belt MERCEDES-BENZ ML320 1997 Complete Repair Manual

Front seats
Seat belts/emergency tensioning retractors
MAINTENANCE
CHECK SETTING OF HIGH BEAM - AP82.10-P-8260-02A
1. The light focal point should be located on the relevant central mark (6). In the event of a deviation: Check
seat of bulb.
Fig. 221: Identifying Central Mark

SET OR INSPECT FOG LAMPS - AP82.10-P-8260-04A
1. The light-dark boundary must be as horizontal as possible at the height of the appropriate dividing line
(4), correct if necessary.
2. For model 140 sedan as of approx. 03.94, 168 and 202: Check seat of bulb.
10.2Install E-call control
module (A35/8) with
bracket Only with emergency call
system E-Call, code 349.AR82.95-P-0008GH
*BA91.10-P-1001-01B
*BA91.40-P-1001-01D
11Install center console AR68.20-P-2000GH
12Install radio (A2) AR82.60-P-7502EA
NumberDesignationModel Series 163
BA91.10-P-1001-01BBolt of seating mounting
bracket to vehicle floorNm40
NumberDesignation
Model 163 up to
08/99Model 163 as of
09/99
BA91.40-P-1001-
01DScrew on belt end
fittingNm3535

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
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material (8)
18Plug remaining antenna
cable of FM modulator
(9) into radio
19Install radio (A2)
Remove/install radio AR82.60-P-7502EA
20Retrofit video monitor (2)
and wiring harness of
video monitor (C) With glass version of
electric sliding/tilting
roof, code 414a.AZ82.60-P-0004-02A
Except glass version
of electric sliding/ tilting
roof, code 414a.AZ82.60-P-0004-02B
21Secure upper right B-
pillar paneling Ensure that the lugs of
the seat belt height
adjustment are located
correctly in the recess
clearance of the paneling.
22Install right front handle
23Install right sun visor
Remove/install sun visor AR68.60-P-5480GH
24Install right front A-pillar
cover
Remove/install paneling
on A-pillar AR68.30-P-4050GH
25Re-secure upper area of
rubber door seal
26Route wiring harness of
video/DVD player (B),
additional interface
module (4) and wiring
harness of video monitor
(C) later Up to VIN A289564,
X754619.AZ82.60-P-0004-03A
As of VIN A289565,
X754620.AZ82.60-P-0004-03B
27Retrofit auxiliary
interface module (4) in
center console Up to VIN A289564,
X754619.AZ82.60-P-0004-04A
As of VIN A289565,
X754620.AZ82.60-P-0004-04B
28Install center console
insulating mat
29Install center console
Remove/install center
console AR68.20-P-2000GH

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
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Fig. 348: Identifying CD Changer Components
Remove
1Disconnect ground cable
of battery
Disconnect ground lead
from battery AR54.10-P-0003A
2Remove radio
Remove/install radio AR82.60-P-7502EA
3Remove right side
paneling in footwell
Remove/install paneling
in footwell AR68.30-P-4010GH
4Remove right-hand side
entrance strip
Remove/install door sill
molding AR68.30-P-4100GH
5Unscrew the bolt for the
outer rear seat belt on the
right side *BA91.40-P-1001-01D
6Remove the front load
compartment hooks on
the right C-pillar
7Remove load

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
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Seat belts/emergency tensioning retractors
Parts ordering notes
RETROFITTING TELEPHONE CONSOLE - AZ82.70-P-0001-01A
compartment cover and
unscrew the bolt in the
bracket
8Remove cover for the CD
changer and unscrew bolt
behind the cover in the
top left corner
Install
9Retrofitting D2B wiring
harness for CD changer Risk of fracture! Do
not kink or stretch the
D2B fiber optic cable.
Install caps on fiber
optic cable connector and
equipment connection.AZ82.64-P-0001-01MA
Cover fiber optic cable AR82.95-P-0005-01A
10Retrofit CD changer in
trunk AZ82.64-P-0001-05MA
11Complete vehicle
(following steps 8 to 1)
12Carry out start-up and
function test Code CD changer to
vehicle with STAR
DIAGNOSIS.
NumberDesignation
Model 210 up to
08/99Model 163 as of
09/99
BA91.40-P-1001-
01DBelt end fitting
screwNM3535
Part no.DesignationQuantity
KG82 Group 82 (see EPC)CD changer1
KG82 Group 82 (see EPC)Wiring harness, fiber optic cable1
KG82 Group 82 (see EPC)Holder for CD changer1
KG54 (see EPC)Contact spring1
KG82 Group 82 (see EPC)Coupling, 10-pin1
KG82 Group 82 (see EPC)Plug (radio)1
KG82 Group 82 (see EPC)Plug (CD changer)1
KG82 Group 82 (see EPC)Protective cap2
KG82 Group 82 (see EPC)Clip fastener for screw plug1
KG82 Group 82 (see EPC)Clip fastener for bracket2

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
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Saturday, October 02, 2010 3:30:13 PMPage 420 © 2006 Mitchell Repair Information Company, LLC.

2001-04 STARTING & CHARGING SYSTEMS
Generators & Regulators - 163 Chassis
IDENTIFICATION
CHASSIS & ENGINE IDENTIFICATION
DESCRIPTION
Bosch generators are available in various amp ratings depending on engine application. Voltage regulators are
transistorized and internal to generator. See GENERATOR APPLICATION
table.
GENERATOR APPLICATION
ADJUSTMENTS
DRIVE BELT ROUTING
For drive belt routing, see Fig. 1 . WARNING:Vehicles are equipped with air bag supplemental restraint system. Before
attempting any repairs involving steering column, instrument panel or
related components, see SERVICE PRECAUTIONS (or AIR BAG SAFETY
PRECAUTIONS) and DISABLING & ACTIVATING AIR BAG SYSTEM in
appropriate AIR BAG RESTRAINT SYSTEMS article.
NOTE: When the battery is disconnected, vehicle computer and memory system may
lose data. Driveability problems may exist until computer systems have
completed a relearn cycle.
Model (Year)ChassisEngine
ML55 AMG (2001-03)163.174113.981
ML320 (2001-02)163.154112.942
ML350 (2003-04)163.157112.970
ML430 (2001)163.172113.942
ML500 (2002-04)163.175113.965
ApplicationAmp Rating
V6115
V8150
NOTE: Vehicles have automatic belt tensioners. No adjustment is necessary.

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Generators & Regulators - 163 Chassis

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Generators & Regulators - 163 Chassis
me
Saturday, October 02, 2010 3:20:31 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.
me
Saturday, October 02, 2010 3:20:35 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.

Fig. 1: Drive Belt Routing
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TROUBLE SHOOTING
PRELIMINARY INSPECTION
Verify customer complaint by operating system. Visually inspect for obvious signs of mechanical and electrical
damage. Check generator belt tension and condition. Ensure that battery voltage is within specifications. Inspect
for blown fuses and damaged relays.
Verify ground connection integrity between engine, body, battery and generator. Check for damaged wiring
harnesses and/or switches. Check for a broken or partially broken wire inside insulation, which could cause
system malfunction but prove good in a continuity/voltage check with system disconnected. Ensure any
aftermarket electronic equipment is properly installed. If fault is found, repair as necessary. If no fault is found,
check for conditions that might cause an intermittent situation.
SERVICE PRECAUTIONS
BATTERY DISCONNECT/CONNECT
Disconnect Procedures
1. On vehicles not equipped with TELE AID, go to step 5 . Vehicles equipped with TELE AID, switch
TELE AID into service mode by turning ignition ON.
2. Turn ON telephone and enter code "*#4610#" on handset.
3. Confirm that "No Telematics Service" appears on handset with okay.
4. Turn OFF handset.
5. Turn OFF ignition.
6. Open hood and open snap fasteners (1) on dust filter housing. See Fig. 2
.
7. Remove dust filter housing (2) exposing battery.
8. If not using quiescent current retention unit, go to step 14 . If using quiescent current retention unit, go to
next step.
9. Connect quiescent current retention unit by switching on quiescent current retention unit (7) and then first
connecting positive terminal (8) and negative terminal (9) of retention unit to positive cable and battery
ground (W10). See Fig. 3
.
10. On vehicles equipped with TELE AID, remove luggage compartment cargo anchoring lugs and remove
floor paneling.
11. Remove screws (1). See Fig. 4
.
12. Dismantle cover from TELE AID control module (A35/8).
13. Disconnect connection coupling for back up battery and remove back up battery.
14. Disconnect ne
gative battery cable (1) and insulate terminal. See Fig. 5. NOTE: Numbers and letters in text refer to numbers and letters in figures.

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Generators & Regulators - 163 Chassis
me
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Fig. 8: Connecting Hand Held Tester Scan Tool To OBD-II Data Link Connector
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ON-VEHICLE TESTING
WIRING CONTINUITY
1. Connect voltmeter between generator B+ terminal and ground. Voltmeter should indicate battery voltage.
If battery voltage is not indicated, check battery and check wiring between generator and battery for
corrosion, loose terminals, etc.
2. Turn ignition on and ensure instrument cluster charge indicator light (battery symbol) comes on. If light
does not come on, check wiring between generator and warning light, including indicator bulb.
GENERATOR OUTPUT
1. Ensure connections at battery and generator are clean and tight. Ensure generator, engine and body are
properly grounded. Ensure generator drive belt is properly adjusted and in good condition.
2. Connect load tester/ammeter as per tester manufacturer's instructions. Connect voltmeter leads to battery
terminals. See Fig. 9
. Start engine and run at 2200 RPM for V6 or 2500 RPM for V8. Adjust load tester
to obtain maximum generator output. DO NOT allow voltage to drop to less than 12.7 volts.
3. Maximum generator output should be within a few amps of generator rated output stamped on generator.
If output is not within a few amps of generator rated output, check generator diodes. See DIODE TEST
.
Replace
generator as necessary.

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Generators & Regulators - 163 Chassis
me
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Fig. 14: Identifying Oscilloscope Patterns (Negative Diode Defective)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVAL & INSTALLATION
GENERATOR
Removal & Installation (Model 163)
Disconnect and shield negative battery cable. Remove air cleaner housing. Remove engine trim panel. Remove
"V" belt b
y swiveling tensioning pulley and holding in place with a drift. Disconnect generator B+ electrical
NOTE: Numbers in text refer to numbers in figures.

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Generators & Regulators - 163 Chassis
me
Saturday, October 02, 2010 3:20:32 PMPage 22 © 2006 Mitchell Repair Information Company, LLC.

AR01.30-P-5800MV
Remove/install cylinder head
22.7.98

ENGINE
112.942 in MODEL 163.154

ENGINE
112.970 in MODEL 163.157

ENGINE
113.942 in MODEL 163.172

ENGINE
113.981 in MODEL 163.174

ENGINE
113.965 in MODEL 163.175

P01.30-2032-06

Shown on model 163.154 with engine 112

1
Air baffle

2
Viscous fan

3
Fan shroud

4
Bolts

5
Air cleaner housing

6
Air intake manifold

7
Resonance unit

8
Poly-V-belt

9
Fender liner

10
Shield

11
Exhaust bracket

P01.30-2033-06

12
Right and left ignition coils

13
Left and right cylinder head covers

14
Intake manifold

15
Camshaft position sensor

16
Coolant line

17
Chain tensioner

18
Oil filter housing

19
Camshaft sprockets

28
Camshaft bearing bridges

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

16
Remove poly V-belt (8)


Installation:
Lock tensioning device with

a drift or pin (diameter 5 mm).

Model 163.154 /157 /172.

AR13.22-P-1202B

Model 163.174 /175.

AR13.22-P-1202BA

17
Detach the coolant line (16) at the cylinder

head on the left

6 mm socket hexagon

*WH58.30-Z-1001-06A

7 mm socket hexagon

*WH58.30-Z-1002-06A

18.1
Remove fender liner (9)

Only with engine 113.113.942 /965 / 981.

AR88.10-P-1300GH

19.1
Remove shield (10)

Only with engine 113.942 /965 /981.

20.1
Remove exhaust bracket (11)

Only with engine 113.942 /965 /981.

Support exhaust system.

21
Detach exhaust system at exhaust manifold


Installation:
On vehicles with engine

damage, the exhaust system must be

examined for swarfs before assembling and

any swarfs present must be removed, in order

to avoid consequential damage.


*BA14.10-P-1002-01B

22
Position crankshaft to 40° after ignition TDC

on cylinder 1


The engine must not be turned back;

otherwise the timing chain can get jammed.

AR05.10-P-6858V

Rotate engine at the crankshaft in running

direction until scribe mark 40° on pulley/

vibration damper corresponds with scribe

mark on timing case.

The grooves on the camshafts must be

pointing toward the inner V.

23
Lock camshafts with locating plates

Locating plate

*112589003200

Locating plate

*112589013200

24
Remove chain tensioner (17)
Model 163.154 /157 with engine 112.942/

970, model 163.172 with engine 113.942.
AR05.10-P-7800C

Model 163.174 /175 with engine 113.981/ 965.
AR05.10-P-7800CA

25.1
Remove oil filter housing (18) together with oil-

water heat exchanger
Engine 113.942.

AR18.20-P-3471B

Engine 112.942/970.

AR18.20-P-3471BA

26
Unscrew camshaft sprockets (19)

If camshaft sprockets are removed,

engine must no longer be cranked, otherwise

timing chain might jam.

Engine 113.942 /965 /981:
#

Tie timing chain tight on both camshaft

sprockets with tie straps.

Engine 112.942 /970:

#

Right-hand camshaft sprocket:

Tie timing chain tight on camshaft sprocket

with tie strap.

Left-hand camshaft sprocket:
Mark camshaft sprocket to timing chain and

remove camshaft sprocket.

It is not possible for the timing chain to

jump across at the crankshaft and balancing

shaft.

After installation:
#

Inspect basic position of camshafts.

AR05.10-P-6858V

If necessary after checking:
#

Set the basic position of camshafts

AR05.20-P-6020AU

Open-end wrench

*112589000100

Insertion tool

*112589010300

Torque wrench

*001589722100


*BA05.20-P-1001-01B

27
Remove camshaft bearing bridges (28)

Pay attention to slackening and tightening

pattern!

AR05.20-P-7103AU

28
Unscrew bolts, cylinder head
!
timing case

cover (20)


*BA01.40-P-1002-01C

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 4