Page 2217 of 4133
Fig. 33: Identifying Generator, Belt Pulley And Collar Nut
Fig. 34: Identifying Double He xagon Wrench And Generator
Remove/Install
1Remove alternatorEngine 112, 113 in Model
129.AR15.40-P-5032CT
Engine 166.940 /960 in AR15.40-P-5032GF
2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 63 © 2006 Mitchell Repair Information Company, LLC.
Page 2218 of 4133

Generator
Generator
REMOVE/INSTALL REGULATOR OF ALTERNATOR - AR15.40-P-5760GH
ENGINE 111.977, 112.942/970, 113.942/965/981 in MODEL 163
Model 168.
Engine 111, 112, 113 in
model 163.AR15.40-P-5032GH
2Unscrew collar nut (1) To hold generator shaft
(2), insert screwdriver bit
through double hexagon
wrench (4).
Shorten double hexagon
wrench to remove the belt
pulley Model 163 onlyWF58.50-P-1540-01I
Engines 111, 112, 113: ?
*BA15.40-P-1004-01A
Engine 166: ?
*BA15.40-P-1003-01B
3Remove ribbed V-belt
pulley (3) When replacing
generators after mileages in
excess of
100.000 km simultaneously
also replace the poly-V-
belt
pulley (3).
4Install in the reverse order
NumberDesignationEngine 166.940/ 960
BA15.40-P-1003-01BCollar nut to poly V-belt
pulleyNm80
NumberDesignationEngine 111Engine 112.91/92/94/
953/954/955/ 96/97,
113.94/96/98
BA15.40-P-1004-
01ACollar nut to poly
V-belt pulleyNm8080
2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 64 © 2006 Mitchell Repair Information Company, LLC.
Page 2219 of 4133
Fig. 35: Identifying Alternator Regulator Remove/Install Components
Modification notes
26.4.05Remove alternator omitted
Remove the right fender
liner in the front fender
addedStep 1
Remove heat shield addedStep 2
Remove/Install
1Remove right inner fender in
front fender AR88.10-P-1300GH
2Remove the heat shield over
the alternator
3Unscrew bolts (1)
4Unclip cover (2) and remove Push apart retaining
lugs (3).
5Remove screws (4).
6Remove regulator (5)
towards the side Installation: When
inserting the governor (5)
ensure, that the ground lug
(6) sits close to the
governor (5).
7Install in the reverse order
2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 65 © 2006 Mitchell Repair Information Company, LLC.
Page 2220 of 4133
TEST DIODES OF GENERATOR - AR15.40-P-9301-02EA
Commercially available tools
Fig. 36: Generator Connection Diagram
- Model 129
Model 129 with engine 119 up to vehicle ident end no. 1F 032 589: Problems with power supply system -
test batter
y voltage-dependent idle speed increase (refer to Diagnosis Manual Engine Volume 2 Group 07.3).
NumberDesignation
WH58.30-Z-1046-13AEngine tester with oscilloscope
2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 66 © 2006 Mitchell Repair Information Company, LLC.
Page 2221 of 4133
Fig. 37: Generator Connection Diagram - Model 163
Fig. 38: Generator Connection Diagram
- Model 168
2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 67 © 2006 Mitchell Repair Information Company, LLC.
Page 2222 of 4133
Fig. 39: Generator Connection Diagram - Model 414
Fig. 40: Generator Connection Diagram
- Model 170
2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 68 © 2006 Mitchell Repair Information Company, LLC.
Page 2223 of 4133
Fig. 41: Generator Connection Diagram - Model 202
Fig. 42: Generator Connection Diagram
- Model 208
Model 210: as of 1.6.99 a fuse for protection of
generator is located in the te rminal block circuit 30 (X12/3).
2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 69 © 2006 Mitchell Repair Information Company, LLC.
Page 2224 of 4133
Fig. 43: Generator Connection Diagram - Model 210
1. Connect DC clip-on probe (065) from engine tester with oscilloscope (030) to positive pole of battery
(G1)
2. Start engine.
3. Switch on low beam.
4. Assess diode harmonics at 3000 rpm (engine speed).
In this test it is not possible to assess the exciter diodes.
Fig. 44: Identifying Harmonics
- Negative Diode Defective
2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 70 © 2006 Mitchell Repair Information Company, LLC.