1997 MERCEDES-BENZ ML320 engine

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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Page 2

AF54.30-P-2064A
Fuel gauge not registering correctly after refueling vehicle
4.2.03

MODEL
163.### #A as of 221506 up to 364039,

163.### #X as of 734088 up to 777100

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

Sector

Op. no.
Operation text

Time
Acc. no.
Code

P
023803
RECODE INSTRUMENT CLUSTER
003 WU/0.3 h
54 208 50
---

Damage Code
Cause
Remedy

Refuel recognition software may not

recognize incremental refueling (< 7 L).

In case of complaint
#

The fuel gauge operation defaults to back-

up mode, and continuously decreases last

stored sensor value based on consumption

data supplied via engine management. This

continues until either refuel recognition or

instrument cluster (A1) reset occurs (via

STAR Diagnosis or power disconnect).
Vehicles with 83 L fuel tank (as of MY2002)
are more susceptible to this condition.

This applies only to instrument clusters

(A1) with diagnostic version 3/05, 3/06,

and 3/07.
1
Connect STAR Diagnosis.

2
Under "Control module adaptations" in

"ICM" menu, set "Fuel tank characteristic

curve" from "Normal" to "Direct sensor

value".

DO NOT replace the instrument cluster

(A1) or fuel pump assembly (M3) for this

condition.

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Page 1

AR47.10-P-7000GI
Remove/install fuel level sensor
21.2.01

MODEL
163.113 with ENGINE 612.963

MODEL
163.128 with ENGINE 628.963

P47.10-2128-06

1
Rear seat console

2
Left C-pillar cover

4
Wiring harness

5
Seat retaining cable

P47.10-2083-09

3
Housing

84
Closing cover

89
Union nut

6
Seal

90/10
Fuel intake line
90/11

Fuel-return line

90/12
Fuel feed line

90/13
Stationary heater connection

B4
Fuel level gage sensor


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, naked flame and smoking

prohibited.

Pour fuels only into suitable and appropriately

marked containers

Wear protective clothing when handling fuel

AS47.00-Z-0001-01A

1
Drain fuel

Fuel tank must not be filled to more than

3/4. If fuel tank is full, drain at least

23 liters of fuel.

AR47.10-P-4000GH

Pay attention to filling capacity of fuel tank.

*BF47.10-P-1001-01A

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Page 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.

3
Fold 60% bench seat forward into footwell

As of VIN A145273, X708319. See

operator's manual.

4
Pull floor covering below rear seat mounting

bracket (1) of 60% seat forward

Ensure that the floor covering is not torn

when pulled forward.

As of VIN A145273, X708319.

5
Pull floor covering below front corner of trim

panel of C-pillar (2) forward

Ensure that the floor covering is not torn

when pulled forward.

As of VIN A145273, X708319.

6
Cut into floor covering directly behind seat

retaining cable (5)

Ensure that the wiring harness (4) is not

damaged when cutting into floor covering.

As of VIN A145273, X708319. broken line

marks cut-in.

7
Turn back floor covering to gain access to

cap (84)


Do not kink floor covering.

8
Remove cap (84)


Cap (84) is sealed in with body sealer.

Heat with hot air blower to make it easier to

remove.


Installation:
Replace cap and install with

new sealing compound.

9
Detach fuel feed line (90/12) and fuel return

line (90/11) and, if fitted, the fuel line at

connection (90/13)


Do not kink the fuel lines.


If no stationary heater is fitted to vehicle,

do not remove connection (90/13) otherwise

housing will be damaged.

*163589003700

10
Remove nut (89)

*163589010700


*BA47.20-P-1006-01B

11
Remove housing (3)

Fuel lever sensor and housing are a

single part and cannot be removed separately.


Installation:
Re-install nut (89) together

with seal (89/2).

Apply a thin film of oil to seal.

12
Install in the reverse order


Fuel pump

Number

Designation
Engine 612Engine 628

BA47.20-P-1006-01B
Union nut for fuel tank sensor on fuel

tank
Nm
6565


Fuel tank

Number

Designation
Models

163.113/
136/154/

172 up to

31.08.01
Model

163.113/
136/154/

172 as of

01.09.01


Model

163.157/

175
Model

163.128

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liter
728383

Reserve capacity
Liter
101212

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Page 2

AR47.25-P-1000-01A
Separate fuel lines from engine, reconnect

P47.25-0212-03

1
Release arm

2
Sealing ring

A
Release position

B
Assembly position

P47.25-0213-03

The low pressure lines of the fuel system have plug connections

with a release arm (1) in place of screw connections.

The lines are sealed by means of a seal (2).

Disconnecting
1
Press the release arms (1) down to the stop in release position

as shown in picture A (arrow).

2
Disconnect connector on low-pressure line.

3
Pull back the release arms (1) again immediately to the stop

into the assembly position as shown in picture B (arrow).

The release arms (1) must not be kept over a long period in

the release position (A) otherwise leaks can occur due to

deformation of the low-pressure line.
Attaching

4
Check whether the release arm (1) is in the installed position
(b).

If the release arms (1) were kept for a long time in the

release position (A) the low-pressure line must be replaced

otherwise leaks can occur due to deformation of the low-

pressure line.

5
Insert connector on low-pressure line.

6
Ensure that the connector is firmly seated and free of leaks.
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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

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Page 1

AR47.10-P-4001GH
Emptying, filling the fuel tank
11.3.97

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

P47.10-0411-06

1/1
Service valve

17
Fuel rail

17/2
Fuel feed line

80/9
Fuel hose

F1K3
Fuel pump relay

Draining or pumping out

Danger!

Risk of explosion
if ignition takes place,
risk

of poisoning
caused by inhaling fuel vapors

or swallowing fuel as well as
risk of injury
to

skin and eyes exposed to fuel.
No fire, sparks, open flames or smoking.

Only pour fuels into suitable and appropriately

marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1
Release fuel pressure through service valve

(1/1)

Collect fuel.

Pressure hose

*119589046300

2
Unscrew fuel feed line (17/2) at fuel distributor

(17)


*BA07.52-P-1001-01A

3
Connect fuel hose (80/9) to fuel feed line (17/2)

Use 10 mm diameter fuel hose.

4
Insert fuel hose (80/9) into safety reservoir

5
Pull fuel pump relay (F1k3) out of relay holder

n

Assignment and cable connections of fuse

blocks

GF54.15-P-1255GH

6
Bridge fuel pump

Connect slot 30 (battery positive) to slot

87 (relay contact input).


*220589009900

7
Switch on ignition

8
Pump fuel out into safety canister


*BF47.10-P-1001-01A


Fuel rail

Number

Designation
Engine

112 except

112.945/951/

960/961

BA07.52-P-1001-01A
Fuel feed line on fuel distributor
Nm
38

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Page 1

Fuel rail

Number

Designation
Engines

113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/988/

BA07.52-P-1001-01A
Fuel feed line on fuel distributor
Nm
38


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

163.174

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liters
728393

Reserve capacity
Liters
101212

220 589 00 99 00

Electrical connection set

Pressure hose

119 589 04 63 00

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Page 2