fuel filter MERCEDES-BENZ ML320 1997 Complete User Guide

Fig. 83: Identifying Valve Springs And / Or Valve Stem Seal Components -Shown On Engine 112 (2 Of
2)
Remove/install
1Remove engine cover or
air filterRemove engine trim
panel or air filter by
pulling it vertically up
and off the cylinder head
covers.
2Remove viscous fan (1) Right-hand thread!AR20.40-P-5660C
3Fan shroud (2) On model 163
unscrew bolts at bottom
of fan shroud.
Models 163.AR20.40-P-5000GH
Model 463.AR20.40-P-6800V
4Remove poly-V-belt (3) Installation: Lock
tensioning device with a
drift or pin (diameter 5
mm).AR13.22-P-1202B
5Remove cylinder head
covers (6)Air filter located at
vehicle side.AR01.20-P-5014B
Air filter located on
engine side.AR01.20-P-5014BV
6
Remove spark plugs (8)Only one spark plug at
each cylinder.
Models 163.AP15.10-P-1580GH
Models 129, 202, 208,
210.AP15.10-P-1580A
Model 463.AP15.10-P-1580GA
7Remove intake manifold
(7) The intake manifold
system must not be
disassembled.
Remove intake
manifold together with
fuel rail.
Models 129, 163, 202,
208, 210.AR09.20-P-1310A
Model 463.AR09.20-P-1310AG
8Position crankshaft to 40°
after ignition TDC of
cylinder 1 Engine must not be
cranked back!AR05.10-P-6858V
9Remove chain tensioner
(5) AR05.10-P-7800C
10Remove camshaft AR15.10-P-2000A

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 79 © 2006 Mitchell Repair Information Company, LLC.

lRemove/install
External torx setFig. 49
Torx bit setFig. 48
1Remove engine trim panel
2Remove air filter housing
(1).
3Remove resonance body (2)
4Remove the resonance tube
(3) with hot film mass air
flow sensor
At this time pull out the
hot film mass air flow
sensor plug.
Removal:
Pay attention to the
mounting projection of the
resonance tube (3)!
All except model 163 with
engine 113.942/981AR07.07-P-1454A
Model 163 with engine
113.942/981AR07.07-P-1454MV
5Unbolt dipstick guide tube
of automatic transmission
6Unbolt ignition coils (6, 7)
at cylinder head covers

AR15.12-P-2003A
*BA01.20
-P-1002-01E
7Disconnect spark plug
connectors
Pay attention to markings
for spark plug connectors
on cylinder head covers
and ignition coils

Fig. 57
8Detach the vacuum hoses at
connections (8, 9) of the
cylinder head covers
9Detach crankcase
ventilation hose at cylinder
head cover fitting (10) Only on left side.
Risk of explosion caused
by ignition of flammable
products, risk of poisoning
caused by inhaling fuel
vapors or swallowing fuel
as well as risk of injury to
skin and eyes exposed to
fuel.No fire, sparks, open
flames or smoking. Pour
fuels only into suitable
and appropriately marked
containers.
Wear protective clothing
when handling fuel.AS47.00-Z-0001-01A
10Disconnect fuel line at fuel Only in case of

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 63 © 2006 Mitchell Repair Information Company, LLC.

Engine 112 in model 208,
Engine 112, 113, 612.963, 628.963 in model
163,
Engines 112.923/943, 113.961 in model 129,
Engines 137, 275 in models 215, 220,
Engines 613.960, 628.960 in model 220,
Engine 113.992 in model 230.474,
Engine 271 in MODELS 209, 203,
Engine 285.950 in models 240.078 /178,
Engine 612.967 in model 209.316,
Engine 648 in model 220 Engine 112.951 in
model
639.601/603 /605 /701 /703 /705 /801 /803 /805
Engine 646.983 /984 in model
639. /605 /701 /703/705/801 /803/805
Engine 646.982 in model
639.601 /603 /605 /701 /703 /705
9Remove air filter
housing (5).
10Remove air intake
pipe (6) with
resonance body (7) For this step separate connector of hot film
mass air flow sensor (HFM) and unscrew air
intake pipe at cylinder head cover.
The air intake pipe is attached to the rear of
the intake manifold with a plastic strap.
Do not damage the plastic strap.
Engines 112.942/970AR07.07-P-
1454A
Engines 113.942/965/981AR07.07-P-
1454MV
Risk of explosion
caused by fuel
igniting, risk of
poisoning caused by
inhaling and
swallowing fuel as
well as risk of
injury to eyes and
skin caused by
contact with fuel.No fire, sparks, open flames or smoking.
Pour fuels only into suitable and appropriately
marked containers.
Wear protective clothing when handling fuel.AS47.00-Z-0001-
01A
11Disconnect fuel line
at fuel rail Release fuel pressure at service valve.
Collect fuel!
Engine 112: ?
*BA07.52-P-
1001-01A
Engine 113: ?

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 86 © 2006 Mitchell Repair Information Company, LLC.

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

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

AR47.20-P-1070M
Removing and installing fuel full-flow filter
24.8.99

ENGINE
612.963 in MODEL 163.113

P47.20-2043-06

1
Fuel feed line

2
Fuel return flow line

3
Fuel cooler

4
Bolts of fuel cooler

70
Fuel full-flow filter

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

Op. no.
Operation text

P
075560
REMOVING AND INSTALLING FUEL FULL-FLOW FILTER

P
075563
REPLACING FUEL FULL-FLOW FILTER

P
075564
REPLACING FUEL FULL-FLOW FILTER (AFTER INSPECTING)

Removing, installing

Danger!

Risk of injury
from fingers being
jammed or

bruised
when removing or installing and

aligning hood, doors, trunk lid/tailgate or

sliding roof
Ensure that no parts of your body or limbs are

within the operating range when moving such

components.

AS00.00-Z-0011-01A

Danger!

Risk of explosion
as a result of fuel vapors

igniting.
Risk of poisoning
as a result of

inhaling fuel vapors.
Risk of injury
as a

result of fuel coming into contact with skin

and eyes.
No fire, naked flame or smoking.

Pour fuels only into suitable and appropriate

marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1
Open hood and raise to vertical position


Have assistant secure hood.

AR88.40-P-1000GI

2
Remove trim panel of charge air distribution

pipe

AR01.20-P-5014-02B

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

3
Disconnect fuel lines (1, 2) at fuel full-flow

filter (70)


Collect fuel which flows out.

Pay attention to use of locking arm. See:
#

Disconnecting and connecting fuel lines at

engine.

AR47.25-P-1000-01A

4
Take off fuel cooler (3)

Take off only the bolts (4) and raise fuel

cooler slightly.

5
Remove fuel full-flow filter (70)


Collect fuel which flows out.

Installation:
If the fuel full-flow filter has been

drained, it must be filled with fuel after being

installed and before starting the engine to

ensure engine starts properly.

*BA47.20-P-1001-02A

6
Install in the reverse order

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

Danger!

Risk of accident
as a result of vehicle

starting off when engine running.
Risk of

injury as a result of bruises and burns if you

insert your hands into engine when it is being

started or when it is running.
Secure vehicle to prevent it starting off.

Wear closed and close-fitting work clothes.

Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

7
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 of trim panel of charge air distribution

pipe to charge air distribution pipe
Nm
10


Fuel filter

Number

Designation
Engine

612.961/

963

BA47.20-P-1001-02A
Bolt of fuel filter to charge air distribution pipe
Nm
14

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

AR47.20-P-1070HBRemove/install fuel full-flow filter
21.11.97

ENGINE
611.960 /961 /962, 612.961 /963, 613.960 /961

P07.57-0222-12

Shown on Engine 611.960

1
Fuel outlet line

2
Fuel feed line

70
Fuel full-flow filter

P47.20-2024-12

Illustrated on Engine 613.961

1
Fuel feed line of fuel tank

2
Fuel feed line to predelivery pump

3
Fuel return line from rail

4
Fuel return line to fuel cooler (fuel tank)

70
Fuel full-flow filter


Remove/install


Danger!
Risk of explosion
due to combustion,
Risk

of poisoning
due to inhalation and

swallowing of fuel
Injury hazard
due to skin

and eye contact with fuel
Fire, sparks, open flames or smoking

forbidden.

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
Engine 611

AR01.20-P-5014-02A

Engine 612

AR01.20-P-5014-02B

Engine 613

AR01.20-P-5014-02C

*BA01.20-P-1003-01A

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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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

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

Commercial vehicle engines, Industrial engines from the commercial vehicle sector (BR 300, BR 400, BR
500, BR 900)
This table only serves as an overview!
The detailed maintenance and oil change regulations can be found in the maintenance booklet for the respective
vehicle/ major assembly.
• Enable
o Can only be used in exceptional cases or under certain operating conditions/in certain applications.
- Must not be used
1. Sheets 227.0/. 1 no longer exist! Replaced by engine oils in sheets 228.0/. 1/.2/.3/.5/51.
2. Use in combination with low-sulfur (S <50 ppm) or sulfur-free (S <10 ppm) fuel! If fuels with sulfur
contents of S> 500 ppm are being used, the oil change intervals must be reduced!
3.Restriction: Onl
y "Mobil 1 5W-50", SAE 5W-50, sheet 229.3 is approved!
MB
Specifications
for
Operating
Fluids Sheet
1.)226.9
Multi-
grade228.0/.1
Single/
Multi-
grade226.9229.3
Single/
Multi-
grade229.5
Multi-
grade228.51 '
Multi-
grade229.1
Multi-
grade229.3
Multi-
grade229.31
Multi-
grade229.5
Multi-
grade229.51
Multi-
grade
Commercial
vehicles,
buses without
particulate
filter
BR 300, 400,
500, 900; OM
457, 460 up to
and including
Euro 3-o/•o/•••-----
BR 500, 900;
OM 457, 460
Euro 4/5--o/•••-----
Gas engines•---•-----
Commercial
vehicles,
buses with
particulate
filter
BR 500, 900;
OM 457, 460--oo•-----

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:52 PMPage 416 © 2006 Mitchell Repair Information Company, LLC.

Valve seal not okay :
#
3
Remove/install/replace valve seal.

AR05.30-P-3500B

Cause 6:
Remedy 6:

00 001 70
1.5 mm hole missing on individual right

cylinder head covers at connection to

crankcase ventilation.
1
Check cylinder head cover

Up to production 06/1999.

Crankcase ventilation out of order, engine can

sludge up and consume oil as a result

Cylinder head cover not okay:
#
2
Remove/install/replace cylinder head

cover.

ENGINE
112

Air cleaner positioned on engine

side.

ENGINE
113

Air cleaner positioned on engine

side.
AR01.20-P-5014BV

ENGINE

112

Air cleaner positioned on engine side

ENGINE
113

Air cleaner positioned on engine side

AR01.20-P-5014B

Cause 7:
Remedy 7:

00 001 70
Engine oil sludging due to excessively long

engine oil change intervals
Service information: Oil sludge

SI18.00-P-0010A

If the service interval according to

ASSYST is exceeded, the engine oil sludges

up sooner or later depending on the oil

quality, type of operation and operating time.

Engine consumes oil.

See Service Information.

1
Print out ASSYST printout.

2
Check oil change intervals

3
Inform vehicle owner.

4
Remove/install/replace piston rings.

AR03.10-P-7311BV

Disassemble and clean sludged engines

completely because dirty oil usually gets into

clean-oil side due to clogged oil filter.

Cause 8:
Remedy 8:

00 001 70
Piston rings sticky or have coke deposits from

engine oils (e.g. API-S in USA) in connection

with regionally poor fuel quality.

Always use engine oils according to

Specifications for Operating Fluids 229.3, do

not add special additives to engine oil and fuel

BB00.40-P-0229-03A

1
Remove/install/replace piston rings.

AR03.10-P-7311BV

Cause 9:
Remedy 9:

00 001 70
Piston ring wear due to excessive

contamination/dust (model 163) through air

intake system.
1
Remove/install/replace gaskets on air

intake line and distribution element of

partial load ventilation.

e.g. due to incorrect assembly after

workshop visit or embrittlement of gaskets
The distribution element with optimized

material will be available as of 11/ 2000 as a

standard feature.

2
Remove/install/replace intake module.

Exterior oil loss, e.g. due to cast iron

porosity on left side of crankcase in area of

engine support is not considered to be oil

consumption

In the event of a customer complaint

regarding the engine oil consumption, always

determine the oil consumption definitely

because the oil indicator lamp can come on

due to other causes (e.g. defective oil sensor).

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e. g.)
Order number

WH58.30-Z-1009-05A
Flexible inspection light
Scope of supply 1 (complete unit):

-glass fiber optical fiber

-light projector

-230 V, storage case

-operating instructions

-graphics protocol
Richard Wolf GmbH

Pforzheimerstr. 32

D-75438 Knittlingen

Karl Storz GmbH

Mittelstr. 8

D-78532 Tuttlingen
1.00565.00

80902

WH58.30-Z-1010-05A
Flexible inspection light

Scope of delivery 2 (for workshops which already have an approved

Wolf or Storz inspection light):

-storage case

-operating instructions

-pictures protocol
Richard Wolf GmbH

Pforzheimerstr. 32

D-75438 Knittlingen

Karl Storz GmbH

Mittelstr. 8

D-78532 Tuttlingen
7.05065.00

K03506AJ

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 2