alternator MERCEDES-BENZ ML350 1997 Complete User Guide

297 Technical data
Electrical system
Electrical system
Model
ML 350
ML 500
Generator (alternator)
14 V / 120 A
14 V / 150 A
Starter motor
12 V / 1.7 kW
12 V / 1.7 kW
Battery
12 V / 100 Ah
12 V / 100 Ah
Spark plugs
Bosch F 8 DPP332
Bosch F 8 DPER
Bosch F 8 DPP332
Bosch F 8 DPER
Electrode gap
0.039 in (1.0 mm)
0.039 in (1.0 mm)
Tightening torque
15 – 22 lb-ft (20 – 30 Nm)
15 – 22 lb-ft (20 – 30 Nm)

314 Technical termsPoly-V-belt drive
Drives engine-components (alternator,
AC compressor, etc.) from the engine.
Power train
Collective term designating all compo-
nents used to generate and transmit
motive power to the drive axles, includ-
ing


engine


clutch / torque converter


transmission


transfer case


drive shaft


differential


axle shafts / axlesRemote Vehicle Diagnostics
Transmission of vehicle data and cur-
rent location to the Mercedes-Benz
Customer Assistance Center for sub-
scribers to Tele Aid service.
REST
(Residual engine heat utilization)
Feature that uses the engine heat
stored in the coolant to heat the vehi-
cle interior for a short time after the en-
gine has been turned off.
Restraint system
Seat belts, belt tensioner, airbags and
child seat restraint systems. As inde-
pendent systems, their protective func-
tions complement one another.RON
(R
esearch O
ctane N
umber)
The Research Octane Number for gaso-
line as determined by a standardized
method. It is an indication of a gaso-
line's ability to resist undesired detona-
tion (knocking). The average of both
the ->MON (Motor Octane Number)
and RON (Research Octane Number) is
posted at the pump, also known as
ANTI-KNOCK INDEX.
Shift lock
When the vehicle is parked, this lock
prevents the transmission selector le-
ver from being moved out of positionP
without key turned and brake pedal de-
pressed.
SRS
(S
upplemental R
estraint S
ystem)
Seat belts, emergency tensioning de-
vice and airbags. Though independent
systems, they are closely interfaced to
provide effective occupant protection.

AR54.10-P-0005GH
Remove/install battery
23.3.00

MODEL
163.113 /128 /136 /154 /157 /172 /174 /175

P54.10-2066-06

Right-hand drive vehicle shown

1
Ground line

2
Positive wire

3
Seal

4
Shield

5
Alternator line

6
Starter line

7
Brake booster line

8
Overflow hose

9
Control cable

10
Suction fan locking bracket

11
Bolt

12
Clamping wedge

13
Retaining bracket

G1 Battery

M13
Heating water circulation pump


Remove, Install

Danger!

Risk of explosion
from electrolytic gas.
Risk

of poisoning and irritation
if battery acid is

swallowed.
Risk of injury
through burns to

skin and eyes from battery acid or when

handling damaged lead-acid batteries
No fire, sparks, naked flames or smoking.

Wear acid-resistant gloves, clothing and eye

protection. Pour battery electrolyte only into

suitable and appropriately marked containers.

AS54.10-Z-0001-01A

Notes on battery
All models

AH54.10-P-0001-01A

1
Turn ignition key to position "0"

to avoid fault codes.

2
Disconnect ground cable (1) from battery


To prevent unintended contact, insulate

the ground lead cable lug.

AR54.10-P-0003A

3
Remove protective shield at positive pole of

battery and remove all lines attached to

positive cable (2)

4
Disconnect positive cable (2) from the battery

(G1).

5
Remove seal (3) at shield (4)

6.1
Unscrew bolt for securing generator line to

shield

As of VIN A145273, X708319.

7
Slacken retaining clip at side of shield (4),

guide all lines through shield and lay to one

side

8.1
Detach coolant circulation pump (M13) from

shield

As of VIN A145273, X708319.

9
Remove cable strap at lines at side of shield

10
Detach overflow hose (8) and control cable

(9) at shield

11.1
Detach locking bracket of suction fan (10) at

the front from the shield and remove line from

shield

Only if fitted.

12
Unscrew bolt (11) at shield


*BA54.10-P-1002-01A

13
Remove clamping wedge (12) at retaining

bracket

14
Detach retaining bracket (13) by pressing

downwards

15
Detach and remove shield (4)

Rotate the shield forwards and move back

in order to loosen the front retaining lugs.

16
Remove battery (G1).

17.1
Dispose of battery

If battery is defective.

o

Dispose of battery
All models

OS54.10-P-0001-01Z

18
Install in the reverse order

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

Starter
Engine mounts, engine supports
PREREQUISITES FOR TESTING GENERATOR - AR15.40-P-5009GH
ENGINE 111.977, 112.942/970, 113.942/965/981, 612.963, 628.963 in MODEL 163
Fig. 29: Connection Schematic Between Battery And Alternator

NumberDesignationEngine 112 except
112.951, 113.94/ 96/98
BA15.30-P-1001-01ANut for connection of
circuit 30Nm14
BA15.30-P-1002-01ANut for connection of
circuit 50Nm6
BA15.30-P-1003-01ABolt for starter on
crankcaseNm42
NumberDesignationEngines 112.942/970
113.942/965/981 in model
163.154/157/17 2/174/175
BA22.10-P-1004-01LBolt for front engine
mount on engine supportNm65
Remove/Install
1Open engine hood and raise Up to A145272, X708318.AR88.40-P-1000GH

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 52 © 2006 Mitchell Repair Information Company, LLC.

Test values for generator charge indicator lamp
CHECKING REGULATION VOLTAGE OF ALTERNATOR - AR15.40-P-5010GH
ENGINES 111.977, 112.942/970, 113.942/965/981, 612.963, 628.963 in MODEL 163
to vertical position As of A145273, X708319.AR88.40-P-1000GI
Testing
2Check electrical line
terminal 30 to the following
items for firm seat and
flawless conditionBattery (G1) (+)
Generator (G2)(B+)

3Check electric cable for
circuit 31 at the following
positions for correct seat
and conditionBattery (G1) (-)
Right major assemblies
compartment ground,
Common ground
(W16/4)
Engine ground
strap/body

4Inspect tension of poly V-
belt
5Inspect operation of charge
indicator in instrument
cluster *BE54.30-P-1001-01A
6Install in the reverse order
NumberDesignationModel 129, 163, 168,
170, 202, 203, 208, 210
BE54.30-P-1001-01APosition of ignition / glow
start switchCharge indicator lamp
Of
f
0/1
Charge indicator lamp On2

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 53 © 2006 Mitchell Repair Information Company, LLC.

Fig. 30: Identifying Connection Diagram - Checking For Alternator Regulation Voltage
Checking
Risk of explosion caused
by oxyhydrogen gas. Risk
of poisoning and caustic
burns caused by
swallowing battery acid.
Risk of injury caused by
burns to skin and eyes
from battery acid or when
handling damaged lead-
acid batteriesNo fire, sparks, open flames
or smoking. Wear acid-
resistant gloves, clothing and
safety glasses. Only pour
battery acid into suitable and
appropriately marked
containers.
AS54.10-Z-0001-01A
Notes on battery AH54.10-P-0001-01A
1Check condition of
battery (G1) AR54.10-P-1129Z
2Check whether
preconditions for
alternator testing have
been fulfilled AR15.40-P-5009GH
3Attach volt ampere tester
(079) according to
connection plan Volt ampere tester with
load resistance*WH58.30-Z-1002-09A
Volt ampere tester ETT
011.00*WH58.30-Z-1003-09A
Risk of accident caused Secure vehicle to prevent it AS00.00-Z-0005-01A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 54 © 2006 Mitchell Repair Information Company, LLC.

by vehicle starting off by
itself when engine is
running. Risk of injury
caused by contusions and
burns during starting
procedure or when
working near the running
enginefrom moving by itself.
Wear closed and snug-fitting
work clothes.
Do not grasp hot or rotating
parts.
4Start engine
5Check function of charge
indicator lamp when
engine is idling and with
increasing engine speed
(up to 3000 rpm) Charge indicator lamp
must extinguish.
6Load battery (G1) using a
permanent consumer and
check regulation voltage
of alternator (G2)Engines 111, 112, 113*BE15.40-P-1001-02A
Engines 612, 628*BE15.40-P-1001-02C
Volt ampere tester with
load resistance*WH58.30-Z-1002-09A
Volt ampere tester ETT
011.00*WH58.30-Z-1003-09A
Regulation voltage > 15.0
V: ?
Replace regulator

Engine 628

Engines 111, 112, 113
Replace alternator
(G2)
AR15.40-P-5760GH
Engine 612
Regulation voltage < 13.0
V: ?
Check electrical
connections for
charging system for
transition resistances;
repair if necessary.

Electrical connections OK: ?
AR15.40-P-5032GI
Check alternator (G2)
diodes AR15.40-P-9301-02EA

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 55 © 2006 Mitchell Repair Information Company, LLC.

Check values for regulator
Check values for regulator
Commercially available tools
CHECKING CHARGING CURRENT OF ALTERNATOR - AR15.40-P-5011GH
Engine tester with
oscilloscope
If diodes are faulty: ?
Replace alternator
(G2)
*WH58.30-Z-1046-13A
Engine 111, 112, 113AR15.40-P-5032GH
Engine 612AR15.40-P-5032GI
Engine 628AR15.40-P-5032IA
7Turn off engine
8Disconnect volt ampere
tester (079) Volt ampere tester with
load resistance*WH58.30-Z-1002-09A
Volt ampere tester ETT
011.00*WH58.30-Z-1003-09A
NumberDesignationEngines 103,104,111,
112,113,119, 120,
137, 155, 166, 275
BE15.40-P-1001-
02ARegulating voltage
(at battery)Loading: only on
permanent consumerV13 to 15
Engine speedrpm3000
measured afterminapprox.2
NumberDesignationEngines
601,602,603, 604,
605, 606,
611,613,628, 646,
647, 668Engine 612
except 612.966
BE15.40-P-
1001-02CRegulating
voltage (at
battery)Loading: only on
permanent
consumerV13 to 1513 to 15
Engine speedrpm30003000
measured afterminapprox.2approx.2
NumberDesignation
WH58.30-Z-1002-09AVolt-amp(s) tester with load resistance (no longer
available)
WH58.30-Z-1003-09AVolt ampere tester
WH58.30-Z-1046-13AEngine tester with oscilloscope

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 56 © 2006 Mitchell Repair Information Company, LLC.

ENGINES 111.977, 112.942/970, 113.942/965/981, 612.963, 628.963 in MODEL 163
Fig. 31: Identifying Checking For Alternator Charging Current

Modification notes
18.10.05Charging current of
alternatorEngine 111*BE15.40-P-1001-01A
Checking
Risk of explosion caused
by oxyhydrogen gas. Risk
of poisoning and caustic
burns caused by
swallowing battery acid.
Risk of injury caused by
burns to skin and eyes
from battery acid or when
handling damaged lead-
acid batteriesNo fire, sparks, open flames
or smoking. Wear acid-
resistant gloves, clothing
and goggles. Only pour
battery acid into suitable
and appropriately marked
containers.AS54.10-Z-0001-01A
Notes on battery AH54.10-P-0001-01A
1Check regulation voltage
of alternator AR15.40-P-5010GH
2Connect volt ampere
tester (079) with current
clamp (065) according to Volt ampere tester with
load resistance*WH58.30-Z-1002-09A
Volt ampere tester ETT *WH58.30-Z-1003-09A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 57 © 2006 Mitchell Repair Information Company, LLC.

connection diagram011.00
Risk of accident caused
by vehicle starting off by
itself when engine is
running. Risk of injury
caused by contusions and
burns during starting
procedure or when
working near the running
engineSecure vehicle to prevent it
from moving by itself.
Wear closed and snug-
fitting work clothes.
Do not grasp hot or rotating
parts.AS00.00-Z-0005-01A
3Start engine
4Load battery (G1) with
volt ampere tester (079)
and check charging
current of alternator (G2)
with increased engine
speed Vary load resistance
long enough until the
maximum load current is
achieved; when this is
done, the regulating voltage
must not drop below 12.7
V.
Engines 111, 612*BE15.40-P-1001-01A
Engines 112, 113*BE15.40-P-1001-01K
Engine 628*BE15.40-P-1001-01J
Volt ampere tester with
load resistance*WH58.30-Z-1002-09A
Volt ampere tester ETT
011.00*WH58.30-Z-1003-09A
Charging current below
desired value: ?
Check diodes for
alternator (G2).
AR15.40-P-9301-02EA
Engine tester with
oscilloscope
If diodes are faulty: ?
Replace alternator
(G2)
*WH58.30-Z-1046-13A
Engines 111, 112, 113AR15.40-P-5032GH
Engine 612AR15.40-P-5032GI
Engine 628 with water-
cooled alternator (G2)AR15.40-P-5032IA
Engine 628 with air-cooled
alternator (G2)AR15.40-P-5032GD
5Turn off engine
6Disconnect volt ampere
tester (079) with current Volt ampere tester with
load resistance*WH58.30-Z-1002-09A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 58 © 2006 Mitchell Repair Information Company, LLC.