MERCEDES-BENZ ML430 1997 Complete Repair Manual

Fig. 10: Identifying Intake Manifo ld Remove/Install Components - Shown On Engine 112
Fig. 11: Identifying Crankcas e Ventilation Hose And Line

Remove/install

Risk of
explosion
caused by fuel
igniting, risk
of poisoning
caused by
inhaling and
swallowing
fuel and risk of
injury to eyes
No fire, sparks, ope n flames or smoking.
Only pour fuels into suitable and appropriately marked containers.
Wear protective clothing when handling fuel. AS47.00-
Z-0001-
01A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:57 PMPage 10 © 2006 Mitchell Repair Information Company, LLC.

and skin caused
by contact with
fuel
1
Remove key
from electronic
ignition switchOnly on vehicles with electronic ignition switch.
Vehicles with Keyless Go code 889: Switch off engine, remove Keyless
Go-Cards out of vehicle and store outside of the sender range.

2
Remove cover
on front side of
engine
Model 129, 211, 215, 220, 230 only
3.1
Remove engine
cover with
integrated air
filterExcept model 171.473, 203.076 /276, , 209.376 /476 from 24.4.04
The air filter is integrated in the engine cover. Remove engine cover or air
filter by pulling it vertically up and off the cylinder head covers.

3.2Remove air
filter housingModel 171.473
Model 203.076/ 276
Model 209.376/ 476 as of 24.4.04AR09.10-
P-1150AC
4
Remove hot
film mass air
flow sensor
with air intake
pipe
Engine 112.910/ 920/ 921/940/ 941/ 942/ 970
Engine 113.940AR07.07-
P-1454A
Engine 112.922 /944 /972 /973 /975
Engine 113.941/ 948/ 960/ 961/ 963/ 966AR07.07-
P-1454AA
Engine 112.912 /913 /916 /917 /946 /947 /949 /954 /953 /955
Engine 113.968 /967 /969 /987 /988 /989AR07.07-
P-1454SV
Engine 112.923 /943
Engine 113.943 /944 /980 /984AR07.07-
P-1454AG
Engine 113.942 /965/981
AR07.07-
P-
1454MV
5
Disconnect
lead line (17/2)
at the fuel
distributor
Release fuel pressure via service valve and collect fuel.

*BA07.52
P-1001-
01A
Fig. 12
6
Removing fuel
rail with
injection valvesEngine 112.910 /920 /921 /923 /940 /941 /942 /943 /970
Engine 113.940 /942 /943 /944 /961 /965 /980 /981 /984AR07.03-
P-1451A

Engine
112.912/913 /916 /917 /922 /944 /946 /947 /949 /953 /954 /955 /972 /973 /975
Engine 113.941 /948 /960 /963 /966 /967 /968 /969 /987 /988 /989AR07.03-
P-1451AA
Unscrew

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:57 PMPage 11 © 2006 Mitchell Repair Information Company, LLC.

7.1cylinder head
cover (2/1) boltModel 230.475 only

*BA01.20
P-1001-
01E
7.2
Remove
crankshaft
ventilation
hose (2) and
line (89/2) and
place to one
side
Model 171.473 only
Remove cylinder head cover (2/1) bolt in order to detach exhaust gas
recirculation valve (89) bracket.


*BA01.20
P-1001-
01E
8
Disconnect
vacuum lines
from intake
pipe (19)
Installation: Observe intake manifold connection diagram. ?
Engine 112 except 112.913 /917 /949 /954AR09.20
-
P-1310-
01A
Engine 112.913/917 /949 /954AR09.20
-
P-1310-
01T

Engine 112 with USA version, code 494, except engine
112.913 /916 /917 /949 /953 /954 /975
Engine 112.913/916 /917 /949 /953 /954 /975 with USA version, code 494AR09.20-
P-1310-
01AA
Engine 113 except 113.967 /969AR09.20
-
P-1310-
01AU
Engine 113.967/969AR09.20
-
P-1310-
01TA

Engine 113 with USA version, code 494, except engine
113.948 /963 /966 /984 /967 /969 /989 /988
Engine 113.948 /963 /966 /984 /967 /969 /988 /989 with USA version, code
494AR09.20-
P-1310-
01AC
9
Disconnect
electrical
connectors

10
Unscrew acorn
nut from pipe
(89/2) to
exhaust gas
recirculation
Counterhold connection fitting when unscrewing.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:57 PMPage 12 © 2006 Mitchell Repair Information Company, LLC.

Crankcase ventilation, cylinder head cover
valve (89)

*BA14.20
P-1002-
01B
11Unscrew screw
(19/1)Except engine 113.987 as of 24.04.04,
Engine 113.988/989

*BA09.20
P-1001-
01D
11.2
Remove bolts
from right
combination
valve (6) and
left
combination
valve (6)
Only with engine 113.987 as of 24.04.04
Engine 113.988/989

*BA09.20
P-1001-
01D
12.1
Remove
combination
valve (6)Except engine 113.987 as of 24.04.04
Engine 113.988/989
Installation: Install new gasket

12.2
Loosen right
combination
valve (6) and
left
combination
valve (6) and
place to one
side
Only engine 113.987 from 24.04.04
Engine 113.988/989
Installation: Replace the gaskets.

13
Dismount
intake manifold
(19) Plug intake ducts. Use centering bolt for exact positioning of intake
manifold and for centering the gasket (19/3).

*BA09.20
P-1001-
01D
Fig. 13
14Replace gasket
(19/3)
15Install in the
reverse order
NumberDesignationEngine
113.940/941/942/943/944/948/960/961/962/963/964/965/966/967/968/969/971/980/981
/

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:58 PMPage 13 © 2006 Mitchell Repair Information Company, LLC.

Fuel distributor
Fuel distributor
Intake manifold
Exhaust gas recirculation
Exhaust gas recirculation
BA01.20-
P-1001-
01ECylinder
head cover
bolt Nm10
NumberDesignation
Engine 112 except
112.945/951/960/961
BA07.52-P-1001-01AFuel feed line to fuel
distributorNm38
NumberDesignationEngine113.987Engine113.940/941/942/943/944/945/946/948/960/961/962/9
BA07.52-
P-1001-
01AFuel feed
line to
fuel
distributorNm3838
NumberDesignationEngine112,113
BA09.20-P-1001-
01DBolt, intake
manifold to
cylinder headM8Nm20
NumberDesignationEngine
112.910/912/916/920/921/922/923/940/941/942/943/944/945/946/947/953/
9
BA14.20-
P-1002-
01BUnion nut,
exhaust gas
recirculation
pipe to
exhaust gas
recirculation
valveNm40
NumberDesignationEngine113.989
BA14.20-P-1002-01BUnion nut, exhaust gas
recirculation pipe to
exhaust gas recirculation
valveNm40

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:58 PMPage 14 © 2006 Mitchell Repair Information Company, LLC.

Fig. 12: Identifying Pressure Hose (119 589 04 63 00)
Fig. 13: Identifying Set Of Dowel Bolts (112 589 02 62 00)

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:58 PMPage 15 © 2006 Mitchell Repair Information Company, LLC.

AIR BAG SAFETY PRECAUTIONS
Observe following precautions when working with air bag systems:
When working around steering column components and before any repairs are performed, disable air bag
system. See DISABLING & ACTIVATING AIR BAG SYSTEM
.
Before straightening any damage to body, or before performing electrical arc-welding, disable air bag
system. See DISABLING & ACTIVATING AIR BAG SYSTEM
.
Always wear safety glasses and gloves when handling a deployed air bag module. Air bag module may
contain sodium hydroxide deposits which are irritating to the skin.
DO NOT repair any portion of SRS wiring harness.
Always handle air bag module with trim cover away from your body. Always place air bag module on
workbench with trim cover up, away from loose objects.
DO NOT expose any SRS component to temperatures in excess of 212 F (100 C).
DO NOT expose any SRS component to cleaning agents such as solvents, gasoline, lye, etc.
DO NOT connect Hand-Held Tester (6511 0001 99) to Data Link Connector (DLC) with ignition on.
Damage to HHT may result.
DO NOT connect HHT (6511 0001 99) to vehicle if a battery charger is connected to vehicle battery.
Dama
ge to HHT may result.

2001 Mercedes-Benz ML320
2000-01 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems

2001 Mercedes-Benz ML320
2000-01 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems
me
Saturday, October 02, 2010 3:43:48 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.
me
Saturday, October 02, 2010 3:43:51 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.

AR68.30-P-4050GH
Removing and installing paneling on A-pillar
12.3.97

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

P68.30-0537-06

Vehicle illustrated up to 31.8.98

1
A-pillar paneling

2
Door rubber seal

3
Cover cap

4
Bolt


Remove/install

1
Remove door rubber seal (2) in area of A-pillar

2.1
Remove cap (3)
Up to 08/98.

3.1
Unscrew screw (4)Up to 08/98.

4
Remove A-pillar paneling (1)

The paneling is fastened in the instrument

panel at the bottom with lugs and will be

fastened with a clip at top as of 09/98.

Installation:
Replace clip

Long wedge

*115589035900

5
Install in the reverse order

On vehicles up to 08/98, on which a new

paneling should be installed, the upper area

of the fixing opening at the top of the A-pillar

must be enlarged so that the clip retainer of

the paneling can be installed in the A-pillar.

Long wedge

115 589 03 59 00

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

GF54.15-P-1255GH
Assignment and cable connections of fuse blocks
18.3.97

MODEL
163

P54.15-0438-06

Fuses
1-42

Relay
k1-k32

P54.15-2486-12

Overview of fuse and relay module in right front footwell

Fuse and relay box, fuses, relay holder
Engines 612.963 and 628.963

GF54.15-P-1255-12G

Fuse and relay box, fuses, relay holder
up to 31.08.01

GF54.15-P-1255-15GH

Fuse and relay box, fuses, relay holder
as of 01.09.01
GF54.15-P-1255-15GA

Fuse and relay box, fuses, relay holder
Fuse and module box in right front footwell

GF54.15-P-1255-15GI

Fuse and relay box, relay/relay holder
up to 31.08.01

GF54.15-P-1255-18GH

Fuse and relay box, relay/relay holder
as of 01.09.01
GF54.15-P-1255-18GA

Fuse and relay box, relay/relay holder
Fuse and module box in right front footwell

GF54.15-P-1255-18GI

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

1998-03 AUTOMATIC TRANSMISSIONS
Complete Transmissions - ML 320 - 722.662
MODEL IDENTIFICATION
MODEL IDENTIFICATION
COMPLETE TRANSMISSION
REMOVE/INSTALL OIL PUMP
Model (Year)ChassisEngineTransmission
ML320 (2001-03)163.154112.942722.662

2001 Mercedes-Benz ML320
1998-03 AUTOMATIC TRANSMISSIONS Complete Transmissions - ML 320 - 722.662

2001 Mercedes-Benz ML320
1998-03 AUTOMATIC TRANSMISSIONS Complete Transmissions - ML 320 - 722.662
me
Saturday, October 02, 2010 3:15:25 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.
me
Saturday, October 02, 2010 3:15:33 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.