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Fig. 26: Identifying Left Knock Sensor 2 - Shown On Engine 112 In Model 220 
 Knock sensors 
  Remove/install  
1.1Remove intake manifoldAll except model, 463 with 
engine 113.962/982/993 
Model 463 with engine 
112.945 
Model 170.466 with engine 
112.960 
Model 203.065/265 with 
engine 112.961 
Model 211.076/276 with 
engine 113.990AR09.20-P-1310A 
Model 463 with Engine 
112.945, 113.962/982AR09.20-P-1310AG
1.2Remove compressorModel 170.466 with engine, 
112.960 model 203.065/265 
with engine, 112.961 model 
211.076/276 with engine 
113.990AR09.50-P-4705SVK
Model 463.270/271 with 
engine 113.993AR09.50-P-4705GX
2Detach knock sensor 1, 
right and knock sensor 2, 
left (A16/2) from cylinder 
block *BA15.10-P-1001-02A
3Install in the reverse order  
 
2001 Mercedes-Benz ML320 
1998-2005 ENGINE Electrical System - Engine - 163 Chassis  
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SERVICING WIRING HARNESS - AR15.18-P-0500A 
MODEL 124, 126, 129, 140, 163, 168, 170, 201, 202, 208, 210, 215, 220  
Fig. 27: Identifying Terminal Block And Cable Connection Of Mass Air Flow Sensor And Temperature 
Sensor 
 If a cable break or similar damage exists in the area of the plug connection of the mass air flow sensor (B2) 
or temperature sensor (B11), it is possible to repair the wiring harness in order to avoid costly replacement of a 
wiring harness. 
Modification notes 
NumberDesignationEngine 
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/ 
973/975/976Engine 
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/ 
993/995Engine 
113.989
BA15.10-P-
1001-02ABolt securing 
knock sensor to 
cylinder blockNm202020
27.9.99Supersedes SI 54/76 dated 
23.1.96Remove SI 54/76 from 
your file. 
 
2001 Mercedes-Benz ML320 
1998-2005 ENGINE Electrical System - Engine - 163 Chassis  
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        Page 2203 of 4133

Parts ordering notes 
REMOVE AND INSTALLING THE STARTER - AR15.30-P-7100GH 
ENGINE 112.942 in MODEL 163.154  
  Removing and installing   
1Remove air cleaner, install. Only on engine 119 
2Expose wiring harness to 
mass air flow sensor or 
temperature sensor. Ignition switched 
off  
3Unplug socket from mass 
air flow sensor or 
temperature sensor.  
4Plug in repair socket 
together with cables at 
mass air flow sensor or 
temperature sensor and 
insert into cable duct.  
5Repair wiring harness 
using end soldering sleeves 
(Z). Turn together cable of 
engine wiring harness and 
cable repair socket of the 
same color and insert into 
end soldered sleeves (Z). 
 Use end soldered 
sleeves (Z) only in cross 
section area Ø 0.7 - Ø 4.0 
mm
2 
AR54.18-P-0100-02A 
6Insert cables into the cable 
duct.  
7Connect HHT, read faults 
and erase see Diagnosis Manual 
Engine Volume 2 Index 0: 
Connecting and using test 
equipment 
8Install in the reverse order  
Part no.DesignationQuantity
140 540 00 36Repair kit socket (B2)1 
1) Consisting of repair socket (B2) 
and 5 cable connectorsacc. to condition
140 540 00 81Repair socket (B2)acc. to condition
202 540 01 81Repair socket (B11) 3-pinacc. to condition
126 540 30 81Repair socket (B11) 4-pinacc. to condition
001 546 99 41Cable connectoracc. to condition
006 989 84 85Fabric tapeacc. to condition
 
2001 Mercedes-Benz ML320 
1998-2005 ENGINE Electrical System - Engine - 163 Chassis  
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        Page 2204 of 4133
ENGINE 112.970 in MODEL 163.157  
ENGINE 113.942 in MODEL 163.172  
ENGINE 113.981 in MODEL 163.174  
ENGINE 113.965 in MODEL 163.175  
Fig. 28: Identifying Starter Remove/Install Components
 
Modification notes 
3.9.03Check ring gear, newly 
recordedStage 7 
  Removing/installing  
 Risk of explosion caused by 
oxyhydrogen gas. Risk of 
poisoning and caustic burns 
caused by swallowing battery 
acid. Risk of injury through 
burns to skin and eyes from 
battery acid or when handling 
damaged lead-acid batteriesNo fire, sparks, open 
flames or smoking. Wear 
acid-resistant gloves, 
clothing and safety 
glasses. Only pour battery 
acid into suitable and 
appropriately marked 
containers.AS54.10-Z-0001-01A 
 Notes on self-locking nuts and 
bolts AH00.00-N-0001-01A 
 
2001 Mercedes-Benz ML320 
1998-2005 ENGINE Electrical System - Engine - 163 Chassis  
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1Disconnect ground cable from 
battery Insulate ground line as 
a protection against 
unintentional contact of 
dismounted ground line 
with ground point of 
battery.AR54.10-P-0003A 
 Notes on battery AH54.10-P-0001-01A 
2Remove inner fender in right 
front fender AR88.10-P-1300GH 
3.1Unscrew nut (6) at shield (5) 
of left engine mount and take 
out shieldEngine 112 
 
*BA22.10-P-1004-01L
4Dismount electrical line 
circuit 30 (1) and electrical 
line circuit 50 (2) Nut, terminal 30 
connection*BA15.30-P-1001-01A
   Nut of connection 
circuit 50*BA15.30-P-1002-01A
5Remove bolts (3) *BA15.30-P-1003-01A
6Take out starter (M1) to the 
side  
7.1Check ring gear at flywheel 
for wear and damageWhen replacing the 
starter on vehicles fitted 
with manual transmission
 Rotate engine at the 
crankshaft in direction of 
rotation. 
7.2Check ring gear on the drive 
plate for wear and damageWhen replacing the 
starter on vehicles fitted 
with automatic 
transmission 
 Rotate engine at the 
crankshaft in direction of 
rotation. 
8Install in reverse order  
9Perform function check  
10Render electrical system 
operationalSee ? Perform basic 
programmingAR00.19-P-0200GH 
11Read out fault memory and 
erase When the work is 
complete stored faults 
must be worked on in the 
diagnostic trouble code 
memories and erased. ? 
 Connect up STAR 
DIAGNOSIS, read out 
fault memory
AD00.00-P-2000-04A 
 
2001 Mercedes-Benz ML320 
1998-2005 ENGINE Electrical System - Engine - 163 Chassis  
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        Page 2206 of 4133
 Starter 
 Engine mounts, engine supports 
PREREQUISITES FOR TESTING GENERATOR - AR15.40-P-5009GH 
ENGINE 111.977, 112.942/970, 113.942/965/981, 612.963, 628.963 in MODEL 163  
Fig. 29: Connection Schematic Between Battery And Alternator
 
NumberDesignationEngine 112 except 
112.951, 113.94/ 96/98
BA15.30-P-1001-01ANut for connection of 
circuit 30Nm14
BA15.30-P-1002-01ANut for connection of 
circuit 50Nm6
BA15.30-P-1003-01ABolt for starter on 
crankcaseNm42
NumberDesignationEngines 112.942/970 
113.942/965/981 in model 
163.154/157/17 2/174/175
BA22.10-P-1004-01LBolt for front engine 
mount on engine supportNm65
  Remove/Install  
1Open engine hood and raise  Up to A145272, X708318.AR88.40-P-1000GH 
 
2001 Mercedes-Benz ML320 
1998-2005 ENGINE Electrical System - Engine - 163 Chassis  
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        Page 2207 of 4133

Test values for generator charge indicator lamp 
CHECKING REGULATION VOLTAGE OF ALTERNATOR - AR15.40-P-5010GH 
ENGINES 111.977, 112.942/970, 113.942/965/981, 612.963, 628.963 in MODEL 163  
to vertical position As of A145273, X708319.AR88.40-P-1000GI 
 Testing   
2Check electrical line 
terminal 30 to the following 
items for firm seat and 
flawless conditionBattery (G1) (+)  
Generator (G2)(B+)  
 
3Check electric cable for 
circuit 31 at the following 
positions for correct seat 
and conditionBattery (G1) (-)  
Right major assemblies 
compartment ground, 
Common ground 
(W16/4)  
Engine ground 
strap/body  
 
4Inspect tension of poly V-
belt  
5Inspect operation of charge 
indicator in instrument 
cluster *BE54.30-P-1001-01A
6Install in the reverse order  
NumberDesignationModel 129, 163, 168, 
170, 202, 203, 208, 210
BE54.30-P-1001-01APosition of ignition / glow 
start switchCharge indicator lamp 
Of
f
0/1
Charge indicator lamp On2
 
2001 Mercedes-Benz ML320 
1998-2005 ENGINE Electrical System - Engine - 163 Chassis  
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        Page 2208 of 4133

Fig. 30: Identifying Connection Diagram - Checking For Alternator Regulation Voltage 
 Checking   
 Risk of explosion caused 
by oxyhydrogen gas. Risk 
of poisoning and caustic 
burns caused by 
swallowing battery acid. 
Risk of injury caused by 
burns to skin and eyes 
from battery acid or when 
handling damaged lead-
acid batteriesNo fire, sparks, open flames 
or smoking. Wear acid-
resistant gloves, clothing and 
safety glasses. Only pour 
battery acid into suitable and 
appropriately marked 
containers.
AS54.10-Z-0001-01A 
 Notes on battery AH54.10-P-0001-01A 
1Check condition of 
battery (G1) AR54.10-P-1129Z 
2Check whether 
preconditions for 
alternator testing have 
been fulfilled AR15.40-P-5009GH
3Attach volt ampere tester 
(079) according to 
connection plan Volt ampere tester with 
load resistance*WH58.30-Z-1002-09A
 Volt ampere tester ETT 
011.00*WH58.30-Z-1003-09A
 Risk of accident caused Secure vehicle to prevent it AS00.00-Z-0005-01A 
 
2001 Mercedes-Benz ML320 
1998-2005 ENGINE Electrical System - Engine - 163 Chassis  
me  
Saturday, October 02, 2010 3:18:54 PMPage 54 © 2006 Mitchell Repair Information Company, LLC.