1997 MERCEDES-BENZ ML320 engine

Wheel location, hub
Front final-drive unit
Propeller shaft of front axle gear
Front axle gear
Thrust pieceFig. 45
SupportFig. 46
PressFig. 47
5Remove lower engine compartment
panelingModel 163.157 /172 /174 /175AR61.20-P-
1105GH
Model 163.113 /128AR94.30-P-
5400GH
6Press left and right front axle shafts out
of front axle gear Do not damage shield.
Suspend steering knuckle with
wire.

7Disconnect vent hose from front axle
gear
8Remove bolts (14a) *BA33.30-P-
1001-03B
9Remove front axle gear (14).
10Install in the reverse order
NumberDesignationModel 163
BA33.20-P-1001-01DSelf-locking nut, upper wishbone follower joint to steering knuckleNm50
NumberDesignationModel 163
BA33.30-P-1001-03BBolt securing front axle gear to front axle carrierNm135
BA33.30-P-1002-03BOil filler screw, front axle gearNm50
BA33.30-P-1003-03BOil drain screw, front axle gearNm50
NumberDesignationModel 163
BA41.20-P-1001-01ASelf-locking bolt of propeller shaft to front-axle gear flangeNm40
Number Designation Model 163
BF33.30-P-1001-
03BFilling capacityFront axle gearLiters1.2
Specifications for Operating
FluidsSheetBB00.40-P-0235-
07B

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:22 PMPage 43 © 2006 Mitchell Repair Information Company, LLC.

AR07.16-P-1100MM
Remove, install fuel cooler
5.11.99

ENGINE
612.963 in MODELS 163.113

P47.00-2042-12

1
Fuel feed hose

2
Fuel drain hose

3
Coolant feed hose

4
Coolant return flow hose

5
Fuel cooler

7
Bolts of fuel cooler

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

Op. no.
Operation text

P
075890
REMOVING AND INSTALLING FUEL COOLER

P
075895
REPLACE FUEL COOLER


Remove, Install


Danger!
Risk of injury
to
fingers being jammed or

squeezed
when removing and installing or

aligning hoods, doors, tailgate/tailgate and

sliding roof.
When moving components ensure that no

body parts or limbs are in the area of motion.

AS00.00-Z-0011-01A


Danger!
Risk of injury
to skin and eyes suffering

scalding from contact with hot coolant spray.
Risk of poisoning
from swallowing coolant.
Do not open cooling system unless coolant

temperature is below 90 °C. Open cap slowly

and release the pressure. Do not pour coolant

into beverage bottles.

Wear protective gloves, protective clothing

and eye protection.

AS20.00-Z-0001-01A


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
Open engine hood and raise to vertical position


Have second person secure hood.

AR88.40-P-1000GI

2
Remove trim panel of cylinder head cover

AR01.20-P-5014-02B


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

3
Drain coolant

At radiator.

AR20.00-P-1142M

4
Close fuel feed hose (1) at the fuel cooler (5)

Set of plugs

*129589009100

*WH58.30-Z-1001-06A
*WH58.30-Z-1002-06A

5
Detach fuel outlet hose (2)

Clamp

*000589543700

Set of plugs

*129589009100

*WH58.30-Z-1001-06A
*WH58.30-Z-1002-06A

6
Disconnect coolant return flow hose (4) to

thermostat housing

Hose clamp pliers (length 210 mm;

adjustment range 80 mm)

*WH58.30-Z-1026-02A

7
Unscrew bolts (7) at fuel cooler

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d by Modification services.
Page 1

8
Disconnect coolant feed hose (3) to fuel cooler

Raise fuel cooler.

Hose clamp pliers (length 210 mm;

adjustment range 80 mm)

*WH58.30-Z-1026-02A

9
Install in the reverse order


Danger!
Risk of accident
as vehicle may start off by

itself with the engine running.
Risk of injury


as working around the engine during start-up

or while running may result in contusions and

burns
Secure vehicle to prevent it from moving off

by itself.

Wear closed and tight-fitting work clothes.

Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

10
Pour in coolant
*BF20.00-P-1001-02E

Switch heater to maximum and warm up

engine at moderate revs. Top up coolant

constantly at coolant expansion reservoir.

Close coolant expansion reservoir once

coolant temperature is 60-70 °C.


Note on coolant level
Models 124, 129, 140, 168, 170, 202, 208,

210, 220, 463

AH20.00-P-1142-01A

11
Inspect cooling system for leaks

AR20.00-P-1010HA

12
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 attaching cover panel to charge air

distribution pipe
NM
10


Cooling system

Number

Designation
Engine

612.963

BF20.00-P-1001-02E
Cooling system
Total capacity
Liter
Y
11,0

Capacity of anticorrosion/

antifreeze agent down to -37 °C
Liter
Y
5,5

Capacity of anticorrosion/

antifreeze agent down to -45 °C
Liter
Y
6,25

Specifications for Service

Products
SheetBB00.40-P-0310-01A
SheetBB00.40-P-0325-02A

129 589 00 91 00

Set of closure plugs

Circuit

000 589 54 37 00

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e.g.) g.)
Order number

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Page 2

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

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Page 1

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

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d by Modification services.
Page 2

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

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d by Modification services.
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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

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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

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Page 1