alternator MERCEDES-BENZ ML350 1997 Complete Owner's Manual

Check values for alternator
Check values for alternator
Check values for alternator
Commercially available tools
clamp (065) Volt ampere tester ETT
011.00*WH58.30-Z-1003-09A
NumberDesignationEngine 111 in
models 163, 203
Engine 111 in
models 202, 208
with code 910
Bosch/ ValeoEngine 612 in
models 163,203,
209, 210, 463
Delphi
BE15.40-P-1001-
01ACharging current
of alternatormax.A120190
min.A90150
Engine speedrpm25002500
RatioI=2.932.53
NumberDesignationEngine 628.963
in model 163
NF 14V 150AEngine 628.963
in model 163
E10 14V 90-
200A
BE15.40-P-1001-
01JCharging current
of alternatormax.A150200
min.A120160
Engine speedrpm25002500
RatioI=2.82.93
NumberDesignationEngine 112 in
models 163, 170,
202, 203, 208,
209, in model 210
without code 978,
in model 211
without code 910,
Bosch/ValeoEngine 113 in
models
163,171,203,208,
209,210,211,215,
219, 220, 230 except
models 211.076/276,
215.374, 219.376,
220.074/174,
230.472/474 Bosch
BE15.40-P-
1001-01KCharging
current of
alternatormax.A120150
minA90120
Engine speedrpm25002500
RatioI=2.932.93
NumberDesignation
WH58.30-Z-1002-09AVolt-amp(s) tester with load resistance (no longer
available)

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 59 © 2006 Mitchell Repair Information Company, LLC.

Alternator
Repair materials
REMOVE/INSTALL GENERATOR BELT PULLEY - AR15.40-P-5710GF
ENGINE 111.977, 112.942/970, 113.942/965/981 in MODEL 163
ENGINE 166.940 /960 in MODEL 168
ENGINE 112.923 /943, 113.961 in MODEL 129
sequence
10Perform basic programming AR00.19-P-0200GH
Risk of accident caused by
vehicle starting off by itself
when engine is running.
Risk of injury caused by
contusions and burns when
working in engine during
starting procedureSecure vehicle to prevent it from
moving. Wear closed and snug-
fitting work clothes.
Do not grasp hot or rotating
parts.AS00.00-Z-0005-01A
11Carry out engine test run Visual inspection of the poly-
V-belt.
12Perform operational check
NumberDesignationEngine 111Engine
112.91/92/94/953/954/955/96/97,113.94/96/98
BA15.40-P-
1001-01ANut of circuit
B+ to generatorNm1518
BA15.40-P-
1002-01ANut of circuit
D+ to
generatorNm45
BA15.40-P-
1003-01AScrew,
alternatorNm4242
NumberDesignationOrder number
BR00.45-Z-1002-06ALubricantA 000 989 01 60

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 62 © 2006 Mitchell Repair Information Company, LLC.

Fig. 33: Identifying Generator, Belt Pulley And Collar Nut
Fig. 34: Identifying Double He xagon Wrench And Generator

Remove/Install
1Remove alternatorEngine 112, 113 in Model
129.AR15.40-P-5032CT
Engine 166.940 /960 in AR15.40-P-5032GF

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 63 © 2006 Mitchell Repair Information Company, LLC.

Generator
Generator
REMOVE/INSTALL REGULATOR OF ALTERNATOR - AR15.40-P-5760GH
ENGINE 111.977, 112.942/970, 113.942/965/981 in MODEL 163
Model 168.
Engine 111, 112, 113 in
model 163.AR15.40-P-5032GH
2Unscrew collar nut (1) To hold generator shaft
(2), insert screwdriver bit
through double hexagon
wrench (4).
Shorten double hexagon
wrench to remove the belt
pulley Model 163 onlyWF58.50-P-1540-01I
Engines 111, 112, 113: ?

*BA15.40-P-1004-01A
Engine 166: ?

*BA15.40-P-1003-01B
3Remove ribbed V-belt
pulley (3) When replacing
generators after mileages in
excess of
100.000 km simultaneously
also replace the poly-V-
belt
pulley (3).

4Install in the reverse order
NumberDesignationEngine 166.940/ 960
BA15.40-P-1003-01BCollar nut to poly V-belt
pulleyNm80
NumberDesignationEngine 111Engine 112.91/92/94/
953/954/955/ 96/97,
113.94/96/98
BA15.40-P-1004-
01ACollar nut to poly
V-belt pulleyNm8080

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 64 © 2006 Mitchell Repair Information Company, LLC.

Fig. 35: Identifying Alternator Regulator Remove/Install Components
Modification notes
26.4.05Remove alternator omitted
Remove the right fender
liner in the front fender
addedStep 1
Remove heat shield addedStep 2
Remove/Install
1Remove right inner fender in
front fender AR88.10-P-1300GH
2Remove the heat shield over
the alternator
3Unscrew bolts (1)
4Unclip cover (2) and remove Push apart retaining
lugs (3).
5Remove screws (4).
6Remove regulator (5)
towards the side Installation: When
inserting the governor (5)
ensure, that the ground lug
(6) sits close to the
governor (5).
7Install in the reverse order

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 65 © 2006 Mitchell Repair Information Company, LLC.

Timing chain, chain tensioner
REMOVE/INSTALL CHAIN TE NSIONER - AR05.10-P-7800CA
ENGINE 112 in MODELS 170, 208, 202, 210, 209, 203
Remove/install
1Remove viscous fan (1) Right-hand thread!AR20.40-P-5660C
2Remove fan shroud (2).On model 163 unscrew
bolts at bottom of fan
shroud.
Model 463AR20.40-P-6800V
3Remove poly-V belt (3) Installation: Lock
tensioning device with a
drift or pin (diameter 5
mm).AR13.22-P-1202B
4Remove alternator (4)Model 129AR15.40-P-5032CT
Model 163AR15.40-P-5032GH
Model 208 with engine
113AR15.40-P-5032EB
Model 210 with engine
113AR15.40-P-5032ED
Model 463 with engine
112, 113AR15.40-P-5032GV
5Take chain tensioner (6) off
timing case cover (5) Installation: Replace
seal (7).
*BA05.10-P-1001-01C
Design of chain tensionerEngines 112, 113GF05.10-P-7801-01A
6Install in the reverse order
NumberDesignationEngines
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/
973/975/976Engines
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/
993/995
BA05.10-P-1001-
01CChain tensioner in
timing case coverNm8080

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 41 © 2006 Mitchell Repair Information Company, LLC.

Models 209.361 /461 with
engine 112.912
Models 209.365 /465 with
engine 112.955
Models 209.375 /475 with
engine 113.968
Models 209.376 /476 with
engine 113.987
Model 163.174 with engine
113.981
Model 163.175 with engine
113.965AR20.40-P-5000GH
2.1Remove alternator (G2) On alternator (G2)only
unscrew upper bolt, slacken
lower bolt. Fold away the
alternator (G2).
Models 202.088,
210.061 /062/261 /262
Models 163.174/175 with
ENGINE 113AR15.40-P-5032GH
Model 170 with Engine 112AR15.40-P-5032G
Models 203.061 /261 with
engine 112.912AR15.40-P-5032P
Models 203.064 /264 /764
with engine 112.946
Models 203.065 /265 with
engine 112.961
Models 209.361 /461 with
engine 112.912
Models 209.365 /465 with
engine 112.955
Models 209.375 /475 with
engine 113.968
Models 209.376 /476 with
ENGINE 113.987
Models
203.081 /084 /281 /284 with
engine 112AR15.40-P-5032PW
Model 202 with engine
112.910 /920, except 202.088
with engine 112AR15.40-P-5032EB
Model 208 with engine
112.940, 113.943 /984
Model 210 with engine
112.921 /941, except AR15.40-P-5032ED

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 43 © 2006 Mitchell Repair Information Company, LLC.

Engine 113 in model 129, 202, 208, 210
Engine 113 (except 113.965 /981) in model 163
Engine 112 in model 202, 208, 210AR13.22-P-
1202BA
Engine 112 in model 220
Engine 113 in model 215.373 /375
Engine 113 in models
220.070 /073 /075 /083 /084 /170 /173 /175 /183 /184 /875
Engine 113.965 in model 163.175
Engine 113.981 in model 163.174
Engine 113.984 in model 208.374 /474
Engine 113.963 in models 230.475AR13.22-P-
1202R
Engine 113.992 in model 230.474
Engine 112.947 in model 170.465AR13.22-P-
1202SV
10Remove cylinder
head covers (6)Engine 112, 113 air filter located on vehicle sideAR01.20-P-
5014B
Engine 112, 113 air filter located on engine sideAR01.20-P-
5014BV
11Detach coolant
line (17, 18) from
coolant pump
(12).
12Detach coolant
line (16) at
thermostat
housing (13).
13Dismount
refrigerant
compressor (A9) Place to the side with lines connected.

*BA83.55-P-
1001-01A
14.1Remove
alternator (G2)Engine 113.963 in models 230.475
Engine 113.992 in model 230.474AR15.40-P-
5032R
15.1Remove ATF line
bracket (23).Model 230
15.2Detach ATF line
from front axle
carrierModel 163
16Remove oil pan
bottom section (9)Engine 112.942 in model 163.154AR01.45-P-
7555V
Engine 112.970 in model 163.157
Engine 113.942 in model 163.172
Engine 113.965 in model 163.175AR01.45-P-
7555VE

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 100 © 2006 Mitchell Repair Information Company, LLC.