engine MERCEDES-BENZ ML320 2003 W163 Manual Online

261 Practical hints
Battery
Battery
The battery is located in the engine com-
partment on the right-hand side.
Disconnecting the battery
Turn off all electrical consumers.

Open the hood (
page 202).

Disconnect the battery negative lead.

Remove the cover from the positive ter-
minal.

Disconnect the battery positive lead.
Warning!
G
Failure to follow these instructions can re-
sult in severe injury or death.
Never lean over batteries while connecting,
you might get injured.
Battery fluid contains sulfuric acid. Do not
allow this fluid to come in contact with eyes,
skin or clothing. In case it does, immediately
flush affected area with water and seek
medical help if necessary.
A battery will also produce hydrogen gas,
which is flammable and explosive. Keep
flames or sparks away from battery, avoid
improper connection of jumper cables,
smoking etc.
!Never loosen or detach battery termi-
nal clamps while the engine is running
or the key is in the steering lock. Other-
wise the alternator and other electronic
components could be severely dam-
aged.
Have the battery checked regularly by
an authorized Mercedes-Benz Light
Truck Center.
Refer to Service Booklet for mainte-
nance intervals or contact your autho-
rized Mercedes-Benz Light Truck
Center for further information.Warning!
G
Do not place metal objects on the battery as
this could result in a short circuit.
Use leak-proof battery only to avoid the risk
of acid burns in the event of an accident.
Warning!
G
With a disconnected battery

y o u w i l l n o l o n g e r b e a b l e t o t u r n t h e k e y
in the steering lock


the selector lever will remain locked in
positionP

264 Practical hintsJump starting
Jump starting
If the battery is discharged, the engine can
be started with jumper cables and the bat-
tery of another vehicle. Observe the follow-
ing:

Jump starting should only be performed
when the engine and catalytic convert-
er are cold.


Do not start the engine if the battery is
frozen. Let the battery thaw out first.


Only jump start from batteries with the
same voltage rating (12V). Jump start-
ing with a more powerful battery could
damage the vehicle's electrical system,
which will not be covered by the Mer-
cedes-Benz Limited Warranty.


Use only jumper cables with sufficient-
cross-section, insulated terminal
clamps and polarity reversal protec-
tion.
Warning!
G
Failure to follow these directions will cause
damage to the electronic components, and
can lead to a battery explosion and severe
injury or death.
Never lean over batteries while connecting
or jump starting, you might get injured.
Battery fluid contains sulfuric acid. Do not
allow this fluid to come in contact with eyes,
skin or clothing. In case it does, immediately
flush affected area with water, and seek
medical help if necessary.
A battery will also produce hydrogen gas,
which is flammable and very explosive. Keep
flames or sparks away from battery, avoid
improper connection of jumper cables,
smoking etc.
Attempting to jump start a frozen battery
can result in it exploding, causing personal
injury.
Read all instructions before proceeding.
iJumper cables with polarity reversal
protection are available at any autho-
rized Mercedes-Benz Light Truck
Center.

265 Practical hints
Jump starting
The battery is located in the engine com-
partment.
Make sure that the two vehicles do not
touch.

Turn off all electrical consumers.

Apply parking brake.

Shift selector lever to positionP.1Positive terminal
2Cable clamps
3Negative terminal
4Cover

Remove cover4 from positive terminal
on both vehicles.

Connect positive terminals1 on the
batteries with the jumper cables. Start
with the charged battery.
!Jump starting may only be performed
on the battery installed in the engine
compartment.
Avoid repeated and lengthy starting at-
tempts.
Do not attempt to start the engine us-
ing a battery quick charge unit.
If engine does not run after several un-
successful starting attempts, have it
checked at the nearest authorized
Mercedes-Benz Light Truck Center.
Excessive unburned fuel generated by
repeated failed starting attempts may
damage the catalytic converter.
Make sure the jumper cables do not
have loose or missing insulation.
Make sure the cable clamps do not
touch any other metal part while the
other end is still attached to a battery.
Warning!
G
Keep flames or sparks away from battery.
Do not smoke.
Observe all safety instructions and precau-
tions when handling automotive batteries
(page 261).

266 Practical hintsJump starting
Let the engine of the assisting vehicle
run at idle speed.

Connect the negative terminals3 of
the batteries with the jumper cables.
Start with the charged battery.

Start the engine of the disabled vehi-
cle.Now you can again turn on the electrical
consumers. Do not turn on the lights under
any circumstances.

Remove the jumper cables first from
the negative terminals3 of the batter-
ies and then from the positive
terminals1.

Have the battery checked at the
nearest authorized Mercedes-Benz
Center.iThe vehicle cannot be started via
tow-start.

267 Practical hints
Towing the vehicle
Towing the vehicle
Mercedes-Benz recommends that the vehi-
cle be transported with all wheels off the
ground using flatbed or appropriate wheel
lift/dolly equipment. This method is pref-
erable to other types of towing.When circumstances do not permit the
recommended towing methods, the vehi-
cle may be towed with all wheels on the
ground only so far as necessary to have the
vehicle moved to a safe location where the
recommended towing methods can be em-
ployed.
!Use flatbed or wheel lift/dolly equip-
ment, with key in steering lock turned
to position0.
Do not tow with sling-type equipment.
Towing with sling-type equipment over
bumpy roads will damage radiator and
supports.
To prevent damage during transport,
do not tie down vehicle by its chassis or
suspension parts. Use the towing eyes.
Switch off the ESP (
page 76),
tow-away alarm (
page 80) and the
automatic central locking (
page 89).
!When towing the vehicle with all wheels
on the ground, the selector lever must
be in position N and the key m us t be in
steering lock position 2.
When towing the vehicle with all wheels
on the ground, the vehicle may be
towed only for distances up to 30 miles
(50 km) and at a speed not to exceed
30 mph (50 km/h).
If the vehicle is towed with the front
axle raised (observe instructions re-
garding flexible drive shaft), the engine
must be shut off (key in steering lock
position1). Otherwise, the 4-ETS may
become engaged which may cause loss
of towing control.
!To be certain to avoid additional dam-
age to the vehicle powertrain, however
you should observe the following:

With damage to the front axle

raise front axle


remove flexible drive shaft be-
tween rear axle and transfer
case


With damage to the rear axle

raise rear axle


tow vehicle with wheel lift or
dolly placed under front wheels


With damage to the transfer case

remove flexible drive shaft to
the drive axles
Always install new self-locking nuts
when reinstalling flexible drive shaft.

268 Practical hintsTowing the vehicleWarning!
G
If circumstances require towing the vehicle
with all wheels on the ground, always tow
with a tow bar if:

the engine will not run


there is a malfunction in the power sup-
ply or in the vehicle’s electrical system
Prior to towing the vehicle with all wheels on
the ground, make certain that the key is in
steering lock position2.
If the key is left in steering lock position0
for an extended period of time, it can no
longer be turned in the switch. In this case,
the steering is locked. To unlock, remove
key from steering lock and reinsert.
Warning!
G
With the engine not running, there is no
power assistance for the braking and steer-
ing systems. In this case, it is important to
keep in mind that a considerably higher de-
gree of effort is necessary to brake and
steer the vehicle. Adapt your driving accord-
ingly.iTo signal turns while being towed with
hazard warning flasher in use, turn key
in steering lock to position2 and acti-
vate combination switch for left or right
turn signal in usual manner – only the
selected turn signal will operate.
Upon canceling the turn signal, the haz-
ard warning flasher will operate again.iThe vehicle cannot be started via
tow-start.
!When towing the vehicle with all wheels
on the ground, note the following:
With the automatic central locking acti-
vated and the key in steering lock
position2, the vehicle doors lock if the
left front wheel is turning at vehicle
speeds of approx. 9 mph (15 km/h) or
more.
To prevent the vehicle doors from lock-
ing, deactivate the automatic central
locking (
page 89).
Towing of the vehicle should only be
done using the towing eye. Never at-
tach tow cable, tow rope or tow rod to
vehicle chassis, frame or suspension
parts.

271 Practical hintsFuses
Fuses
The fuse chart is printed on the corre-
sponding fuse box cover. The amperages
of the fuses are also indicated there.
Fuse box in engine compartment
The fuse box is located in the engine com-
partment on the left-hand side.
1Clamps
2Fuse box cover
Removing/installing cover
Release clamps1

Lift fuse box cover2 up.

Install cover1 in reverse order.3Fuse chart
4Fuse extractor
5Spare fuses
iOnly install fuses that have been tested
and approved by Mercedes-Benz and
that have the specified amperage rat-
ing.
Never attempt to repair or bridge a
blown fuse. Have the cause determined
and remedied by an authorized
Mercedes-Benz Light Truck Center.

273 Technical data
Spare parts service
Warranty coverage
Identification labels
Layout of poly-V-belt drive
Engine
Rims and tires
Electrical system
Main Dimensions
Weights
Fuels, coolants, lubricants etc.
Consumer information

276 Technical dataIdentification labels
Identification labels1Certification label and Paintwork num-
ber2Engine number (engraved on engine)
3VIN, visible (lower edge of windshield)
4Emission control label
Vacuum line routing for emission con-
trol system
5Information label, California version
iWhen ordering spare parts, please
specify vehicle identification and en-
gine numbers.

278 Technical dataEngine
EngineModel
ML 320 (163.154
1)
1The quoted data apply only to the standard vehicle. See an authorized Mercedes-Benz Center for the corresponding data of all special bodies and special equipment.
ML 350 (163.157
1)
ML 500 (163.175
1)
ML 55 AMG (163.174
1)
Engine
112
112
113
113
Mode of operation
4-stroke engine, gaso-
line injection
4-stroke engine, gaso-
line injection
4-stroke engine, gaso-
line injection
4-stroke engine, gasoline
injection
No. of cylinders
6
6
8
8
Bore
3.54 in (89.90 mm)
3.81 in (97.00 mm)
3.81 in (97.00 mm)
3.81 in (97.00 mm)
Stroke
3.31 in (84.00 mm)
3.31 in (84.00 mm)
3.31 in (84.00 mm)
3.62 in (92.00 mm)
Total piston displacement
195cu.in. (3199cm
3)
227cu.in. (3724cm
3)
303cu.in. (4966cm
3)
332cu.in. (5439cm
3)
Compression ratio
10:1
10:1
10:1
10.5:1
Output acc. to SAE J 1349
215 hp / 5600 rpm
(160 kW / 5600 rpm)
241 hp / 5600 rpm
(180 kW / 5600 rpm)
288 hp / 5600 rpm
(215 kW / 5600 rpm)
342 hp / 5500 rpm
(255 kW / 5500 rpm)
Maximum torque acc. to
SAE J 1349
233 ft.lb/ 3000 rpm
(315 Nm /3000 rpm)
259ft.lb/3000rpm
(350 Nm /3000 rpm)
325 ft.lb / 2700 rpm
(440 Nm / 2700 rpm)
376 ft.lb / 2800 rpm
(510 Nm / 2800 rpm)
Maximum engine speed
6000 rpm
6000 rpm
6000 rpm
6000 rpm
Firing order
1-4-3-6-2-5
1-4-3-6-2-5
1-5-4-2-6-3-7-8
1-5-4-2-6-3-7-8
Poly-V-belt
7ft 10in (2390mm)
7ft 10in (2390mm)
7 ft 10 in (2390 mm)
7ft 10in (2390mm)