1997 MERCEDES-BENZ ML320 fuel pressure

AP82.10-P-8260GH
Check and correct headlamp adjustment
2.7.97

MODEL
163

a=Marking for low beams

b=Marking for high beams

c=Marking for fog lamps

P82.10-0212-02


Check

1
Drive vehicle to level surface
The vehicle level must not change when the

brakes are applied.

Vehicle must be in ready-for-the-road

condition (unladen weight, fuel tank full or

proper additional weight).

Correctly adjust tire pressure.

Load driver's seat with 75 kg or a person

(except USA)

2
Align headlamp adjustment tester to vehicle

and adjust height according to marking in lens

Follow the operating instructions for

headlamp beam setting equipment exactly

*WH58.30-Z-1002-09A


Danger!

Risk of accident
from vehicle starting off by

itself when engine running.
Risk of injury


suffered in the form of bruises or burns to the

hands when reaching in while the engine

cranks or runs
Secure vehicle to prevent it from moving off

by itself.

Wear closed and close-fitting work clothes.

Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

3
Run engine and switch on low beam

4
Check headlamp range control for proper

function
(except USA)


The light beams from both headlamps should

change uniformly

5
Set headlamp range control switch to position 0

6
Check low beams
Adjust if necessary (except USA)

AP82.10-P-8260-01A


Due to the common reflector unit, the low

beams, high beams and fog lamps are

adjusted simultaneously.

US version:
#

See "Owner's Manual"

7
Check high beam adjustment

AP82.10-P-8260-02A

8
Check fog lamps

AP82.10-P-8260-04A

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e.g.)
Order number

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d by Modification services.
Page 1

8
Attach guard plate for radiator/condenser

y

Guard plate for radiator/condenser
Engine 606 in model 124,
Engine 606.961 in model 140,

Engine 112, 113, 604, 605, 611.960 in model

202,

Engine 602.983, 612.966 in model 461,

Engine 628.962, 612.965, 606.964, 112.945,

113.962/ 982 in model 463,

Engine 111, 112, 611.962, 612.962 in model

203,

Engine 112, 113, 611.961, 612.961, 613.961

in model 210,

Engine 112 in model 170,
Engine 112 in model 220,

Engine 113 in model 211, 215, 220,

Engine 112 in model 208,

Engine 112, 113, 612.963, 628.963 in model

163,

Engine 112.923 /943, 113.961 in model 129,

Engine 137, 275 in model 215, 220,

Engine 613.960, 628.960 in model 220,

Engine 113.992 in model 230.474,

Engine 271 in model 209, 203,

Engine 285.950 in model 240.078 /178,

Engine 612.967 in model 209.316,

Engine 648 in model 220

Engine 112.951 in model 639.601/603/ 605/

701 /703 /705 /801 /803 /805

Engine 646.983 /984 in model 639.601/

603 /605 /701 /703 /705 /801 /803 /805

Engine 646.982 in model 639.601/ 603/ 605/
701 /703 /705

WF58.50-P-0110-01A

9
Remove air cleaner housing (5)

10
Remove air intake pipe (6) with resonance
tube (7)

Separate connector of hot film mass air

flow sensor (HFM) for this step and unbolt air

intake pipe at cylinder head cover

The air intake pipe is attached at the rear

at the intake manifold with a plastic plate.

Do not damage the plastic strap.

Engine 112.942/ 970

AR07.07-P-1454A

Engine 113.942/ 965/ 981

AR07.07-P-1454MV


Danger!

Risk of explosion
caused by fuel igniting,

risk of poisoning
caused by inhaling and

swallowing fuel as well as
risk of injury
to

eyes and skin caused by contact with fuel.
No fire, sparks, open flames or smoking.

Pour fuels only into suitable and appropriately

marked containers.

Wear protective clothing when handling fuel.
AS47.00-Z-0001-01A

11
Disconnect fuel line at fuel rail

Release fuel pressure at service valve!

Collect fuel!

Engine 112:
#

*BA07.52-P-1001-01A

Engine 113:
#

*BA07.52-P-1001-01A

Pressure hose

*119589046300

12
Remove right and left ignition coils (12)

AR15.12-P-2003A

13
Remove right and left cylinder head covers (13)

AR01.20-P-5014B

14
Remove the intake manifold (14)


Installation:

On vehicles with engine

damage, the intake manifold must be

examined for swarfs before assembling and

any swarfs present must be removed, in order

to avoid consequential damage.

AR09.20-P-1310A

The intake manifold system must not be

disassembled.

Remove intake manifold with fuel distributor

15.1
Remove camshaft position sensor (15)

Only necessary if the right cylinder head is

removed.

AR15.10-P-2000A

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d by Modification services.
Page 3

8
Attach guard plate for radiator/condenser

y

Guard plate for radiator/condenser
Engine 606 in model 124,
Engine 606.961 in model 140,

Engine 112, 113, 604, 605, 611.960 in model

202,

Engine 602.983, 612.966 in model 461,

Engine 628.962, 612.965, 606.964, 112.945,

113.962/ 982 in model 463,

Engine 111, 112, 611.962, 612.962 in model

203,

Engine 112, 113, 611.961, 612.961, 613.961

in model 210,

Engine 112 in model 170,
Engine 112 in model 220,

Engine 113 in model 211, 215, 220,

Engine 112 in model 208,

Engine 112, 113, 612.963, 628.963 in model

163,

Engine 112.923 /943, 113.961 in model 129,

Engine 137, 275 in model 215, 220,

Engine 613.960, 628.960 in model 220,

Engine 113.992 in model 230.474,

Engine 271 in model 209, 203,

Engine 285.950 in model 240.078 /178,

Engine 612.967 in model 209.316,

Engine 648 in model 220

Engine 112.951 in model 639.601/603/ 605/

701 /703 /705 /801 /803 /805

Engine 646.983 /984 in model 639.601/

603 /605 /701 /703 /705 /801 /803 /805

Engine 646.982 in model 639.601/ 603/ 605/
701 /703 /705

WF58.50-P-0110-01A

9
Remove air cleaner housing (5)

10
Remove air intake pipe (6) with resonance
tube (7)

Separate connector of hot film mass air

flow sensor (HFM) for this step and unbolt air

intake pipe at cylinder head cover

The air intake pipe is attached at the rear

at the intake manifold with a plastic plate.

Do not damage the plastic strap.

Engine 112.942/ 970

AR07.07-P-1454A

Engine 113.942/ 965/ 981

AR07.07-P-1454MV


Danger!

Risk of explosion
caused by fuel igniting,

risk of poisoning
caused by inhaling and

swallowing fuel as well as
risk of injury
to

eyes and skin caused by contact with fuel.
No fire, sparks, open flames or smoking.

Pour fuels only into suitable and appropriately

marked containers.

Wear protective clothing when handling fuel.
AS47.00-Z-0001-01A

11
Disconnect fuel line at fuel rail

Release fuel pressure at service valve!

Collect fuel!

Engine 112:
#

*BA07.52-P-1001-01A

Engine 113:
#

*BA07.52-P-1001-01A

Pressure hose

*119589046300

12
Remove right and left ignition coils (12)

AR15.12-P-2003A

13
Remove right and left cylinder head covers (13)

AR01.20-P-5014B

14
Remove the intake manifold (14)


Installation:

On vehicles with engine

damage, the intake manifold must be

examined for swarfs before assembling and

any swarfs present must be removed, in order

to avoid consequential damage.

AR09.20-P-1310A

The intake manifold system must not be

disassembled.

Remove intake manifold with fuel distributor

15.1
Remove camshaft position sensor (15)

Only necessary if the right cylinder head is

removed.

AR15.10-P-2000A

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 3

GF54.30-P-2002A
Display instruments, location / task / 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

Display
Type of data transmission

D
Outside temperature indicator (A1p4)

D
Fuel level gauge (A1p2)

D
Engine oil pressure gauge (A1p3), only

model 129 and model 140

D
Low windshield washer fluid level

indicator lamp (A1e13), model 163 as of

01.09.01

Direct lines

GF54.30-P-3004A

D
Total mileage odometer (A1h4)

D
Electronic speedometer (A1p8)

D
Tachometer (A1p5)

D
Coolant temperature gauge (A1p1)

D
Active service system (ASSYST)

D
Gear indicator (A1p12), only model 168

CAN data lines

GF54.30-P-3005A

D
Electronic clock
Internal

GF54.30-P-3011A

Copyright DaimlerChrysler AG 04.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1

CIRCUIT PROTECTION DEVICES
CIRCUIT PROTECTION DEVICES LOCATION
box.
Fuel Pump RelayIn left side of engine compartment, in fuse & relay
box.
Headlamp Cleaning System RelayIn right front footwell fuse & relay box.
Heated Rear Window RelayIn right front footwell fuse & relay box.
Heater RelayAt right kick panel.
Heater Relay (Stage 1)At right kick panel.
Heater Relay (Stage 2)At right kick panel.
High Pressure/Return Pump RelayIn left side of engine compartment, in fuse & relay
box.
Left Front Power Window RelayIn left side of engine compartment, in fuse & relay
box.
Left Turn Signal RelayIn left side of engine compartment, in fuse & relay
box.
Low Beam Headlamp Relay (W/ DRL)In left side of engine compartment, in fuse & relay
box.
Rear Foglight RelayIn left side of engine compartment, in fuse & relay
box.
Rear Wall Door Washer Pump RelayIn left side of engine compartment, in fuse & relay
box.
Rear Window Defroster RelayIn right front footwell fuse & relay box.
Right Front Power Window RelayIn left side of engine compartment, in fuse & relay
box.
Right Turn Signal RelayIn left side of engine compartment, in fuse & relay
box.
Seat Comfort RelayIn right front footwell fuse & relay box.
Seat Heater Relay (Stage 1)On underside of left/right front seat.
Seat Heater Relay (Stage 2)On underside of left/right front seat.
Secondary Air Injection Pump RelayIn left side of engine compartment, in fuse & relay
box.
Starter RelayIn left side of engine compartment, in fuse & relay
box.
Two-Tone Horn RelayIn left side of engine compartment, in fuse & relay
box.
ComponentComponent Location
E-BoxIn left side of engine compartment.
Fuse & Relay BoxIn left side of engine compartment, in E-box. See
Fig. 1
.
Right Front Footwell Fuse & Relay BoxBelow right side of dash, behind kick panel. See

2001 Mercedes-Benz ML320
2001 MERCEDES-BENZ ML320 & ML430
me
Saturday, October 02, 2010 3:21:17 PMPage 2 © 2006 Mitchell Repair Information Company, LLC.

SENDING UNITS & SENSORS
SENDING UNITS & SENSORS LOCATION
Fuel PumpIn top of fuel tank.
Headlamp Range Adjustment Motor (Right/Left)Behind respective headlamp.
Headlamp Washer PumpIn left front of engine compartment, on side of
washer fluid reservoir.
In-Car Temperature Sensor Aspirator BlowerBehind center of dash.
Lamella Sun Roof Motor (Left/Right)At rear of roof.
Module Box Blower MotorIn left side of engine compartment, in E-box.
Rear Wall Door Washer PumpIn left side of engine compartment, on side of
washer fluid reservoir.
Tailgate Window Wiper MotorIn liftgate, behind trim.
Transfer Case Range Selection MotorOn left rear of transfer case.
Windshield Washer PumpIn left front of engine compartment, on washer fluid
reservoir.
Wiper MotorAt left rear of engine compartment, under plenum
cover.
ComponentComponent Location
ABS Lateral Acceleration SensorBelow center console, behind shift assembly.
Camshaft Hall Effect SensorOn right front of engine.
Crankshaft Position (CKP) SensorOn left rear of engine.
ECT SensorOn front center of engine.
ESP Brake Pressure Sensor No. 1In left rear of engine compartment.
ESP Brake Pressure Sensor No. 2In left rear of engine compartment.
Freeze Protection Temperature SensorBehind right side of dash, in evaporator.
Front Axle SensorBehind right front wheel.
Fuel Level SensorOn top of fuel tank.
Fuel Tank Emissions Monitoring Pressure SensorIn left rear side of cargo area, behind trim on fuel
filler pipe.
Hot Film MAF SensorIn right side of engine compartment.
In-Car Temperature SensorBehind center of dash.
Knock Sensor No. 1 (KS 1)On right side of engine, below intake manifold.
Knock Sensor No. 2 (KS 2)On left side of engine, below intake manifold.
Left Front Brake Pad Wear SensorBehind left front wheel.
Left Front VSSBehind left front wheel.
Left Rear Brake Pad Wear SensorBehind left rear wheel.
Left Rear VSSBehind left rear wheel.
Membrane Travel SensorIntegral to brake booster.
Oil SensorOn lower right front of engine.
Outside Temperature Indicator Temperature SensorBehind left side of front grille.

2001 Mercedes-Benz ML320
2001 MERCEDES-BENZ ML320 & ML430
me
Saturday, October 02, 2010 3:21:17 PMPage 4 © 2006 Mitchell Repair Information Company, LLC.

NOTES ON AVOIDING DAMAGE TO IGNITION SYSTEM - AH15.10-P-0002-01D
Engine 104, 111, 112, 113, 119, 120, 156, 271
To avoid damage to control unit connect and disconnect the two connectors on control unit only when
ignition is switched off.
Terminal 1 of ignition coils must not be short-circuited to GND, e.g. as anti-theft protection.
Install only original ignition system components.
Do not operate ignition system at starting speed unless all of the ignition cables are connected.
No tests such as holding ignition cable 4 at a distance to GND, unplugging a spark plug connector or
pulling cable 4 out of the ignition coils, may be performed at starting speed or when the engine is
running.
Every high voltage circuit must be loaded with at least 2 kohms (spark plug connector).
If it is necessary to test the ignition spark when providing roadside assistance, this must only be done with
a spark plug at a cylinder ignition cable. Ensure that the spark plug has good contact to ground.
Before working at cranking speed, e.g. checking compression pressure, switch off ignition and disconnect
connector "2" from control unit.
Engine 120 has two fuel injection and ignition systems.
Use of testers
Only connect and disconnect secondary measuring sensor to corresponding ignition cables when vertical
engine and ignition are switched off.
If the shot-circuit protection is operated (cylinder comparison) and the engine stays upright, it is not
possible to conduct the test with this test instrument.
Do not connect test lamp to ignition coil terminals 1 and 15.
NOTES ON IGNITION COIL CHARACTERISTICS OF IGNITION SYSTEMS - AH15.10-P-1001-01A
Engine 104, 111, 112, 113, 119, 120

In the case of the twin-spark ignition coil with kV pickup in ignition systems ME-SFI 2.1 and HFM-SFI, no
measurement facilit
y exists at the ignition coil using the kV pickup although a kV pickup is fitted. It is only
damage to ignition system
Notes on avoiding
damage to ignition systemENGINE 104, 111, 112, 113,
119, 120, 156, 271, 112 mit
Benzin-Einspritz- und
Zundsystem MEAH15.10-P-0002-01D
Notes for ceramic glow
plugsENGINE 646.8, 642AH15.20-P-0001-01A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 2 © 2006 Mitchell Repair Information Company, LLC.

AF07.00-P-9000B
Engine runs rough, surges or does not turn over
29.4.02

ENGINE
611 in MODEL 203, 202, 210

ENGINE
612 in MODEL 163, 203, 210, 209

ENGINE
613 in MODEL 210, 220

ENGINE
628 in MODEL 163, 220, 211

ENGINE
646 in MODEL 203, 211

ENGINE
647 in MODEL 211

ENGINE
648 in MODEL 220, 211

ENGINE
668 in MODEL 168

ENGINE
612, 628 in MODEL 463

Modification notes

23.3.01

Supersedes STIP 07.16-014 dated 11.12.00

Damage code
Cause
Remedy

07 206 D5
High-pressure pump

To verify whether high pressure pump is

damaged.

#

High pressure pump of common rail

injection system is damaged mechanically.

1
Remove/install/replace high pressure

pump.

When the high pressure pump of the common

rail injection system is damaged metal chips

and/or damage to the pump drive (timing

drive) can occur due to contamination of the

injection system components.
2
Turn high pressure pump by hand with

driver.

If mechanical resistance can be felt,

perform the following tests. Clarify additional

work with ESKULAB by specifying repair work:

#
3
Check driver of high pressure pump or

mount in sprocket for damage (visual

check).

If high pressure pump is locked:
#
4
Check timing

5
Check timing drive for damage.

In each case:
#
6
Remove/install/replace timing chain.

If timing deviates by a crankshaft angle of

more than 20 degrees (corresponding to one

tooth skipped):

#
7
Check pressure loss.

8
Open low pressure connection on high

pressure pump return (plastic line in

area of pressure regulator valve) and

check connection point in rail for chips.

If chips are present when checking

injection system:

#
9
Thoroughly clean all fuel low pressure

lines as well as feed and return lines.

Flush and blow out with compressed air.

10
Remove fuel preheater and fuel filter

with filter housing, replace.

Fuel preheater is only installed in models

202, 203 and 163.

11
Remove/install/replace fuel cooler at

vehicle and engine end.

Not installed in model 210 up to 6/99 and

model 168.

12
Remove fuel tank, replace.

On engine 628:
#

13
Remove/install/replace electric supply

pump.

14
Remove/install/replace injectors, rail

(including pressure regulation valve and

rail pressure sensor), high pressure

lines and injector leak oil rail.*

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1