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  
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        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  
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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  
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        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  
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        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
 
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1998-2005 ENGINE Electrical System - Engine - 163 Chassis  
me  
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