000GH
Model 163.136 /154 /172 #A as
of 145273,
Model 163.136 /154 /172 #X
from 708319,
Model
163.113/128 /157 /174 /175AR88.40-P-1000GI
2Disconnect battery ground
line Insulate cable lug of ground
line for protection against
unintentional contact of
disconnected ground line.AR54.10-P-0003A
Notes on batteryAll modelsAH54.10-P-0001-
01A
3Remove air cleaner housing Installation: Apply liquid
lubricant to the mounting
rubbers and to the connection to
the air hose.
Lubricant
*BR00.45-Z-1002-
06A
4.1Remove engine trim panel Engine 112, 113 only.
Pull the engine cover
vertically upwards and detach it
from the cylinder head covers.
5Slacken poly V-belt Do not remove the poly-V-
belt!
Engine 111AR13.22-P-1202A
Engine 603.931/972,
Engine 113.942AR13.22-P-1202B
Engine 113.981/965AR13.22-P-1202BA
6Disconnect electrical line
circuit 30 (B+) (1) and
electrical line circuit 61 (D+)
(2) On engine 112, 113 take off
cover sleeve (4).

*BA15.40-P-1001-
01A
*BA15.40-P-1002-
01A
7Unscrew bolts (3) of the
generator (G2) *BA15.40-P-1003-
01A
8Take out generator (G2)
9Install in the reverse

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 61 © 2006 Mitchell Repair Information Company, LLC.

Alternator
Repair materials
REMOVE/INSTALL GENERATOR BELT PULLEY - AR15.40-P-5710GF
ENGINE 111.977, 112.942/970, 113.942/965/981 in MODEL 163
ENGINE 166.940 /960 in MODEL 168
ENGINE 112.923 /943, 113.961 in MODEL 129
sequence
10Perform basic programming AR00.19-P-0200GH
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 procedureSecure 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
11Carry out engine test run Visual inspection of the poly-
V-belt.
12Perform operational check
NumberDesignationEngine 111Engine
112.91/92/94/953/954/955/96/97,113.94/96/98
BA15.40-P-
1001-01ANut of circuit
B+ to generatorNm1518
BA15.40-P-
1002-01ANut of circuit
D+ to
generatorNm45
BA15.40-P-
1003-01AScrew,
alternatorNm4242
NumberDesignationOrder number
BR00.45-Z-1002-06ALubricantA 000 989 01 60

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 62 © 2006 Mitchell Repair Information Company, LLC.

Fig. 33: Identifying Generator, Belt Pulley And Collar Nut
Fig. 34: Identifying Double He xagon Wrench And Generator

Remove/Install
1Remove alternatorEngine 112, 113 in Model
129.AR15.40-P-5032CT
Engine 166.940 /960 in AR15.40-P-5032GF

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 63 © 2006 Mitchell Repair Information Company, LLC.

Generator
Generator
REMOVE/INSTALL REGULATOR OF ALTERNATOR - AR15.40-P-5760GH
ENGINE 111.977, 112.942/970, 113.942/965/981 in MODEL 163
Model 168.
Engine 111, 112, 113 in
model 163.AR15.40-P-5032GH
2Unscrew collar nut (1) To hold generator shaft
(2), insert screwdriver bit
through double hexagon
wrench (4).
Shorten double hexagon
wrench to remove the belt
pulley Model 163 onlyWF58.50-P-1540-01I
Engines 111, 112, 113: ?

*BA15.40-P-1004-01A
Engine 166: ?

*BA15.40-P-1003-01B
3Remove ribbed V-belt
pulley (3) When replacing
generators after mileages in
excess of
100.000 km simultaneously
also replace the poly-V-
belt
pulley (3).

4Install in the reverse order
NumberDesignationEngine 166.940/ 960
BA15.40-P-1003-01BCollar nut to poly V-belt
pulleyNm80
NumberDesignationEngine 111Engine 112.91/92/94/
953/954/955/ 96/97,
113.94/96/98
BA15.40-P-1004-
01ACollar nut to poly
V-belt pulleyNm8080

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 64 © 2006 Mitchell Repair Information Company, LLC.

Fig. 35: Identifying Alternator Regulator Remove/Install Components
Modification notes
26.4.05Remove alternator omitted
Remove the right fender
liner in the front fender
addedStep 1
Remove heat shield addedStep 2
Remove/Install
1Remove right inner fender in
front fender AR88.10-P-1300GH
2Remove the heat shield over
the alternator
3Unscrew bolts (1)
4Unclip cover (2) and remove Push apart retaining
lugs (3).
5Remove screws (4).
6Remove regulator (5)
towards the side Installation: When
inserting the governor (5)
ensure, that the ground lug
(6) sits close to the
governor (5).
7Install in the reverse order

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 65 © 2006 Mitchell Repair Information Company, LLC.

TEST DIODES OF GENERATOR - AR15.40-P-9301-02EA
Commercially available tools
Fig. 36: Generator Connection Diagram
- Model 129
Model 129 with engine 119 up to vehicle ident end no. 1F 032 589: Problems with power supply system -
test batter
y voltage-dependent idle speed increase (refer to Diagnosis Manual Engine Volume 2 Group 07.3).
NumberDesignation
WH58.30-Z-1046-13AEngine tester with oscilloscope

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 66 © 2006 Mitchell Repair Information Company, LLC.