MERCEDES-BENZ ML350 1997 Complete Repair Manual

Fig. 37: Generator Connection Diagram - Model 163
Fig. 38: Generator Connection Diagram
- Model 168

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 67 © 2006 Mitchell Repair Information Company, LLC.

Fig. 39: Generator Connection Diagram - Model 414
Fig. 40: Generator Connection Diagram
- Model 170

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 68 © 2006 Mitchell Repair Information Company, LLC.

Fig. 41: Generator Connection Diagram - Model 202
Fig. 42: Generator Connection Diagram
- Model 208
Model 210: as of 1.6.99 a fuse for protection of
generator is located in the te rminal block circuit 30 (X12/3).

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 69 © 2006 Mitchell Repair Information Company, LLC.

Fig. 43: Generator Connection Diagram - Model 210
1. Connect DC clip-on probe (065) from engine tester with oscilloscope (030) to positive pole of battery
(G1)
2. Start engine.
3. Switch on low beam.
4. Assess diode harmonics at 3000 rpm (engine speed).
In this test it is not possible to assess the exciter diodes.
Fig. 44: Identifying Harmonics
- Negative Diode Defective

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 70 © 2006 Mitchell Repair Information Company, LLC.

Fig. 45: Identifying Harmonics - Positive Diode Defective
Fig. 46: Identifying Diode Harmonics OK

REPLACE SPARK PLUGS - AP15.10-P-1580GH
ENGINE 112.942 in MODEL 163.154
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

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 71 © 2006 Mitchell Repair Information Company, LLC.

Fig. 47: Identifying Spark Plugs And Cylinder 4 Ignition Coil

Remove/install and
replacing

Risk of death due to
contact with high-voltage
conductive partsDo not touch parts which
conduct high voltages.
Persons who are carriers
of electronic implants
(e.g. cardiac pacemaker)
may not carry out any
work on the ignition
systemAS15.10-Z-0001-01A
Notes on avoiding damage
to ignition systemEngine 104, 111, 112,
113, 119, 120,271AH15.10-P-0002-01D
1Remove/install air filter
upper section
2
Remove ignition coils
Remove/install ignition
coils
AR15.12-P-2003A
3Disconnect spark plug
connectors Prise over cylinder
head cover.
Double open-ended
wrenchFig. 24
Checking
4Check spark plug Replace, if necessary.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 72 © 2006 Mitchell Repair Information Company, LLC.

Spark plugs
Fig. 48: Identifying Spark Plug Wrench (112 589 01 09 00)

Fig. 49: Identifying Open
-End Wrench, Double (110 589 01 01 00)
connectors, ignition coil
connectors and ignition
lines for damage,
deformation and crack
formation
5Remove/install spark plugs
(R4) *BA15.10-P-1001-01A
Spark plug wrenchFig. 48
NumberDesignationEngine
104,110,111,
113.940/941/942/943/
944/948/960/961/962/
963/964/965/966/967/
968/969/971/980/981/
982/984/986/992/993/
995,115,117,119,
120Engines
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/
973/975/976
BA15.10-P-1001-
01ASpark plugsNm2828

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 73 © 2006 Mitchell Repair Information Company, LLC.

GF54.30-P-3011A
Electronic clock, location/function
24.10.96

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

P54.30-0520-06

General

A periodic process with a period of high

accuracy is required to measure time (clock)

(e.g. rotation of the earth, pendulum

oscillation.)

Electronic clock

Accordingly an electrical clock signal of high

frequency accuracy is required for an

electronic clock. This clock signal is usually

derived from the very constant mechanical

oscillations of an oscillator crystal. A quartz

(q) with a really high frequency

(e.g. f
1
= 1 MHz) is normally used. This

frequency is then adjusted down to the

required frequency f
2
1 Hz or 1/60 Hz by an

electronic frequency divider (t), i.e. one pulse
is generated every second or minute. The

display unit can be actuated by this pulse. A

stepper motor (s) is used on clocks with a

pointer and a liquid crystal display (I) on

clocks with a digital display.

With an additional circuit (b) the clock can be adjusted via control

buttons.
In addition the time or a time/date pulse is also made available to

other systems (e.g. trip computer, Active Service System (ASSYST),

maintenance display).

Trip computer interface, location/task

GF54.30-P-2016A

Liquid crystal display, location/task/function

GF54.30-P-3015A

Oscillator crystal, function

GF54.30-P-3017A

Stepper motor, location/design/function

GF54.30-P-3009A

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

AR47.10-P-4000GH
Empty fuel tank if fuel pump is faulty
28.10.97

MODEL
163.113 with ENGINE 612.963

MODEL
163.128 with ENGINE 628.963

MODEL
163.136 with ENGINE 111.977

MODEL
163.154 with ENGINE 112.942

MODEL
163.157 with ENGINE 112.970

MODEL
163.172 with ENGINE 113.942

MODEL
163.174 with ENGINE 113.981

MODEL
163.175 with ENGINE 113.965

P47.20-2076-06

1
Fondsitzkonsole

2
Cover of left C-pillar

3
Seat retaining cable

4
Wiring harness

P47.10-2077-09

84
Closing cover

90/10
Ground line (vacuum unit)

90/11
Fuel return line
90/12

Fuel feed line

90/13
Stationary heater connection

90/14
Extraction hose


Remove, Install


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.
Fire, sparks, open flames or smoking

forbidden.

Pour fuels only into suitable and appropriately

marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

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

1.1
Unscrew bolts at rear of 2/3 seat bench and

raise rear of seat bench

Up to VIN A145272, X708318.

1.2
Remove covers at seat frame of 60% bench

seat

As of VIN A145273, X708319.

AR91.12-P-1100GH

Only remove the covers which are
identified in the document with A, D and E.

2.1
Fold 60% bench seat forward into footwell

As of VIN A145273, X708319. See

operator's manual.

3.1
Pull floor covering below rear seat mounting

bracket (1) of 60% seat forward

Carefully pull floor covering forward under

the seat console to prevent it from tearing.

As of VIN A145273, X708319.

4.1
Pull the floor covering forward under the front

corner of the left C-pillar cover (2)

Carefully pull the floor covering forward

under the cover to prevent it from tearing.

As of VIN A145273, X708319.

5
Cut into floor covering directly behind seat

retaining cable (3)

Ensure that the wiring harness (4) is not

damaged when cutting the floor covering.

As of VIN A145273, X708319. Broken

line marks the cut.

6
Fold floor mat back

Do not crease floor mat!

Fold floor mat back far enough to provide

access to cap (84) between body and fuel

pump.

7
Remove end cover (84) of body


Installation:
Replace cap and insert with

new sealing compound.


Cap (84) is sealed in with body sealer.

Heat with hot air blower to make it easier to

remove.

8
Seal fuel return line (90/11)

Pliers

*163589003700

9
Connect extraction hose (90/14) with adapter
hose to connection for fuel return line (90/11)

Extraction hose

*168589009000


Adapter hose

*163589009100

10
Connect ground cable (90/10) of extraction

pump ground terminal vehicle battery

Pumping out

11
Pump fuel out into safety container using

extraction pump


*BF47.10-P-1001-01A


*WH58.30-Z-1001-16A

12
Install in the reverse order


Fuel tank

Number

Designation
Models

163.113/
136/154/

172 up to

31.08.01
Models

163.113/
136/154/

172 as of

01.09.01


Models

163.157/

175
Model

163.128
Model

163.174

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liter
72838393

Reserve capacity
Liter
10121212

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