air filter MERCEDES-BENZ ML430 1997 Complete Manual PDF

AP47.20-P-0780BB
Replace fuel filter
2.3.99

ENGINE
611.960 in MODEL 202.133 /134 /193 /194

ENGINE
611.961 in MODEL 210.006 /007 /206 /606

ENGINE
612.961 in MODEL 210.016 /216 /616

ENGINE
612.963 in MODEL 163.113

ENGINE
613.961 in MODEL 210.026 /226

ENGINE
613.960 in MODEL 220.026 /126

P47.20-0289-01

Shown on engine 611.960

70
Fuel filter housing

70/1
Fuel filter input

70/2
Fuel filter output

70/3
Threaded ring

70/4
Cap

70/5
Seal

70/6
Filter element

P07.16-2101-01

Shown on engine 612.961

70/1
Fuel line input

70/2
Fuel line output

70/3
Threaded ring

70/4
Cap

70/5
Seal

70/6
Filter element

70/7
Fuel return line

70/8
Fuel feed line


Remove/install and replacing


Danger!
Risk of death.
Death may result if vehicle

slips or topples from the lifting platform.
Align vehicle between the columns of the

lifting platform and position the four support

plates
at the lifting platform support points

specified by the vehicle manufacturer.

AS00.00-Z-0010-01A


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.
No fire, sparks, naked flames or smoking.

Pour fuels only into suitable and appropriately

marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1
Remove trim panel of charge air distribution

pipe

2
Disconnect fuel return line (70/7) and fuel

feed line (70/8 )

3
Unscrew threaded ring (70/3) and remove

together with cover (70/4).

If the fuel filter housing is soiled inside,
it must be removed and cleaned (against
separate order):

#
f

Remove/install fuel full-flow filter

AR47.20-P-1070HB

4
Replace filter insert (70/6)

After inserting the filter element

Fill fuel filter housing with fuel.

5
Replace sealing ring (70/5)

6
Mount threaded ring with cover so that the

groove latches at the fuel filter housing

Tighten threaded ring by hand.

7
Mount fuel return line (70/7) and fuel feed line

(70/8 )

8
Install trim panel of charge air distribution pipe


*BA01.20-P-1003-01A


Danger!
Risk of accident.
Accidents may result if the

vehicle starts off unintentionally with the

engine running.
Risk of injury.
Crushing and

burn injuries may result while working on

engine during when it is being started or when

it is in operation.
Secure 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

9
Run engine and inspect fuel filter for leaks

Crankcase ventilation, cylinder head cover

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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AR47.20-P-1070M
Removing and installing fuel full-flow filter
24.8.99

ENGINE
612.963 in MODEL 163.113

P47.20-2043-06

1
Fuel feed line

2
Fuel return flow line

3
Fuel cooler

4
Bolts of fuel cooler

70
Fuel full-flow filter

Operation no. of operation texts or standard texts and flat rates
Sector

Op. no.
Operation text

P
075560
REMOVING AND INSTALLING FUEL FULL-FLOW FILTER

P
075563
REPLACING FUEL FULL-FLOW FILTER

P
075564
REPLACING FUEL FULL-FLOW FILTER (AFTER INSPECTING)

Removing, installing

Danger!

Risk of injury
from fingers being
jammed or

bruised
when removing or installing and

aligning hood, doors, trunk lid/tailgate or

sliding roof
Ensure that no parts of your body or limbs are

within the operating range when moving such

components.

AS00.00-Z-0011-01A

Danger!

Risk of explosion
as a result of fuel vapors

igniting.
Risk of poisoning
as a result of

inhaling fuel vapors.
Risk of injury
as a

result of fuel coming into contact with skin

and eyes.
No fire, naked flame or smoking.

Pour fuels only into suitable and appropriate

marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1
Open hood and raise to vertical position


Have assistant secure hood.

AR88.40-P-1000GI

2
Remove trim panel of charge air distribution

pipe

AR01.20-P-5014-02B

*BA01.20-P-1002-01A
*BA01.20-P-1003-01A

3
Disconnect fuel lines (1, 2) at fuel full-flow

filter (70)


Collect fuel which flows out.

Pay attention to use of locking arm. See:
#

Disconnecting and connecting fuel lines at

engine.

AR47.25-P-1000-01A

4
Take off fuel cooler (3)

Take off only the bolts (4) and raise fuel

cooler slightly.

5
Remove fuel full-flow filter (70)


Collect fuel which flows out.

Installation:
If the fuel full-flow filter has been

drained, it must be filled with fuel after being

installed and before starting the engine to

ensure engine starts properly.

*BA47.20-P-1001-02A

6
Install in the reverse order

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

Danger!

Risk of accident
as a result of vehicle

starting off when engine running.
Risk of

injury as a result of bruises and burns if you

insert your hands into engine when it is being

started or when it is running.
Secure vehicle to prevent it starting off.

Wear closed and close-fitting work clothes.

Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

7
Run engine and inspect fuel system for leaks

Crankcase ventilation, cylinder head cover

Number

Designation
Engine

612.963

BA01.20-P-1002-01A
Screw of trim panel of cylinder head cover

to cylinder head cover
Nm
10

BA01.20-P-1003-01A
Screw of trim panel of charge air distribution

pipe to charge air distribution pipe
Nm
10


Fuel filter

Number

Designation
Engine

612.961/

963

BA47.20-P-1001-02A
Bolt of fuel filter to charge air distribution pipe
Nm
14

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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AR47.20-P-1070HBRemove/install fuel full-flow filter
21.11.97

ENGINE
611.960 /961 /962, 612.961 /963, 613.960 /961

P07.57-0222-12

Shown on Engine 611.960

1
Fuel outlet line

2
Fuel feed line

70
Fuel full-flow filter

P47.20-2024-12

Illustrated on Engine 613.961

1
Fuel feed line of fuel tank

2
Fuel feed line to predelivery pump

3
Fuel return line from rail

4
Fuel return line to fuel cooler (fuel tank)

70
Fuel full-flow filter


Remove/install


Danger!
Risk of explosion
due to combustion,
Risk

of poisoning
due to inhalation and

swallowing of fuel
Injury hazard
due to skin

and eye 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

1
Remove trim panel of charge air distribution

pipe
Engine 611

AR01.20-P-5014-02A

Engine 612

AR01.20-P-5014-02B

Engine 613

AR01.20-P-5014-02C

*BA01.20-P-1003-01A

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

2.1
Disconnect fuel lines (1,2) at main fuel filter

(70)
Engine 611


Collect escaping fuel.

Pay attention to use of locking arm. Refer

to:

#

Separate fuel lines from engine, reconnect

AR47.25-P-1000-01A

2.2
Disconnect fuel lines (1,2,3,4) at main fuel

filter (70)
Engine 612, 613


Collect escaping fuel.

Pay attention to use of locking arm. Refer

to:

#

Disconnect, connect fuel lines at engine.

AR47.25-P-1000-01A

3
Remove main fuel filter (70)


If the main fuel filter has been emptied, it

must be filled with fuel after being installed

before starting, the engine starts more easily.

*BA47.20-P-1001-02A

4
Install in the reverse order


Danger!

Risk of accident
due to automatic starting-off

when engine is running.
Injury hazard
due to

crimped connection and combustion when

meshing during starting procedure or when

engine is running
Secure vehicle to prevent it from moving off

by itself.

Wear closed and close-fitting work clothes.

Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

5
Run engine and inspect fuel system for leaks

Crankcase ventilation, cylinder head cover

Number

Designation
Engine

611.960/

961/962
Engine

612.961/

962/967
Engine

612.963
Engine

613.960/

961

BA01.20-P-1003-01A
Screw attaching cover panel to charge air

distribution pipe
Nm
10101010


Fuel filter

Number

Designation
Engine

611.960/

961
Engine

611.962
Engine

612.961/

963
Engine

613.960/

961

BA47.20-P-1001-02A
Bolt of fuel filter to charge air distribution pipe
Nm
14141414

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Repair materials
RETROFITTING & CONVERSION
TABLE OF CONTENTS FOR RETROFITTING AND CONVERTING SPECIAL EQUIPMENT - AN00.10-P-1000NZ
MODEL 163
cleaning agents.
Only for Activated
charcoal filter, code 306:
Cover inside of air inlet
grille on engine hood.
Cleaner
14Treat paintwork using
polishing paste and buffer If films still on
paintwork.
Polish*BR00.45-Z-1015-04A
15Perform treatment using
polish and gloss
preservation.Polish*BR00.45-Z-1013-04A
Gloss preserver*BR00.45-Z-1014-04A
NumberDesignationOrder number
BR00.45-Z-1017-04ACleanerA 001 986 13 71
BR00.45-Z-1014-04AGloss preserverA 000 986 44 74
BR00.45-Z-1015-04APolishA 000 986 43 74
BR00.45-Z-1013-04APolishA 000 986 45 74
AN31.10-P-8080AA Retrofit trailer
couplingModel 163.113 /136 /154 /172 #A as
of 145273,
Model 163.113 /136 /154 /172 #X as
of 708319,
Model 163.128 /175 except styling
package, code U49AN31.10-P-8080AA
AN31.10-P-8080AB Retrofit trailer
couplingModel 163.113 /136 /154 /172 #A as
of 145273,
Model 163.113/136 /154 /172 #X as
of 708319,
Model 163.128 /175 with styling
package, code U49
Model 163.174AN31.10-P-8080AB
AN31.10-P-8080AC Retrofit trailer
couplingModel 163.136 /154 /172 #A up to
145272,
Model 163.136 /154 /172 #X up to
708318AN31.10-P-8080AC
AN91.12-P-0001A Retrofit third seat rowModel
163.113 /128 /136/154 /157 /172 /175AN91.12-P-0001A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:52 PMPage 409 © 2006 Mitchell Repair Information Company, LLC.

TABLE OF CONTENTS FOR SUBSEQUENT INSTALLATION AND CONVERSION OF ACCESSORIES - AZ00.10-P-1000JZ
MODELS 163
AN91.12-P-0002A Retrofit third seat row
automatic easy entry
adjustment facilityModel 163.154/172#A as of 145273
Model 163.136 /154 /172 #X from
708319,
Model 163.113 /128 /157 /175 with
3rd seat row, code 847AN91.12-P-0002A
AN20.30-P-0001RRetrofit coolant
preheaterModel 163.136 with engine 111.977AN20.30-P-0001R
AN20.30-P-0001S Retrofit coolant
preheaterModel 163.154 with engine 112.942AN20.30-P-0001S
AN20.30-P-0001T Retrofit coolant
preheaterModel 163.172 with engine 113.942
Model 163.175 with engine 113.965AN20.30-P-0001T
AN49.10-P-0001ARetrofit system for
diesel particle
reductionEngine 612.963 in model 163 except
particulate filter, code 474AN49.10-P-0001A
AN82.61-P-0001H Retrofit navigation
system Audio 30 APSModel 163 up to 30.6.99 except 6-
disk CD changer, code 819
Model 163 as of 1.7.99 in
combination with CD changer with
D2B fiber optic cable systemAN82.61-P-0001H
AN88.30-P-0001A Retrofitting fender
flapModel 163.113/136 /154 /172 #A up
to 289564 up to 31.8.01
Model 163.113/136 /154 /172 #X up
to 754619 up to 31.8.01AN88.30-P-0001A
AN88.30-P-0003A Retrofitting underride
protectionModel
163.113/128/136/154/157/172/175
except styling package, code U49,
except Parktronic system (PTS), code
220AN88.30-P-0003A
AZ49.10-P-0002B Retrofitting AMG
end pipeEngine 111.977 in model 163.136 except
modification kit, code
U47 except styling package, U49
Engine 112.942 in model 163.154 except
modification kit, code U47
except styling package, U49
Engine 112.970 in model 163.157 except
modification kit, code U47
except styling package, U49
Engine 113.942 in model 163.172 except
modification kit, code U47
except styling package, U49
Engine 113.965 in model 163.175 except AZ49.10-P-0002B

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:52 PMPage 410 © 2006 Mitchell Repair Information Company, LLC.

M 160, 160/1,
M 285
(Maybach)--------•-
M 166-----••---
M 266 Turbo,
M 271------••••
Other
M 1xx, M 2xx
that are not
listed above-----••-•-
Diesel engines
without
particulate
filter (DPF)
OM660---•----•-
OM 640, 642,
646 in model
series 639
OM 646, 647,
648---/•••-••••
OM611, 612,
613, 628, 639,
668, 664, 665--/•-/••••••••
Other
OM 6xx not
listed above--/•-/••••••••
with
particulate
filter (DPF)
OM 629, 639,
640, 646, 647,
648, 664, 665
OM 639 in
model series
639 and 906----•--•-•
OM
660
(EU3/EU4 not
with regulated
DPF)---•----•-
Other
OM 6xx with
DPF not listed
above----•--•-•

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:52 PMPage 415 © 2006 Mitchell Repair Information Company, LLC.

Commercial vehicle engines, Industrial engines from the commercial vehicle sector (BR 300, BR 400, BR
500, BR 900)
This table only serves as an overview!
The detailed maintenance and oil change regulations can be found in the maintenance booklet for the respective
vehicle/ major assembly.
• Enable
o Can only be used in exceptional cases or under certain operating conditions/in certain applications.
- Must not be used
1. Sheets 227.0/. 1 no longer exist! Replaced by engine oils in sheets 228.0/. 1/.2/.3/.5/51.
2. Use in combination with low-sulfur (S <50 ppm) or sulfur-free (S <10 ppm) fuel! If fuels with sulfur
contents of S> 500 ppm are being used, the oil change intervals must be reduced!
3.Restriction: Onl
y "Mobil 1 5W-50", SAE 5W-50, sheet 229.3 is approved!
MB
Specifications
for
Operating
Fluids Sheet
1.)226.9
Multi-
grade228.0/.1
Single/
Multi-
grade226.9229.3
Single/
Multi-
grade229.5
Multi-
grade228.51 '
Multi-
grade229.1
Multi-
grade229.3
Multi-
grade229.31
Multi-
grade229.5
Multi-
grade229.51
Multi-
grade
Commercial
vehicles,
buses without
particulate
filter
BR 300, 400,
500, 900; OM
457, 460 up to
and including
Euro 3-o/•o/•••-----
BR 500, 900;
OM 457, 460
Euro 4/5--o/•••-----
Gas engines•---•-----
Commercial
vehicles,
buses with
particulate
filter
BR 500, 900;
OM 457, 460--oo•-----

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:52 PMPage 416 © 2006 Mitchell Repair Information Company, LLC.

Valve seal not okay :
#
3
Remove/install/replace valve seal.

AR05.30-P-3500B

Cause 6:
Remedy 6:

00 001 70
1.5 mm hole missing on individual right

cylinder head covers at connection to

crankcase ventilation.
1
Check cylinder head cover

Up to production 06/1999.

Crankcase ventilation out of order, engine can

sludge up and consume oil as a result

Cylinder head cover not okay:
#
2
Remove/install/replace cylinder head

cover.

ENGINE
112

Air cleaner positioned on engine

side.

ENGINE
113

Air cleaner positioned on engine

side.
AR01.20-P-5014BV

ENGINE

112

Air cleaner positioned on engine side

ENGINE
113

Air cleaner positioned on engine side

AR01.20-P-5014B

Cause 7:
Remedy 7:

00 001 70
Engine oil sludging due to excessively long

engine oil change intervals
Service information: Oil sludge

SI18.00-P-0010A

If the service interval according to

ASSYST is exceeded, the engine oil sludges

up sooner or later depending on the oil

quality, type of operation and operating time.

Engine consumes oil.

See Service Information.

1
Print out ASSYST printout.

2
Check oil change intervals

3
Inform vehicle owner.

4
Remove/install/replace piston rings.

AR03.10-P-7311BV

Disassemble and clean sludged engines

completely because dirty oil usually gets into

clean-oil side due to clogged oil filter.

Cause 8:
Remedy 8:

00 001 70
Piston rings sticky or have coke deposits from

engine oils (e.g. API-S in USA) in connection

with regionally poor fuel quality.

Always use engine oils according to

Specifications for Operating Fluids 229.3, do

not add special additives to engine oil and fuel

BB00.40-P-0229-03A

1
Remove/install/replace piston rings.

AR03.10-P-7311BV

Cause 9:
Remedy 9:

00 001 70
Piston ring wear due to excessive

contamination/dust (model 163) through air

intake system.
1
Remove/install/replace gaskets on air

intake line and distribution element of

partial load ventilation.

e.g. due to incorrect assembly after

workshop visit or embrittlement of gaskets
The distribution element with optimized

material will be available as of 11/ 2000 as a

standard feature.

2
Remove/install/replace intake module.

Exterior oil loss, e.g. due to cast iron

porosity on left side of crankcase in area of

engine support is not considered to be oil

consumption

In the event of a customer complaint

regarding the engine oil consumption, always

determine the oil consumption definitely

because the oil indicator lamp can come on

due to other causes (e.g. defective oil sensor).

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e. g.)
Order number

WH58.30-Z-1009-05A
Flexible inspection light
Scope of supply 1 (complete unit):

-glass fiber optical fiber

-light projector

-230 V, storage case

-operating instructions

-graphics protocol
Richard Wolf GmbH

Pforzheimerstr. 32

D-75438 Knittlingen

Karl Storz GmbH

Mittelstr. 8

D-78532 Tuttlingen
1.00565.00

80902

WH58.30-Z-1010-05A
Flexible inspection light

Scope of delivery 2 (for workshops which already have an approved

Wolf or Storz inspection light):

-storage case

-operating instructions

-pictures protocol
Richard Wolf GmbH

Pforzheimerstr. 32

D-75438 Knittlingen

Karl Storz GmbH

Mittelstr. 8

D-78532 Tuttlingen
7.05065.00

K03506AJ

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d by Modification services.
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