MERCEDES-BENZ ML350 1997 Complete Repair Manual

Fig. 26: Identifying Left Knock Sensor 2 - Shown On Engine 112 In Model 220
Knock sensors
Remove/install
1.1Remove intake manifoldAll except model, 463 with
engine 113.962/982/993
Model 463 with engine
112.945
Model 170.466 with engine
112.960
Model 203.065/265 with
engine 112.961
Model 211.076/276 with
engine 113.990AR09.20-P-1310A
Model 463 with Engine
112.945, 113.962/982AR09.20-P-1310AG
1.2Remove compressorModel 170.466 with engine,
112.960 model 203.065/265
with engine, 112.961 model
211.076/276 with engine
113.990AR09.50-P-4705SVK
Model 463.270/271 with
engine 113.993AR09.50-P-4705GX
2Detach knock sensor 1,
right and knock sensor 2,
left (A16/2) from cylinder
block *BA15.10-P-1001-02A
3Install in the reverse order

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 47 © 2006 Mitchell Repair Information Company, LLC.

SERVICING WIRING HARNESS - AR15.18-P-0500A
MODEL 124, 126, 129, 140, 163, 168, 170, 201, 202, 208, 210, 215, 220
Fig. 27: Identifying Terminal Block And Cable Connection Of Mass Air Flow Sensor And Temperature
Sensor
If a cable break or similar damage exists in the area of the plug connection of the mass air flow sensor (B2)
or temperature sensor (B11), it is possible to repair the wiring harness in order to avoid costly replacement of a
wiring harness.
Modification notes
NumberDesignationEngine
112.910/911/
912/913/914/
915/916/917/
920/921/922/
923/940/941/
942/943/944/
945/946/947/
949/951/953/
954/955/960/
961/970/972/
973/975/976Engine
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/987/988/
990/991/992/
993/995Engine
113.989
BA15.10-P-
1001-02ABolt securing
knock sensor to
cylinder blockNm202020
27.9.99Supersedes SI 54/76 dated
23.1.96Remove SI 54/76 from
your file.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 48 © 2006 Mitchell Repair Information Company, LLC.

Parts ordering notes
REMOVE AND INSTALLING THE STARTER - AR15.30-P-7100GH
ENGINE 112.942 in MODEL 163.154
Removing and installing
1Remove air cleaner, install. Only on engine 119
2Expose wiring harness to
mass air flow sensor or
temperature sensor. Ignition switched
off
3Unplug socket from mass
air flow sensor or
temperature sensor.
4Plug in repair socket
together with cables at
mass air flow sensor or
temperature sensor and
insert into cable duct.
5Repair wiring harness
using end soldering sleeves
(Z). Turn together cable of
engine wiring harness and
cable repair socket of the
same color and insert into
end soldered sleeves (Z).
Use end soldered
sleeves (Z) only in cross
section area Ø 0.7 - Ø 4.0
mm
2
AR54.18-P-0100-02A
6Insert cables into the cable
duct.
7Connect HHT, read faults
and erase see Diagnosis Manual
Engine Volume 2 Index 0:
Connecting and using test
equipment
8Install in the reverse order
Part no.DesignationQuantity
140 540 00 36Repair kit socket (B2)1
1) Consisting of repair socket (B2)
and 5 cable connectorsacc. to condition
140 540 00 81Repair socket (B2)acc. to condition
202 540 01 81Repair socket (B11) 3-pinacc. to condition
126 540 30 81Repair socket (B11) 4-pinacc. to condition
001 546 99 41Cable connectoracc. to condition
006 989 84 85Fabric tapeacc. to condition

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 49 © 2006 Mitchell Repair Information Company, LLC.

ENGINE 112.970 in MODEL 163.157
ENGINE 113.942 in MODEL 163.172
ENGINE 113.981 in MODEL 163.174
ENGINE 113.965 in MODEL 163.175
Fig. 28: Identifying Starter Remove/Install Components

Modification notes
3.9.03Check ring gear, newly
recordedStage 7
Removing/installing
Risk of explosion caused by
oxyhydrogen gas. Risk of
poisoning and caustic burns
caused by swallowing battery
acid. Risk of injury through
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 self-locking nuts and
bolts AH00.00-N-0001-01A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 50 © 2006 Mitchell Repair Information Company, LLC.

1Disconnect ground cable from
battery Insulate ground line as
a protection against
unintentional contact of
dismounted ground line
with ground point of
battery.AR54.10-P-0003A
Notes on battery AH54.10-P-0001-01A
2Remove inner fender in right
front fender AR88.10-P-1300GH
3.1Unscrew nut (6) at shield (5)
of left engine mount and take
out shieldEngine 112

*BA22.10-P-1004-01L
4Dismount electrical line
circuit 30 (1) and electrical
line circuit 50 (2) Nut, terminal 30
connection*BA15.30-P-1001-01A
Nut of connection
circuit 50*BA15.30-P-1002-01A
5Remove bolts (3) *BA15.30-P-1003-01A
6Take out starter (M1) to the
side
7.1Check ring gear at flywheel
for wear and damageWhen replacing the
starter on vehicles fitted
with manual transmission
Rotate engine at the
crankshaft in direction of
rotation.
7.2Check ring gear on the drive
plate for wear and damageWhen replacing the
starter on vehicles fitted
with automatic
transmission
Rotate engine at the
crankshaft in direction of
rotation.
8Install in reverse order
9Perform function check
10Render electrical system
operationalSee ? Perform basic
programmingAR00.19-P-0200GH
11Read out fault memory and
erase When the work is
complete stored faults
must be worked on in the
diagnostic trouble code
memories and erased. ?
Connect up STAR
DIAGNOSIS, read out
fault memory
AD00.00-P-2000-04A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 51 © 2006 Mitchell Repair Information Company, LLC.

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.