sensor MERCEDES-BENZ ML320 1997 Complete Repair Manual

Oil pan
left engine mount, press oil
line of power steering from
bracket.

*BA22.10-P-1001-01L
4Remove resonance tube (3)
with resonance unit (2) Do not damage the
plastic strap.
Separate plug connection
of hot film mass air flow
sensor (HFM) for this step
and unbolt resonance pipe
at cylinder head cover. The
resonance pipe is attached
to the rear of the intake
manifold with a plastic
bracket.AR07.07-P-1454MV
5Put on engine support
bracket AR33.10-P-0100-01BV
Engine lifting device for
ML-class*WE58.40-Z-1007-11A
6Raise engine Ensure that the rear of
the engine does not touch
the body! Do not
overstretch coolant lines
and engine/bodywork
ground strap (W11/5),
detach engine/bodywork
ground strap (W11/5) if
required.
7Remove oil pan bottom
section (6) Installation: Clean
sealing surfaces, apply
sealant to the sealing
surfaces with a bead of 2.0
mm ± 0.5 mm! The sealant
must be applied within 10
minutes! The silicone bead
must not be spread!*BR00.45-Z-1013-01A
Notes on application of
sealant to oil pan AH01.45-P-0001-01E
*BA01.45-P-1002-01B
8Install in the reverse order
Engines
113.940/941/
942/943/944/
945/946/960/
961/962/963/

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 138 © 2006 Mitchell Repair Information Company, LLC.

Fig. 3: Identifying Front Axle Components
Position in major assemblies compartment (left and right)
Fig. 4: Identifying RPM Sensor Connector

Modification notes
7.11.00Figure modified from 170 Nm to
200 NmValue in BA33.10-P-1001-01C changed
for Model 163*BA33.10-P-1001-
01C
Remove/install
Notes on self-locking nuts
and boltsAll modelsAH00.00-N-0001-01A
1Remove front wheels
Remove/install wheels,
rotate if necessaryAP40.10-P-4050GH
2Remove shock absorber AR32.25-P-0105GH
3Unplug speed sensor
connector (L6/1x1,
L6/2x1)
Risk of poisoning caused
by swallowing brake
fluid. Risk of injury
caused by brake fluid
coming into contact with
skin and eyes.Pour brake fluid only into
suitable and appropriately
marked containers. Wear
protective clothing and eye
protection when handling
brake fluid.AS42.50-Z-0001-01A
4Unscrew brake pipe from
brake hoseSeal off line connections
with plugs to prevent brake
fluid from running out.
Installation: The brake
hose must not be twisted
after tightening.
Brake fluid notesAll modelsAH42.50-P-0001-01A
Notes on installation of Model Series 163AH42.10-P-9406-01GH

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:21 PMPage 4 © 2006 Mitchell Repair Information Company, LLC.

Fig. 14: Identifying RPM Sensor Connector
Remove/Install
Notes on self-locking nuts
and boltsAll modelsAH00.00-N-0001-01A
1 Remove front wheels
Remove/install wheels,
rotate if necessaryAP40.10-P-4050GH
2Detach hexagon collared
nut (65a) from front axle
shaft Installation: Install
new hexagon nut with
collar (65a).
*BA33.30-P-1001-02B
3Remove left or right front
springs AR32.20-P-0200GH
4Remove fender liner. AR88.10-P-1300GH
5Remove shock absorber AR32.25-P-0105GH
6Unplug rpm sensor
connector (L6/1x1,
L6/2x1)
Risk of poisoning from
swallowing brake fluid.
Risk of injury from skin
and eye contact with brake
fluid.Pour brake fluid only into
suitable and appropriately
marked containers. Wear
protective clothing and
eye protection when
handling brake fluid.AS42.50-Z-0001-01A
7Unscrew brake line from
brake hose Plug line connections
with plugs to prevent
brake fluid running out.
Installation: The
brake hose must not be
twisted after tightening.
Notes on brake fluidAll modelsAH42.50-P-0001-01A
Notes on installing brake
hosesModel 163AH42.10-P-9406-01GH
*BA42.10-P-1001-04A

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:22 PMPage 13 © 2006 Mitchell Repair Information Company, LLC.

Shown on vehicle with floating caliper
Fig. 56: Identifying Steering Knuckle Components


Remove/Install
Notes on self-locking nuts
and boltsAll modelsAH00.00-N-
0001-01A
1Remove front wheels


Remove/install wheels,
rotate if necessaryAP40.10-P-
4050GH
2Detach collar nut (65a)
from front axle shaft Installation: Replace collar nut (65a)
*BA33.30-P-
1001-02B
3
Unclip cables for speed
sensor and brake lining
wear indicator from guides
Installation: Pay attention to correct line routing.
4Remove brake disc
Model 163.113 up to VIN A289564, X754619,
model 163.154 up to VIN A289564, 163.136,
models 163.154 /157 with USA version, code 494aAR42.10-P-
0220GH
Model 163.113 as of VIN A289565, X754620,
model 163.154 as of FIN A289565,
163.128 /172 /174 /175, models 163.154 /157 except
USA version, code 494a
AR42.10-P-
0220GI

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:22 PMPage 36 © 2006 Mitchell Repair Information Company, LLC.

Wheel location, hub
5
Remove rpm sensor with
bracket from steering
knuckle
AR42.30-P-
0712GH
6Detach tie rod (10) from
steering knuckle
Check rubber boot and ball joint for wear and
damage.AR46.40-P-
0200-02C
*BA46.40-P-
1001-01C
Thrust pieceFig. 16
PullerFig. 58
7
Press out follower joint
from upper transverse
control arm (6) using puller
Check rubber boot and ball joint for wear and
damage.AR33.20-P-
0500-01GH
*BA33.20-P-
1001-01D
Thrust pieceFig. 45
SupportFig. 46
PressFig. 47
8Press front axle shaft out of
front axle shaft flange AR33.30-P-
0620-04GH
Extraction and insertion toolFig. 18
9Press supporting joint off
lower wishbone
Secure steering knuckle to prevent it from falling
down, in order to rule out damage to the steering
knuckle
Check rubber boot and ball joint for wear and
damage.
AR33.20-P-
0440-02GH
*BA33.20-P-
1002-01D
Thrust pieceFig. 16
10Remove steering knuckle
(5) forwards
Check
11Check supporting joint


Inspect front axle joint for
play, inspect rubber bootsAP33.20-P-
3353GH
12Install in the reverse order
13.1Perform chassis alignment
check After installation of new parts.AR40.20-P-
0200GH
NumberDesignationModel 163
BA33.20-P-1001-01DSelf-locking nut, upper wishbone follower joint to steering knuckleNm50
BA33.20-P-1002-01DSelf-locking nut, supporting joint to steering knuckleNm85

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:22 PMPage 37 © 2006 Mitchell Repair Information Company, LLC.

AF54.30-P-2064A
Fuel gauge not registering correctly after refueling vehicle
4.2.03

MODEL
163.### #A as of 221506 up to 364039,

163.### #X as of 734088 up to 777100

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

Sector

Op. no.
Operation text

Time
Acc. no.
Code

P
023803
RECODE INSTRUMENT CLUSTER
003 WU/0.3 h
54 208 50
---

Damage Code
Cause
Remedy

Refuel recognition software may not

recognize incremental refueling (< 7 L).

In case of complaint
#

The fuel gauge operation defaults to back-

up mode, and continuously decreases last

stored sensor value based on consumption

data supplied via engine management. This

continues until either refuel recognition or

instrument cluster (A1) reset occurs (via

STAR Diagnosis or power disconnect).
Vehicles with 83 L fuel tank (as of MY2002)
are more susceptible to this condition.

This applies only to instrument clusters

(A1) with diagnostic version 3/05, 3/06,

and 3/07.
1
Connect STAR Diagnosis.

2
Under "Control module adaptations" in

"ICM" menu, set "Fuel tank characteristic

curve" from "Normal" to "Direct sensor

value".

DO NOT replace the instrument cluster

(A1) or fuel pump assembly (M3) for this

condition.

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

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

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

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
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Page 2

AR47.10-P-4100GH
Remove fuel tank
10.3.97

MODEL
163.113 with ENGINE 612.963

MODEL
163.128 with ENGINE 628.963

MODEL
163.136 with ENGINE 111.977

MODEL
163.154 with ENGINE 112.942

MODEL
163.157 with ENGINE 112.970

MODEL
163.172 with ENGINE 113.942

MODEL
163.175 with ENGINE 113.965

P47.10-0407-06

1
Left side paneling cover

2
Filler cap

3
Bayonet lock

4
Filler cap attachment

5
Rubber seal

B4/3 Fuel tank pressure sensor

X36/4
Fuel tank filler neck/ground screw

connection

P47.10-0413-09

77
Activated charcoal canister

77/1
Fine venting connection

77/2
Regeneration connection

77/3
Spring chamber venting connection
80/19

Mounting screw

90/11
Fuel return line

90/12
Fuel feed line

B4/3 Fuel tank pressure sensor

77/4

Frischluftanschluss

80
Fuel tank

80/2
Tensioning straps

80/18
Longitudinal strut for tensioning

straps

Modification notes
7.11.00

Figure modified from 170 Nm auf 200 Nm
Value in BA35.10-P-1001-01C changed for

model 163

*BA35.10-P-1001-01C

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

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, 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
Drain fuel tank

Via fuel pump. NOT for model 163.113/128.

AR47.10-P-4001GH

If fuel pump faulty, and model 163.113/128.

AR47.10-P-4000GH


*BF47.10-P-1001-01A

2
Unscrew filler cap (2) and detach from filler

cap attachment (4)

3.1
Remove left seat of 3rd seat row

If installed. See owner's manual

4
Unclip cover of left-hand side panel (1)

5.1
Detach fuel lines of expansion reservoir and

separate from filler neck

As of VIN A289565. NOT for model

163.113/128.

6
Detach fuel filler neck from guide funnel


Installation:
Check O-ring and replace if

necessary. Ensure that the bayonet-lock
remains above
the pressure sensor.

Ensure it is correctly located when installed.

Open bayonet lock (3) to do this.

7
Pull filler neck through toward interior

Screw on cap again in order to avoid fuel

flowing out.

8.1
Remove fuel tank pressure sensor (B4/3)

Only USA version

AR47.10-P-8022GH
9.1
Detach bolted connection of fuel tank filler

neck/ground (X36/4) from filler neck

NOT for model 163.113/128.

10.1
Cut cable strap for retaining clips of fuel lines
at filler neck and remove retaining clips

As of VIN A289565. NOT for model

163.113/128.


Danger!
Risk of fatal accident
from vehicle slipping

or toppling off the lift platform
Align vehicle between the columns of lifting
platform and position the four support plates


below the support strongpoints specified by

the vehicle manufacturer.

AS00.00-Z-0010-01A

11
Place the vehicle on lifting platform

AR00.60-P-1000GH

12
Separate rubber seal (5) from underside of

vehicle and remove filler neck from interior

Do not damage fuel lines at filler neck.

13
Remove left rear wheel

e

Removing and installing wheels, rotating if

necessary

AP40.10-P-4050GH

14
Remove spare wheel and spare wheel carrier

complete

NOT in the case of spare wheel

holder/spare wheel, code 849.

15
Cut a large safety cable strap for filler neck at

bracket on longitudinal frame member

16
Remove bracket from longitudinal frame

member

17
Disconnect connection for regeneration (77/2)

and fresh air connection (77/4) on activated

charcoal canister (77)


Installation
: Connect up lines as per

connection diagram:

#

Engine 111

AR47.30-P-8212-01GJ

Engines 112, 113

AR47.30-P-8212-01GI

Engines 112, 113 version
I

AR47.30-P-8212-01GH

Charcoal canister and fuel tank form a

single unit.

NOT for model 163.113/128.

18
Detach vent hose

At rear differential to rear of activated

charcoal reservoir.

19
Remove rear exhaust system heat shield.

Do not damage boot at rear axle shaft.

20
Disconnect rear propeller shaft at differential


Installation:
Install new self-locking bolts.


Tie up propeller shaft e.g. using welding

wire

Heat bolts with hot air fan to facilitate

removing. Mark propeller shaft and differential

gear flange for correct installed position.


*BA41.10-P-1002-01C

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