manual transmission MERCEDES-BENZ ML320 1997 Complete Manual PDF

This table only serves as an overview!
• Should be used.
o Can be used.
When changing to a different oil:
Change service life factors in the maintenance system (WS) and pay attention to specified maintenance interval
s
1. Only for: G 1/18-5, G 3/50, G 3/60 without MS synchronization
2. Use engine oils as under Sheet 235.12, SAE 30 for common oil circuits with ZF torque converter clutch 4
0
3. Transmissions with oil coolers only.
4. With intarder 5.)
5. Use engine oils as under Sheet 235.27, SAE 30 for common oil circuits with ZF torque converter clutch 4
0
6. Only install W 4 B 035 as of major assembly end no 00 57 33 or modified shift plate. 00 57 33 or fit modi
shift plate.
7. Only for: G 1/18-5, G 3/50, G 3/60 with MS synchronization
8. Only use in exceptional cases! If no synthetic oil in accordance with 235.4 or 235.11 available.
9. For Allison transmissions, it is absolutely essential to observe the application instructions on Sheet 23
1
under point 3.4!
10. Sheet 236.5 only for HT700
Major
assemblySAE
gradeSheet No.
236.1236.12236.123236.5
Sheet
236.1236No.
236.7
236.8236.9236.81236.81
Mechanical
steeringATF •
MB manual
transmission
7.)
G 1/15,
1/17, 1/18
G 2/24, 2/27
G 3/36, 3/40
G 3/50
G 3/60, 3/61
G 3/70
ATF •
MB power
steeringATF •• ••
ZF power
steeringATF •• ••
Hydraulic
fan drive for
auxiliary
radiatorATF ••
MB ATF• ••• •

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
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Saturday, October 02, 2010 3:47:56 PMPage 513 © 2006 Mitchell Repair Information Company, LLC.

GF54.30-P-2017A
HHT interface, location/task
7.7.99

MODEL
129, 140 as of 1.6.96,

163, 168, 170,

202 as of 1.8.96,

208 up to 31.7.99,

210 as of 1.6.96 up to 30.6.99

The instrument cluster has diagnostic capabilities. In other words,

diagnosis is possible using a hand held test (HHT). The instrument

cluster therefore has a line (K-line) which is connected to the data

link connector (X11/4).
The instrument cluster, including the Active Service System

(ASSYST), is tested with the HHT. The following functions can be

selected:

D
Control module version

D
Error memory

D
Actual valves

D
Controls

D
Manual transmission adaptation:
- variant coding

- settings

Copyright DaimlerChrysler AG 05.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

A/C EVAPORATOR HOUSING UNIT
Removal & Installation
1. Drain engine coolant. Remove coolant expansion reservoir nuts, disconnect hoses and remove reservoir.
Discharge A/C system, using approved refrigerant recovery/recycling equipment.
2. Remove expansion valve self-locking nut and discard. See Fig. 5
. Disconnect refrigerant lines from
expansion valve. Plug exposed refrigerant lines to protect A/C system from moisture and debris.
3. Remove instrument panel. See INSTRUMENT PANEL
. Remove Electronic Transmission Control
(ETC) module. See Fig. 4
. Disconnect air mix flap actuator connector.
4. Disconnect recirculated air flap element. Disconnect evaporator temperature sensor. Disconnect blower
motor resistor and blower motor connectors. Remove A/C push button control module. Release wiring
harness.
5. Remove insulating mat. See Fig. 5
. Disconnect water drain hose from bottom of A/C housing. Release
A/C housing-to-air distributor clips and remove A/C housing upward. To install, reverse removal
procedure. Recode radio. See RECODING RADIO
under PROGRAMMING. WARNING:To avoid injury from accidental air bag deployment, read and carefully
follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR
BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY article in
GENERAL SERVICING.
CAUTION: Before disconnecting battery, obtain 5-digit radio security code from
vehicle owner. Radio will be disabled until properly recoded.

2001 Mercedes-Benz ML320
2000-01 MANUAL A/C-HEATER SYSTEMS ML 320, ML 430 & ML 55
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Fig. 6: Removing Cooling Fans & Condenser
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
COOLING FANS
Removal & Installation
Remove headlight units. Remove upper frame crossmember, release hood release control cable and remove
crossmember. See Fig. 6
. Remove 2 cooling fans frame bolts on radiator. Disconnect cooling fan connector.
Release outside temperature sensor wiring harness. Pull up on cooling fan and remove. To install, reverse
removal procedure. Ensure cooling fan bottom guides are properly seated in lower mounts.
EVAPORATOR
Removal & Installation
Remove A/C housing unit. See A/C HOUSING UNIT . Remove expansion valve. See Fig. 5 . Discard "O"
rings. Disassemble A/C housing unit. Remove evaporator. Remove evaporator temperature sensor. To install,
reverse removal procedure. Use NEW "O" rings lubricated with refrigerant oil. If installing a new or repair
evaporator, add 1.35 ounces of NEW refrigerant oil to evaporator.
EXPANSION VALVE
Removal & Installation
1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Without disconnecting
coolant hoses, remove coolant expansion reservoir and set aside. Remove refrigerant line bracket and
loosen clamps. See Fig. 5
. Pull refrigerant lines out of expansion valve.
2. Remove expansion valve self-locking nut and discard. Remove expansion valve. Discard "O" rings. To
install, reverse removal procedure. Use NEW "O" rings lubricated with refrigerant oil. Tighten NEW self-
locking nut to specification. See TORQUE SPECIFICATIONS
.
INSTRUMENT PANEL & INSTRUMENT PANEL CARRIER
Removal & Installation
1. Secure vehicle against rolling. Set transmission selector to "D" position. Obtain radio security code.
Disconnect negative battery cable. Remove driver-side air bag.
2. Place match marks on steering wheel and steering shaft. Remove steering wheel, upper steering column
covers and combination switch. Remove instrument cluster cover frame. Remove one instrument panel
lower section bolt.
3. Remove screws in footwell from left side of instrument panel bottom section. Remove instrument panel
center section. Remove 4 A/C control panel screws and remove control panel. See Fig. 1
. Release pull
cables and disconnect connectors.
4. Remove screws from center section. Remove glove box. Remove screws in footwell from right side of
instrument panel bottom section. Remove entry courtesy lights. Remove end covers and screws.
5. Release 4 "A" clips between instrument panel bottom section and upper section. See Fig. 7
. Release
parkin
g brake release cable from handle. With assistance, remove instrument panel bottom section.

2001 Mercedes-Benz ML320
2000-01 MANUAL A/C-HEATER SYSTEMS ML 320, ML 430 & ML 55
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2.1
Detach automatic transmission from engine
Models 463.206/ 209/ 232/ 233/ 240/ 241

AR27.10-P-0500BD

Models 463.243/ 244/ 245/ 246/ 247/ 248/

249/ 250/ 254

AR27.10-P-0500GA

Model 230.475

AR27.10-P-0500R

Model 230.474

Model 220 without 4MATIC

AR27.10-P-0500I

Model 220 with 4MATIC

AR27.10-P-0500IW

Models 129, 170, 202, 208, 210

AR27.10-P-0500B

Model 203 without 4MATIC, 209 with Engine

112,113

AR27.10-P-0500P

Model 203 with 4MATIC

AR27.10-P-0500PW

Model 211.061/065/070

AR27.10-P-0500T

Model 163

AR27.10-P-0500GH
2.2
Detach manual transmission from engine
Models 129, 202, 210

AR26.10-P-0020A
Models 203, 209 with Engine 112
AR26.10-P-0020P

Model 211.061

AR26.10-P-0020T

Model 208 with transmission 716.662/622

AR26.10-P-0020E

Model 170,

Model 208 with transmission 716.663

AR26.10-P-0020D

3
Detach top part of oil pan
Models 463.206/ 209/ 232/ 233/ 240/ 241/

243/ 244/ 245/ 246/ 247/ 248/ 249/ 250/ 254

AR01.45-P-7500FG

Model 230.474/
AR01.45-P-7500R

Model 220 without 4MATIC

AR01.45-P-7500I

Model 220 with 4MATIC

AR01.45-P-7500IW

Model 210 with 4MATIC

AR01.45-P-7500FA

Model 210 without 4MATIC

AR01.45-P-7500F

Models 202, 208

AR01.45-P-7500FC

Model 203 without 4MATIC, 209 with Engine

112,113

AR01.45-P-7500PV

Model 203 with 4MATIC

AR01.45-P-7500PW

Models 211.061/065/070

AR01.45-P-7500TV

Model 170

AR01.45-P-7500SV

Model 163

AR01.45-P-7500FB

Model 129

AR01.45-P-7500FD

4
Take off cylinder head

Remove intake manifold with complete

wiring loom during this step.

Models 463.206/ 209/ 232/ 233/ 240/ 241/

243/ 244/ 245/ 246/ 247/ 248/ 249/ 250/ 254

AR01.30-P-5800GV

Engine 112 in model 129 and engine 113 in

models 129, 202, 208, 210

AR01.30-P-5800B

Engine 112 in models 170, 202, 208, 210,

220 and engine 113 in models 220,

230.474 /475

AR01.30-P-5800BA

Model 163

AR01.30-P-5800MV

Models 203, 209 with engine 112, 113

Models 211.061/065/070

AR01.30-P-5800PV

5
Remove oil pump

Push back chain tensioner for this step

and take off chain.

All except models 203, 209, 211.061/065/070,

220 without 4MATIC, 230.474 /475

AR18.10-P-6020B

Model 203 without 4MATIC, 209,

211.061/065/070

AR18.10-P-6020PV

Model 203 with 4MATIC, model 220 with

4MATIC

AR18.10-P-6020PW

Model 230.474/475

AR18.10-P-6020R

6
Remove conrod bearing cap (5)

For this step, mark conrod (4) and

connecting rod bearing cap (5) on one side

relative to each other.

7
Remove conrod (4) together with pistons (3)

by lifting up and out

If pistons have been used (3), the arrows

indicating the direction of the travel and the

markings on the pistons may no longer be

visible due to carbon deposits. For this

reason, remove the carbon deposits from the

pistons. If the arrows indicating direction of
travel on the pistons are no longer

recognizable, these must be re-marked.

8
Remove circlip (1) of piston pin (2)

Do not damage piston (3). Place a clean

cloth underneath.

9
Press out piston pin (2)


Installing

10
Assign piston (3) to cylinder bore

AR03.10-P-7021-02BV

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

25.1
Fit on automatic transmission
Models 463.206/ 209/ 232/ 233/ 240/ 241

AR27.10-P-0500BD

Models 463.243/ 244/ 245/ 246/ 247/ 248/

249/ 250/ 254

AR27.10-P-0500GA

Model 230.475

AR27.10-P-0500R

Model 230.474

Model 220 without 4MATIC

AR27.10-P-0500I

Model 220 with 4MATIC

AR27.10-P-0500IW

Models 210, 208, 202,170. 129

AR27.10-P-0500B

Model 203 without 4MATIC, 209 with engines

112,113

AR27.10-P-0500P

Model 203 with 4MATIC

AR27.10-P-0500PW

Models 211.061/065/070

AR27.10-P-0500T

Model 163

AR27.10-P-0500GH

25.2
Fit on manual transmission
Models 210, 202, 129

AR26.10-P-0020A

Models 203, 209 with engine 112

AR26.10-P-0020P

Model 211.061

AR26.10-P-0020T

Model 208 with transmissions 716.662/622

AR26.10-P-0020E

Model 170,

Model 208 with transmission 716.663

AR26.10-P-0020D

26
Install engine
Models 463.243/ 244/ 245/ 246/ 247/ 248/

249/ 250/ 254

AR01.10-P-2400CC

Model 230.475

AR01.10-P-2400R

Model 230.474

AR01.10-P-2400RVK

Model 220 without 4MATIC

AR01.10-P-2400AB

Model 220 with 4MATIC

AR01.10-P-2400IW

Model 210 with 4MATIC

AR01.10-P-2400C

Model 210 without 4MATIC, 208, 202, 129

AR01.10-P-2400CB

Model 203 without 4MATIC, 209 with engine

112

AR01.10-P-2400PV

Model 203 with 4MATIC

AR01.10-P-2400PW

Model 209 with engine 113

AR01.10-P-2400Q

Models 211.061/065/070

AR01.10-P-2400TC

Model 170

AR01.10-P-2400SV

Model 163

AR01.10-P-2400CA

Inspection data of conrod bolts

Number

Designation
Engine

112 except

112.951,

113.94/96/980/

981/982/984/986
Engine

113.992

BE03.10-P-1001-03A
Conrod bolts
Thread
4M8B18B1

Shank length
when new
mm
4742

max.
mm
47.642.6

Part no.
--

Designation
Engines

112 except

112.951,

113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/980/
981/982/984/
986/987/988/
990/991/992/

993

BA03.10-P-1001-01E
Connecting rod bolt
Stage 1
Nm
5

2nd stage
Nm
25

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

ENGINE 119.980 /981 /982 /985
ENGINE 120.982/983
ENGINE 137.970
Fig. 9: Identifying Pedal Value Sensor Function Diagram

Task
Optimizing driving comfort and safety when reversing.
Design/function
The pedal value sensor characteristic curve is changed if reverse travel is recognized by the ME control unit.
The throttle valve opens more slowly. The entire opening angle in this case is approx. 50%.
Reversing is detected:
if a manual transmission fitted, the ME control unit is connected parallel to the reversing light switch.
if an automatic transmission is fitted, the information is supplied over the CAN by the ETC control unit.
Motor electronics control unit, location/task/
design/functionother than engine 111 EVOGF07.61-P-
5000F
Engine 111 EVOGF07.61-P-
5000GS
Pedal value sensor, location/task/design/ function GF30.20-P-
4011L
Electronic accelerator/cruise control/idle speed GF30.22-P-

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY CAB Throttle Control, Speed Control Systems - 163 Chassis
me
Saturday, October 02, 2010 3:36:27 PMPage 12 © 2006 Mitchell Repair Information Company, LLC.

Vehicles with EZS control unit without column sleeve module (MRM)
The signals from the push-button switch for the cruise control are detected by the control unit EIS and
transmitted to the CAN data bus.
Vehicles without EZS control unit
The signals from the cruise control switch are transmitted directly to the engine control unit.
Vehicles with manual transmission (MT)
Cruise control remains active during gear change, in other words the cruise control is not switched off when the
clutch is operated.
Traction systems control unit
Transmits the vehicle speed signal via CAN to the ME control unit.
CRUISE CONTROL SWITCH, LOCATION/TASK/DESIGN/FUNCTION - GF30.30-P-3100F
ENGINE 104 (except 104.98),
Motor electronics control unit, location/task/
design/functionother than engine 111 EVOGF07.61-P-
5000F
Engine 111 EVOGF07.61-P-
5000GS
Cruise control switch, location/task/design/
functionwith cruise control or Distronic GF30.30-P-
3100F
Variable cruise control switch, location/task/
design/functionwith cruise control or Distronic except
GF30.30-P-
3101A
Electronic accelerator/cruise control/idle speed
control actuator location/task/design/function GF30.22-P-
4010F
Throttle valve actuator, location/task/design/
functionEngine 111 EVOGF30.22-P-
4101GS
Stop lamp switch, location/task/function GF42.10-P-
4000A
Clutch pedal switch, location/task/functionwith MTGF29.10-P-
2100F
Variable speed limiter, functionAdditional cruise control function except
GF30.30-P-
3001A
ETC control unit, location/task
Transmits information about the selector
lever position P/N and the driving mode
selected via CAN.
Transmission 722.6
GF27.19-P-
4012G

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY CAB Throttle Control, Speed Control Systems - 163 Chassis
me
Saturday, October 02, 2010 3:36:27 PMPage 27 © 2006 Mitchell Repair Information Company, LLC.

REMOVING AND INSTALLING ACCELERATOR PEDAL - AR30.12-P-1321GH
ENGINE 111.977 in MODEL 163.136
ENGINE 112.942 in MODEL 163.154
ENGINE 112.970 in MODEL 163.157
ENGINE 113.981 in MODEL 163.174
6Push control cable (32) from vehicle interior
towards the outside Do not push rubber grommet out
of splash wall.
7Remove entire control cable (32) from engine
compartment
8Install in the reverse order
9Check throttle control, adjust
Engine 112.942/970,
113.942/965/981 ?
Automatic transmissionAR30.10-P-
1010GJ
Engine 612.963: ?
Manual/automatic transmissionAR30.10-P-
1010GH
Engine 628.963: ?
Automatic transmissionAR30.10-P-
1010GH

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY CAB Throttle Control, Speed Control Systems - 163 Chassis
me
Saturday, October 02, 2010 3:36:28 PMPage 34 © 2006 Mitchell Repair Information Company, LLC.

Fig. 4: Connecting Hand Held Tester Scan Tool To OBD-II Data Link Connector
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING
Starter malfunctions may cause a Di agnostic Trouble Codes (DTCs) to be stored in Motor Electronics
Sequential Fuel Injection (ME-SFI) sy stem. After repairs are completed check for and erase any DTCs stored in
(ME-SFI) system. See appropriate SE LF-DIAGNOSTICS article in ENGINE PERFORMANCE. If cause of
starter malfunction is not engine pe rformance related, replace starter.
REMOVAL & INSTALLATION
STARTER
Removal & Installation
1. Disconnect and shield negative battery cable. See BATTERY DISCONNECT/CONNECT under
SERVICE PRECAUTIONS.
2. Remove nut (2) for inner fender. See Fig. 5
. Pull front and rear section of inner fender (1) downward.
Move inner fender away inward and downward. Pull toward outside over wheel. DO NOT damage fender
cutout or paint.
3. On vehicles with 112 engine, remove nut (6) at shield (5) of left engine mount and take out shield. See
Fig. 6
.
4. On all vehicles, disconnect circuit 30 (1) and circuit 50 (2) cables from starter. See Fig. 6
. Remove bolts
(3) for starter-to-crankcase. Take starter (M1) out to the side.
5. If replacing starter on vehicles with manual transmission, check ring gear at flywheel for wear and
damage. If replacing starter on vehicles with auto matic transmission, check ring gear on drive plate for
wear and damage. Repair or repl ace damaged parts as necessary.
6. To install, reverse removal proce dure. Replace bolts with locking splines, micro-encapsulated bolts and
self-locking nuts. Mating thread of mi cro-encapsulated bolts must be cleaned to remove all residue of old
bolt locking compound. Tighten fasteners to specification. See TORQUE SPECIFICATIONS
. Connect
battery. See BATTERY DISCONNECT/CONNECTunder SERVICE PRECAUTIONS.
NOTE: Numbers and letters in text refe
r to numbers and letters in figures.

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Starters - 163 Chassis
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Saturday, October 02, 2010 3:19:47 PMPage 9 © 2006 Mitchell Repair Information Company, LLC.