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by vehicle starting off by 
itself when engine is 
running. Risk of injury 
caused by contusions and 
burns during starting 
procedure or when 
working near the running 
enginefrom moving by itself. 
Wear closed and snug-fitting 
work clothes. 
Do not grasp hot or rotating 
parts.
4Start engine
5Check function of charge 
indicator lamp when 
engine is idling and with 
increasing engine speed 
(up to 3000 rpm) Charge indicator lamp 
must extinguish. 
6Load battery (G1) using a 
permanent consumer and 
check regulation voltage 
of alternator (G2)Engines 111, 112, 113*BE15.40-P-1001-02A
Engines 612, 628*BE15.40-P-1001-02C
 Volt ampere tester with 
load resistance*WH58.30-Z-1002-09A
 Volt ampere tester ETT 
011.00*WH58.30-Z-1003-09A
Regulation voltage > 15.0 
V: ? 
Replace regulator  
 
Engine 628
 
Engines 111, 112, 113 
Replace alternator 
(G2)  
AR15.40-P-5760GH
Engine 612 
Regulation voltage < 13.0 
V: ? 
Check electrical 
connections for 
charging system for 
transition resistances; 
repair if necessary.  
 
Electrical connections OK: ?
AR15.40-P-5032GI
Check alternator (G2) 
diodes  AR15.40-P-9301-02EA
 
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Check values for regulator 
Check values for regulator 
Commercially available tools 
CHECKING CHARGING CURRENT OF ALTERNATOR - AR15.40-P-5011GH
Engine tester with 
oscilloscope 
If diodes are faulty: ? 
Replace alternator 
(G2)  
*WH58.30-Z-1046-13A
Engine 111, 112, 113AR15.40-P-5032GH
Engine 612AR15.40-P-5032GI
Engine 628AR15.40-P-5032IA
7Turn off engine  
8Disconnect volt ampere 
tester (079) Volt ampere tester with 
load resistance*WH58.30-Z-1002-09A
 Volt ampere tester ETT 
011.00*WH58.30-Z-1003-09A
NumberDesignationEngines 103,104,111, 
112,113,119, 120, 
137, 155, 166, 275
BE15.40-P-1001-
02ARegulating voltage 
(at battery)Loading: only on 
permanent consumerV13 to 15
Engine speedrpm3000
measured afterminapprox.2
NumberDesignationEngines 
601,602,603, 604, 
605, 606, 
611,613,628, 646, 
647, 668Engine 612 
except 612.966
BE15.40-P-
1001-02CRegulating 
voltage (at 
battery)Loading: only on 
permanent 
consumerV13 to 1513 to 15
Engine speedrpm30003000
measured afterminapprox.2approx.2
NumberDesignation
WH58.30-Z-1002-09AVolt-amp(s) tester with load resistance (no longer 
available)
WH58.30-Z-1003-09AVolt ampere tester
WH58.30-Z-1046-13AEngine tester with oscilloscope
 
2001 Mercedes-Benz ML320 
1998-2005 ENGINE Electrical System - Engine - 163 Chassis  
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        Page 2211 of 4133

ENGINES 111.977, 112.942/970, 113.942/965/981, 612.963, 628.963 in MODEL 163  
Fig. 31: Identifying Checking For Alternator Charging Current
 
Modification notes 
18.10.05Charging current of 
alternatorEngine 111*BE15.40-P-1001-01A
 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 goggles. Only pour 
battery acid into suitable 
and appropriately marked 
containers.AS54.10-Z-0001-01A 
 Notes on battery AH54.10-P-0001-01A 
1Check regulation voltage 
of alternator AR15.40-P-5010GH
2Connect volt ampere 
tester (079) with current 
clamp (065) according to  Volt ampere tester with 
load resistance*WH58.30-Z-1002-09A
 Volt ampere tester ETT *WH58.30-Z-1003-09A
 
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        Page 2212 of 4133

connection diagram011.00
 Risk of accident caused 
by vehicle starting off by 
itself when engine is 
running. Risk of injury 
caused by contusions and 
burns during starting 
procedure or when 
working near the running 
engineSecure vehicle to prevent it 
from moving by itself. 
Wear closed and snug-
fitting work clothes. 
Do not grasp hot or rotating 
parts.AS00.00-Z-0005-01A 
3Start engine
4Load battery (G1) with 
volt ampere tester (079) 
and check charging 
current of alternator (G2) 
with increased engine 
speed Vary load resistance 
long enough until the 
maximum load current is 
achieved; when this is 
done, the regulating voltage 
must not drop below 12.7 
V. 
Engines 111, 612*BE15.40-P-1001-01A
Engines 112, 113*BE15.40-P-1001-01K
Engine 628*BE15.40-P-1001-01J
 Volt ampere tester with 
load resistance*WH58.30-Z-1002-09A
 Volt ampere tester ETT 
011.00*WH58.30-Z-1003-09A
 Charging current below 
desired value: ? 
Check diodes for 
alternator (G2).  
AR15.40-P-9301-02EA
Engine tester with 
oscilloscope 
 If diodes are faulty: ? 
Replace alternator 
(G2)  
*WH58.30-Z-1046-13A
Engines 111, 112, 113AR15.40-P-5032GH
Engine 612AR15.40-P-5032GI
Engine 628 with water-
cooled alternator (G2)AR15.40-P-5032IA
Engine 628 with air-cooled 
alternator (G2)AR15.40-P-5032GD
5Turn off engine  
6Disconnect volt ampere 
tester (079) with current  Volt ampere tester with 
load resistance*WH58.30-Z-1002-09A
 
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1998-2005 ENGINE Electrical System - Engine - 163 Chassis  
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        Page 2213 of 4133

Check values for alternator 
Check values for alternator 
Check values for alternator 
Commercially available tools 
clamp (065) Volt ampere tester ETT 
011.00*WH58.30-Z-1003-09A
NumberDesignationEngine 111 in 
models 163, 203 
Engine 111 in 
models 202, 208 
with code 910 
Bosch/ ValeoEngine 612 in 
models 163,203, 
209, 210, 463 
Delphi
BE15.40-P-1001-
01ACharging current 
of alternatormax.A120190
min.A90150
Engine speedrpm25002500
RatioI=2.932.53
NumberDesignationEngine 628.963 
in model 163 
NF 14V 150AEngine 628.963 
in model 163 
E10 14V 90-
200A
BE15.40-P-1001-
01JCharging current 
of alternatormax.A150200
min.A120160
Engine speedrpm25002500
RatioI=2.82.93
NumberDesignationEngine 112 in 
models 163, 170, 
202, 203, 208, 
209, in model 210 
without code 978, 
in model 211 
without code 910, 
Bosch/ValeoEngine 113 in 
models 
163,171,203,208, 
209,210,211,215, 
219, 220, 230 except 
models 211.076/276, 
215.374, 219.376, 
220.074/174, 
230.472/474 Bosch
BE15.40-P-
1001-01KCharging 
current of 
alternatormax.A120150
minA90120
Engine speedrpm25002500
RatioI=2.932.93
NumberDesignation
WH58.30-Z-1002-09AVolt-amp(s) tester with load resistance (no longer 
available)
 
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1998-2005 ENGINE Electrical System - Engine - 163 Chassis  
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        Page 2214 of 4133

REMOVE AND INSTALL GENERATOR - AR15.40-P-5032GH 
ENGINE 111.977, 112.942/970, 113.942/965/981 in MODEL 163  
Fig. 32: Identifying Generator Remove/Install Components 
- Shown On Engine 112 
Modification notes 
WH58.30-Z-1003-09AVolt ampere tester
WH58.30-Z-1046-13AEngine tester with oscilloscope
14.4.00Specification revised from 
15 Nm to 18 NmSpecification in BA15.40-
P-1001-01A revised for 
Series 112, 113 engines*BA15.40-P-1001-01A
14.4.00Value modified from 4 
Nm to 5 NmSpecification in BA15.40-
P-1002-01A revised for 
112, 113 engines*BA15.40-P-1002-01A
  Removal/installation   
 Risk of poisoning caused by 
swallowing brake fluid. Risk 
of injury caused by brake 
fluid coming into contact 
with skin and eyes.Fire, sparks, naked flames and 
smoking prohibited. Wear acid-
resistant gloves, clothing and 
safety glasses. Pour battery acid 
only into suitable and 
appropriately marked containers.AS54.10-Z-0001-01A
 Risk of injury to fingers When moving components, AS00.00-Z-0011-01A
 
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        Page 2215 of 4133

being jammed or squeezed 
when removing and 
installing or aligning hoods, 
doors, trunk lid/tailgate or 
sliding roof.ensure that no body parts or 
limbs are within the operating 
range of moving parts.
1Open engine hoodModel 163.136/154 /172 #A up 
to 145272, 
Model 163.136 /154 /172 #X up 
to 708318AR88.40-P-1000GH 
Model 163.136 /154 /172 #A as 
of 145273, 
Model 163.136 /154 /172 #X 
from 708319, 
Model 
163.113/128 /157 /174 /175AR88.40-P-1000GI 
2Disconnect battery ground 
line Insulate cable lug of ground 
line for protection against 
unintentional contact of 
disconnected ground line.AR54.10-P-0003A 
 Notes on batteryAll modelsAH54.10-P-0001-
01A 
3Remove air cleaner housing Installation: Apply liquid 
lubricant to the mounting 
rubbers and to the connection to 
the air hose. 
Lubricant
*BR00.45-Z-1002-
06A
4.1Remove engine trim panel Engine 112, 113 only. 
 Pull the engine cover 
vertically upwards and detach it 
from the cylinder head covers. 
5Slacken poly V-belt Do not remove the poly-V-
belt! 
Engine 111AR13.22-P-1202A
Engine 603.931/972, 
Engine 113.942AR13.22-P-1202B 
Engine 113.981/965AR13.22-P-1202BA 
6Disconnect electrical line 
circuit 30 (B+) (1) and 
electrical line circuit 61 (D+) 
(2) On engine 112, 113 take off 
cover sleeve (4). 
 
*BA15.40-P-1001-
01A
 *BA15.40-P-1002-
01A
7Unscrew bolts (3) of the 
generator (G2) *BA15.40-P-1003-
01A
8Take out generator (G2)  
9Install in the reverse   
 
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1998-2005 ENGINE Electrical System - Engine - 163 Chassis  
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        Page 2216 of 4133

 Alternator 
Repair materials 
REMOVE/INSTALL GENERATOR BELT PULLEY - AR15.40-P-5710GF 
ENGINE 111.977, 112.942/970, 113.942/965/981 in MODEL 163  
ENGINE 166.940 /960 in MODEL 168  
ENGINE 112.923 /943, 113.961 in MODEL 129
sequence
10Perform basic programming AR00.19-P-0200GH 
 Risk of accident caused by 
vehicle starting off by itself 
when engine is running. 
Risk of injury caused by 
contusions and burns when 
working in engine during 
starting procedureSecure 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
11Carry out engine test run Visual inspection of the poly-
V-belt. 
12Perform operational check  
NumberDesignationEngine 111Engine 
112.91/92/94/953/954/955/96/97,113.94/96/98
BA15.40-P-
1001-01ANut of circuit 
B+ to generatorNm1518
BA15.40-P-
1002-01ANut of circuit 
D+ to 
generatorNm45
BA15.40-P-
1003-01AScrew, 
alternatorNm4242
NumberDesignationOrder number
BR00.45-Z-1002-06ALubricantA 000 989 01 60
 
2001 Mercedes-Benz ML320 
1998-2005 ENGINE Electrical System - Engine - 163 Chassis  
me  
Saturday, October 02, 2010 3:18:55 PMPage 62 © 2006 Mitchell Repair Information Company, LLC.