1997 MERCEDES-BENZ ML320 Complete Repair Manual

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Page 2225 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual Fig. 45: Identifying Harmonics - Positive Diode Defective
Fig. 46: Identifying Diode Harmonics OK

REPLACE SPARK PLUGS - AP15.10-P-1580GH
ENGINE 112.942 in MODEL 163.154
ENGINE 112.970 in MOD

Page 2226 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual Fig. 47: Identifying Spark Plugs And Cylinder 4 Ignition Coil

Remove/install and
replacing

Risk of death due to
contact with high-voltage
conductive partsDo not touch parts which
conduct h

Page 2227 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual Spark plugs
Fig. 48: Identifying Spark Plug Wrench (112 589 01 09 00)

Fig. 49: Identifying Open
-End Wrench, Double (110 589 01 01 00)
connectors, ignition coil
connectors and ignition
line

Page 2228 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
GF54.30-P-3011A
Electronic clock, location/function
24.10.96

MODEL
129, 140 as of 1.6.96,

163, 168, 170,

202 as of 1.8.96,

208 up to 31.7.99,

210 as of 1.6.96 up to 30.6.99

P54.30-0520-06

Page 2229 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
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 E

Page 2230 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
1.1
Unscrew bolts at rear of 2/3 seat bench and

raise rear of seat bench

Up to VIN A145272, X708318.

1.2
Remove covers at seat frame of 60% bench

seat

As of VIN A145273, X708319.

AR91.12-P

1.1
Unscrew bolts at rear of 2/3 seat bench and

raise rear of seat bench

Up to VIN A145272, X708318.

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.

2.1
Fold 60% bench seat forward into footwell

As of VIN A145273, X708319. See

operator's manual.

3.1
Pull floor covering below rear seat mounting

bracket (1) of 60% seat forward

Carefully pull floor covering forward under

the seat console to prevent it from tearing.

As of VIN A145273, X708319.

4.1
Pull the floor covering forward under the front

corner of the left C-pillar cover (2)

Carefully pull the floor covering forward

under the cover to prevent it from tearing.

As of VIN A145273, X708319.

5
Cut into floor covering directly behind seat

retaining cable (3)

Ensure that the wiring harness (4) is not

damaged when cutting the floor covering.

As of VIN A145273, X708319. Broken

line marks the cut.

6
Fold floor mat back

Do not crease floor mat!

Fold floor mat back far enough to provide

access to cap (84) between body and fuel

pump.

7
Remove end cover (84) of body

Installation:
Replace cap and insert with

new sealing compound.

Cap (84) is sealed in with body sealer.

Heat with hot air blower to make it easier to

remove.

8
Seal fuel return line (90/11)

Pliers

*163589003700

9
Connect extraction hose (90/14) with adapter
hose to connection for fuel return line (90/11)

Extraction hose

*168589009000

Adapter hose

*163589009100

10
Connect ground cable (90/10) of extraction

pump ground terminal vehicle battery

Pumping out

11
Pump fuel out into safety container using

extraction pump

*BF47.10-P-1001-01A

*WH58.30-Z-1001-16A

12
Install in the reverse order

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

163.128
Model

163.174

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liter
72838393

Reserve capacity
Liter
10121212

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

Page 2231 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
163 589 00 91 00

Extraction hose

Adapter hose

Pliers

163 589 00 37 00 168 589 00 90 00

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e.g.)
Order num

Page 2232 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
AP18.00-P-0101AR
Engine - oil and filter change
20.1.99

ENGINE
612

Modification notes

12.9.02

Engine oil level modified
Step 9:

Only Model 203:

Up to engine end number: 134 163 oil level
MAX

AP18.00-P-0101AR
Engine - oil and filter change
20.1.99

ENGINE
612

Modification notes

12.9.02

Engine oil level modified
Step 9:

Only Model 203:

Up to engine end number: 134 163 oil level
MAX. 135
mm,
MIN 110
mm.

As of engine end number: 134 164 oil level

MAX. 124,5
mm,
MIN 99,5
mm.

Remove

Danger!

Risk of death
cased by vehicle slipping or

toppling off of the lifting platform.
Align vehicle between the columns of the

hydraulic hoist and position the four support

plates below the hoist support points specified

by the vehicle manufacturer.

AS00.00-Z-0010-01A

Danger!

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 procedure
Secure 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

Change the engine oil only when the engine

is at operating temperature

1
Remove trim panel of cylinder head cover

AR01.20-P-5014-02B

2
Replace oil filter element, drain oil filter

Model 203: Remove clamp attaching fuel

line in order to insert wrench socket.

AP18.00-P-0101-06EG

*BA18.20-P-1002-01G

Socket wrench bit

*103589020900

3.1
Suction off engine oil

AP18.00-P-0101-02Z
4.1
Remove rear left frame cross brace

Only necessary when draining engine oil

at oil drain plug.

MODEL 163

f

Model 203 except 203.018/218/718, 209
AR94.30-P-5300P

Model 210

AR94.30-P-5300AB

4.2
Detach lower engine compartment paneling

Only necessary when draining engine oil

at oil drain plug.

f

Only Model 203.018/218/718

AR61.20-P-1105P

5.1
Unscrew oil drain plug, drain engine oil

Install

6.1
Screw in oil drain plug

Replace sealing ring, in order to avoid

leakage.

*BA01.45-P-1003-01A

7
Pour in engine oil
Note specified and approved quality

grades and viscosity classes conforming to

SAE at enduring ambient temperatures.

*BE18.00-P-1001-02B

*BF18.00-P-1001-01A

g

Viscosity classes of engine oils (car engines)
Sheet 224.1

BB00.40-P-0224-01A

8
Run engine and inspect for leaks

9
Switch off engine

10.1
Fit on bottom part of noise encapsulation

Only necessary when draining engine oil

at oil drain plug.

f

Model 210

AR94.30-P-5300AB

MODEL 203, 209

AR94.30-P-5300P

MODEL 163

10.2
Install lower engine compartment paneling.

Only necessary when draining engine oil

at oil drain plug.

f

Only Model 203.018/218/718

AR61.20-P-1105P

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
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