engine MERCEDES-BENZ ML320 1997 Complete Repair Manual

Fig. 10: Identifying Intake Manifo ld Remove/Install Components - Shown On Engine 112
Fig. 11: Identifying Crankcas e Ventilation Hose And Line

Remove/install

Risk of
explosion
caused by fuel
igniting, risk
of poisoning
caused by
inhaling and
swallowing
fuel and risk of
injury to eyes
No fire, sparks, ope n flames or smoking.
Only pour fuels into suitable and appropriately marked containers.
Wear protective clothing when handling fuel. AS47.00-
Z-0001-
01A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
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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.

7.1cylinder head
cover (2/1) boltModel 230.475 only

*BA01.20
P-1001-
01E
7.2
Remove
crankshaft
ventilation
hose (2) and
line (89/2) and
place to one
side
Model 171.473 only
Remove cylinder head cover (2/1) bolt in order to detach exhaust gas
recirculation valve (89) bracket.


*BA01.20
P-1001-
01E
8
Disconnect
vacuum lines
from intake
pipe (19)
Installation: Observe intake manifold connection diagram. ?
Engine 112 except 112.913 /917 /949 /954AR09.20
-
P-1310-
01A
Engine 112.913/917 /949 /954AR09.20
-
P-1310-
01T

Engine 112 with USA version, code 494, except engine
112.913 /916 /917 /949 /953 /954 /975
Engine 112.913/916 /917 /949 /953 /954 /975 with USA version, code 494AR09.20-
P-1310-
01AA
Engine 113 except 113.967 /969AR09.20
-
P-1310-
01AU
Engine 113.967/969AR09.20
-
P-1310-
01TA

Engine 113 with USA version, code 494, except engine
113.948 /963 /966 /984 /967 /969 /989 /988
Engine 113.948 /963 /966 /984 /967 /969 /988 /989 with USA version, code
494AR09.20-
P-1310-
01AC
9
Disconnect
electrical
connectors

10
Unscrew acorn
nut from pipe
(89/2) to
exhaust gas
recirculation
Counterhold connection fitting when unscrewing.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:57 PMPage 12 © 2006 Mitchell Repair Information Company, LLC.

Crankcase ventilation, cylinder head cover
valve (89)

*BA14.20
P-1002-
01B
11Unscrew screw
(19/1)Except engine 113.987 as of 24.04.04,
Engine 113.988/989

*BA09.20
P-1001-
01D
11.2
Remove bolts
from right
combination
valve (6) and
left
combination
valve (6)
Only with engine 113.987 as of 24.04.04
Engine 113.988/989

*BA09.20
P-1001-
01D
12.1
Remove
combination
valve (6)Except engine 113.987 as of 24.04.04
Engine 113.988/989
Installation: Install new gasket

12.2
Loosen right
combination
valve (6) and
left
combination
valve (6) and
place to one
side
Only engine 113.987 from 24.04.04
Engine 113.988/989
Installation: Replace the gaskets.

13
Dismount
intake manifold
(19) Plug intake ducts. Use centering bolt for exact positioning of intake
manifold and for centering the gasket (19/3).

*BA09.20
P-1001-
01D
Fig. 13
14Replace gasket
(19/3)
15Install in the
reverse order
NumberDesignationEngine
113.940/941/942/943/944/948/960/961/962/963/964/965/966/967/968/969/971/980/981
/

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:58 PMPage 13 © 2006 Mitchell Repair Information Company, LLC.

Fuel distributor
Fuel distributor
Intake manifold
Exhaust gas recirculation
Exhaust gas recirculation
BA01.20-
P-1001-
01ECylinder
head cover
bolt Nm10
NumberDesignation
Engine 112 except
112.945/951/960/961
BA07.52-P-1001-01AFuel feed line to fuel
distributorNm38
NumberDesignationEngine113.987Engine113.940/941/942/943/944/945/946/948/960/961/962/9
BA07.52-
P-1001-
01AFuel feed
line to
fuel
distributorNm3838
NumberDesignationEngine112,113
BA09.20-P-1001-
01DBolt, intake
manifold to
cylinder headM8Nm20
NumberDesignationEngine
112.910/912/916/920/921/922/923/940/941/942/943/944/945/946/947/953/
9
BA14.20-
P-1002-
01BUnion nut,
exhaust gas
recirculation
pipe to
exhaust gas
recirculation
valveNm40
NumberDesignationEngine113.989
BA14.20-P-1002-01BUnion nut, exhaust gas
recirculation pipe to
exhaust gas recirculation
valveNm40

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:58 PMPage 14 © 2006 Mitchell Repair Information Company, LLC.

Fig. 12: Identifying Pressure Hose (119 589 04 63 00)
Fig. 13: Identifying Set Of Dowel Bolts (112 589 02 62 00)

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:58 PMPage 15 © 2006 Mitchell Repair Information Company, LLC.

GF54.15-P-1255GH
Assignment and cable connections of fuse blocks
18.3.97

MODEL
163

P54.15-0438-06

Fuses
1-42

Relay
k1-k32

P54.15-2486-12

Overview of fuse and relay module in right front footwell

Fuse and relay box, fuses, relay holder
Engines 612.963 and 628.963

GF54.15-P-1255-12G

Fuse and relay box, fuses, relay holder
up to 31.08.01

GF54.15-P-1255-15GH

Fuse and relay box, fuses, relay holder
as of 01.09.01
GF54.15-P-1255-15GA

Fuse and relay box, fuses, relay holder
Fuse and module box in right front footwell

GF54.15-P-1255-15GI

Fuse and relay box, relay/relay holder
up to 31.08.01

GF54.15-P-1255-18GH

Fuse and relay box, relay/relay holder
as of 01.09.01
GF54.15-P-1255-18GA

Fuse and relay box, relay/relay holder
Fuse and module box in right front footwell

GF54.15-P-1255-18GI

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

1998-03 AUTOMATIC TRANSMISSIONS
Complete Transmissions - ML 320 - 722.662
MODEL IDENTIFICATION
MODEL IDENTIFICATION
COMPLETE TRANSMISSION
REMOVE/INSTALL OIL PUMP
Model (Year)ChassisEngineTransmission
ML320 (2001-03)163.154112.942722.662

2001 Mercedes-Benz ML320
1998-03 AUTOMATIC TRANSMISSIONS Complete Transmissions - ML 320 - 722.662

2001 Mercedes-Benz ML320
1998-03 AUTOMATIC TRANSMISSIONS Complete Transmissions - ML 320 - 722.662
me
Saturday, October 02, 2010 3:15:25 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.
me
Saturday, October 02, 2010 3:15:33 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.

Fig. 13: Disconnecting Ground Lead From Battery
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1.1 - Open engine hood.
2 - Disconnect ground cable of battery. See Fig. 13
.
NOTE: Model Series 163.
NOTE: To protect against unwanted contact of the disconnected ground line (1)
W16/4 insulate cable lug of the ground line.

2001 Mercedes-Benz ML320
1998-03 AUTOMATIC TRANSMISSIONS Complete Transmissions - ML 320 - 722.662
me
Saturday, October 02, 2010 3:15:25 PMPage 14 © 2006 Mitchell Repair Information Company, LLC.

The parking lock gear and drive flange are connected to the output shaft by gearing.
Freewheels F1 and F2 optimize shifting. The front freewheel (F1) rests against the stator shaft extension on the
transmission side and connects the sun gear of the front planetary gear set tot the transmission housing in the
locking direction.
The torque converter housing and transmission housing are made of a metal alloy. They are bolted together and
centered via the outer multiple-disc carrier of the multiple-disc brake B1. A coated intermediate panel seals the
two components.
The oil pump and outer multiple-disc carrier of the front multiple-disc brake are bolted to the converter housing.
The mechanical part consists of the propeller shaft, output shaft, a sun gear shaft and three planetary gearsets
which are coupled together.
In transmissions for powerful engines, the planetary gearsets have 4 planetary gears, while for less powerful
engines the front and rear planetary gear system has three planetary gear wheels. The stator shaft is pressed into
this and is secured against turning by a spline.
The rear freewheel (F2) connects the sun gear of the center planetary gear set to the sun gear of the rear
planetary gearset in the locking direction.
The electrohydraulic control unit consists of the shift plate made of light alloy for hydraulic control and an
electronic control unit.
The electrical control unit consists of a supporting body made of plastic in which the electrical components are
combined. The shell is screwed tot he shift plate. Conductor tracks which are integrated into the shell, connect
the electric components to a plug connector. This 13-pin plug connector forms the connection with the vehicle-
side wiring harness and with the ETC 5 (Electronic Transmission Control) control module (N15/5) via a
bayonet lock.
Automatic Transmission, Location Of Mechanical Parts

See AUTOMATIC TRANSMISSION, LOCATION OF MECHANICAL PARTS
.
Automatic Transmission, Location Of Electric/Electronic Components

See AUTOMATIC TRANSMISSION, LOCATION OF ELECTRIC/ELECTRONIC
COMPONENTS.
Automatic Transmission, Location Of Hydraulic Components

See AUTOMATIC TRANSMISSION, POSITION OF HYDRAULIC COMPONENTS
.
Automatic Transmission, Location Of Components, Floor Shift

See AUTOMATIC TRANSMISSION, LOCATION OF COMPONENTS, FLOOR SHIFT
.

2001 Mercedes-Benz ML320
1998-03 AUTOMATIC TRANSMISSIONS Complete Transmissions - ML 320 - 722.662
me
Saturday, October 02, 2010 3:15:26 PMPage 33 © 2006 Mitchell Repair Information Company, LLC.