Filter MERCEDES-BENZ ML320 1997 Complete Manual PDF

Engine 113.963 in models 230.475
Engine 112.947 in model 170.465AR20.00-P-
1142SV
Engine 112.960 in model 170.466
4.1Remove engine
cover with
integrated air
filterModel 129
Type 170.465
Model 202.033/ 093
Model 208.370 /374 /470
Model 220
Type 230.475
Unclip covering on front si de of engine. Remove the
engine cover with integrated air filter from the cylinder
head covers vertically in the upward direction.
4.2Remove air filterEngine 112.960 in model 170.466
Engine 113.992 in model 230.474AR09.10-P-
1150SVK
5.1Remove viscous
fan clutch (1)Engine 112 in model 210, 202, 129
Engine 112 in model 163.154 /157
Engine 113 in model 210, 208, 202, 129
Engine 113 in model 163.172
Right-hand thread!AR20.40-P-
5660C
6.1Remove heater
unitModel 170.465 with retrofitted stationary heater Thermo
Top C.AR83.70-P-
5302NB
7.1Remove fan
shroud (3)Engine 113 in model 215
Engine 112 in model 220
Engine 113 in model 220
Engine 113.963 in models 230.475
Engine 113.992 in model 230.474AR20.40-P-
6800AB
7.2Remove electric
fan Model 163 unscrew bolts at bottom of fan shroud.
Engine 113.965 in model 163.175AR20.40-P-
5000GH
Engine 113.981 in model 163.174
Engine 112.947 in model 170.465AR20.40-P-
5000SV
Engine 112.960 in model 170.466
8Attach guard
plate for radiator /
condenser
Guard plate for
radiator /
condenserEngines 112, 113, 137, 271, 272, 275, 285, 602, 604, 605,
606, 611, 612, 613, 628, 648WF58.50-P-
0110-01A
9.1Remove poly-V-
belt for
superchargerEngine 113.992 in model 230.474AR13.21-P-
1202RVK
9.2Remove poly V-
belt (2)ENGINE 112 in models 129, 163AR13.22-P-
1202B

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 99 © 2006 Mitchell Repair Information Company, LLC.

Engine 113 in model 129, 202, 208, 210
Engine 113 (except 113.965 /981) in model 163
Engine 112 in model 202, 208, 210AR13.22-P-
1202BA
Engine 112 in model 220
Engine 113 in model 215.373 /375
Engine 113 in models
220.070 /073 /075 /083 /084 /170 /173 /175 /183 /184 /875
Engine 113.965 in model 163.175
Engine 113.981 in model 163.174
Engine 113.984 in model 208.374 /474
Engine 113.963 in models 230.475AR13.22-P-
1202R
Engine 113.992 in model 230.474
Engine 112.947 in model 170.465AR13.22-P-
1202SV
10Remove cylinder
head covers (6)Engine 112, 113 air filter located on vehicle sideAR01.20-P-
5014B
Engine 112, 113 air filter located on engine sideAR01.20-P-
5014BV
11Detach coolant
line (17, 18) from
coolant pump
(12).
12Detach coolant
line (16) at
thermostat
housing (13).
13Dismount
refrigerant
compressor (A9) Place to the side with lines connected.

*BA83.55-P-
1001-01A
14.1Remove
alternator (G2)Engine 113.963 in models 230.475
Engine 113.992 in model 230.474AR15.40-P-
5032R
15.1Remove ATF line
bracket (23).Model 230
15.2Detach ATF line
from front axle
carrierModel 163
16Remove oil pan
bottom section (9)Engine 112.942 in model 163.154AR01.45-P-
7555V
Engine 112.970 in model 163.157
Engine 113.942 in model 163.172
Engine 113.965 in model 163.175AR01.45-P-
7555VE

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 100 © 2006 Mitchell Repair Information Company, LLC.

20Remove poly-V-
belt tensioning
device (5)Engine 112 in models 129, 163AR13.25-P-
3200B
Engine 113 in model 129, 202, 208, 210
Engine 113 (except 113.965 /981) in model 163
Models 129, 202, 210 with manual transmission.
Unscrew damper of belt te nsioning device at coolant
pump.
Engine 113.963 in models 230.475AR13.25-P-
3200R
Engine 113.992 in model 230.474
21Remove vibration
damper (4)Engine 112 in models 129, 163AR03.30-P-
1600C
Engine 113 in models 129, 202.033 /093
Engine 113 (except 113.981) in model 163
Engine 113 (except 113.980) in model 210
Engine 113 (except 113.984) in model 208
Engine 112.947 in model 170AR03.30-P-
1600CA
Engine 112 in model 202, 208, 210, 220
Engine 113.981 in model 163.174
Engine 113 (except 113.991) in models 215, 220.
Engine 113.963 in models 230.475
Engine 113.992 in model 230.474AR03.30-P-
1600RVK
22Remove chain
tensioner (14)ENGINE 112 in models 129, 163
Engine 113 (except 113.965 /981) in model 163
Engine 113 in model 129, 202, 208, 210AR05.10-P-
7800C
Engine 112 in model 170, 202, 208, 210
Engine 113 in model 163.174 /175AR05.10-P-
7800CA
Engine 112 in model 220
Engine 113 in model 215.373 /375
Engine 113 in models
220.070 /073 /075 /083 /084 /170 /173 /175 /183 /184 /875
Engine 113 in model 230.474 /475AR05.10-P-
7800AM
23.1Remove oil filter
housingEngine 113.992 in model 230.474AR18.20-P-
3471RKV
23.2Remove oil filter
housing with
oil/water heat
exchanger (7)Engine 112 in models 170, 202, 208, 210, 220AR18.20-P-
3471BA
Engine 113 in model 220
Engine 113.963 in models 230.475
Engine 113.965 in model 163.175
Engine 113.981 in model 163.174
Engine 112 in models 129, 163AR18.20-P-
3471B

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 102 © 2006 Mitchell Repair Information Company, LLC.

oil feed up to final repair
size.
12Measure cylinder boreAllow crankcase to cool
down to approx. 20°C
before measuring
Cylinder diameter*BE01.40-P-1001-01F
Internal measuring
instrument ø 50 to 150
mm, with 0.01 mm
indication and measuring
point pressure relief*WE58.40-Z-1003-21A
13Clean cylinder bore and
dry
14Set honing machine for
lapping Set to same diameter as
after polishing (final
diameter).
Cylinder diameter
according to machining
stage.*BE01.40-P-1003-01F
Stroke setting with 70 mm
felt length on 70th stroke
scale of machine*BE01.40-P-1012-01F
Felt insert overrun at top
and bottom*BE01.40-P-1013-01F
Engine speed*BE01.40-P-1008-01F
Feed*BE01.40-P-1009-01F
Stroke*BE01.40-P-1010-01F
Display*BE01.40-P-1011-01F
Felt insert C 30-F 85*WH58.30-Z-1036-04A
Set of felt insert holders
CK3130*WH58.30-Z-1035-04A
Stone holder for felt
insert CK-30 35*WH58.30-Z-1034-04A
15Rub-in cylinder bore and
filter insert using honing
paste Without honing oil
feed, the cylinder wall
must be dry. Only the
specified honing paste may
be used. Only this one
guarantees the specified
final result.
Polmot honing paste order
no. 600.11
*BR00.45-Z-1050-06A
16Lap cylinder bore and
expose silicone crystals. Without honing oil
feed.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 119 © 2006 Mitchell Repair Information Company, LLC.

Check values for crankcase
Operating time of honing
machine
*BE01.40-P-1014-01F
17Coat filter insert again
with honing paste Do not coat cylinder
bore with honing paste.
Polmot honing paste order
no. 600.11
*BR00.45-Z-1050-06A
18Lap cylinder bore and
expose silicone crystals. Without honing oil
feed, removed material
cannot be measured.
Operating time of honing
machine
*BE01.40-P-1014-01F
19Clean cylinder bore and
dry Clean crankcase very
carefully with honing
paste. If possible, clean
crankcase in a major
assembly washing
machine, so that no
cylinder wall damage will
be caused by residues
when running the engine
later.
20Inspect cylinder boreAllow crankcase to cool
down to approx. 20°C
before inspecting.
Cylinder diameter of repair
size
*BE01.40-P-1001-01F
NumberDesignation
Engine 112
except 112.951,
113.940/941/
942/943/944/
945/946/948/
960/961/963/
965/966/967/
968/980/981/
984/986/992/
995
Engine
113.962/982/
987/988/989/
990/991/993
BE01.40-P-
1001-02E Cylinder borePeak-to-valley
height (R
Z ) of
top separating
surface
mm0.001 to 0.00450.001 to 0.0045
Wear limit at
BDC and TDC
of 1st piston ringmm< or = 30.03< or = 0.03

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 120 © 2006 Mitchell Repair Information Company, LLC.

Engine mounts, engine supports
Engine lubrication
NumberDesignation
951/954/955/
960/961/970/
972/973/976969/980/981/
982/984/986/
992/995
BA01.45-P-
1002-01BSelf-tapping
screw of oil pan
to oil panThread not
pretappedNm1414
Thread pre-
tappedNm1010
BA01.45-P-
1003-01BOil drain screw
to oil panM14Nm3030
NumberDesignation
Engine
112.942/970
113.942/965/981
in model
163.154/157/17
2/174/175
BA22.10-P-1001-01LBolt, front engine mounts
to front axle carrierNm35
NumberDesignation
Engine
112
except
112.916/953/975Engines
113.940/941/
942/943/960/
961/962/969/
982
BF18.00-P-1001-
01HEngine
oil
Filling capacity with oil filterLiters8.08.0
Filling capacity without oil
filterLiters7.5-
Specifications for Operating
Fluids
SheetBB00.40-P-0229-
01A
BB00.40-P-0229-
01A
SheetBB00.40-P-0229-
03A
BB00.40-P-0229-
03A
SheetBB00.40-P-0229-
05A
BB00.40-P-0229-
05A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 136 © 2006 Mitchell Repair Information Company, LLC.

Engine mounts, engine supports
Engine lubrication
Fig. 111: Identifying External Torx Set (001 589 76 09 00)
NumberDesignation
965/967/968/
969/980/981/
982/984/986/
992/995
BA01.45-P-1002-
01BSelf-tapping screw
of oil pan to oil panThread not pre-
tappedNm14
Thread pre-tappedNm10
BA01.45-P-1003-
01BOil drain screw to
oil panM14Nm30
NumberDesignation
Engine
112.942/970
113.942/965/981
in model
163.154/157/17
2/174/17 5
BA22.10-P-1001-01LBolt, front engine mounts
to front axle carrierNm35
NumberDesignation
Engine
113.944/980/981
/984/986/991Engine
113.963/
963/965
BF18.00-P-
1001-01HEngine oilFilling capacity
with oil filterLiters7.57.5
Filling capacity
without oil filterLiters-7.0
Specifications
for Operating
FluidsSheetBB00.40-P-
0229-01A
BB00.40-P-
0229-01A
SheetBB00.40-P-
0229-03A
BB00.40-P-
0229-03A
SheetBB00.40-P-
0229-05A
BB00.40-P-
0229-05A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 139 © 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