1997 MERCEDES-BENZ ML320 fuel pressure

AR47.25-P-1000-01A
Separate fuel lines from engine, reconnect

P47.25-0212-03

1
Release arm

2
Sealing ring

A
Release position

B
Assembly position

P47.25-0213-03

The low pressure lines of the fuel system have plug connections

with a release arm (1) in place of screw connections.

The lines are sealed by means of a seal (2).

Disconnecting
1
Press the release arms (1) down to the stop in release position

as shown in picture A (arrow).

2
Disconnect connector on low-pressure line.

3
Pull back the release arms (1) again immediately to the stop

into the assembly position as shown in picture B (arrow).

The release arms (1) must not be kept over a long period in

the release position (A) otherwise leaks can occur due to

deformation of the low-pressure line.
Attaching

4
Check whether the release arm (1) is in the installed position
(b).

If the release arms (1) were kept for a long time in the

release position (A) the low-pressure line must be replaced

otherwise leaks can occur due to deformation of the low-

pressure line.

5
Insert connector on low-pressure line.

6
Ensure that the connector is firmly seated and free of leaks.
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

AR47.10-P-4001GH
Emptying, filling the fuel tank
11.3.97

Model
163.136 with engine 111.977

Model
163.154 with engine 112.942

Model
163.157 with engine 112.970

Model
163.172 with engine 113.942

Model
163.174 with engine 113.981

Model
163.175 with engine 113.965

P47.10-0411-06

1/1
Service valve

17
Fuel rail

17/2
Fuel feed line

80/9
Fuel hose

F1K3
Fuel pump relay

Draining or pumping out

Danger!

Risk of explosion
if ignition takes place,
risk

of poisoning
caused by inhaling fuel vapors

or swallowing fuel as well as
risk of injury
to

skin and eyes exposed to fuel.
No fire, sparks, open flames or smoking.

Only pour fuels into suitable and appropriately

marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1
Release fuel pressure through service valve

(1/1)

Collect fuel.

Pressure hose

*119589046300

2
Unscrew fuel feed line (17/2) at fuel distributor

(17)


*BA07.52-P-1001-01A

3
Connect fuel hose (80/9) to fuel feed line (17/2)

Use 10 mm diameter fuel hose.

4
Insert fuel hose (80/9) into safety reservoir

5
Pull fuel pump relay (F1k3) out of relay holder

n

Assignment and cable connections of fuse

blocks

GF54.15-P-1255GH

6
Bridge fuel pump

Connect slot 30 (battery positive) to slot

87 (relay contact input).


*220589009900

7
Switch on ignition

8
Pump fuel out into safety canister


*BF47.10-P-1001-01A


Fuel rail

Number

Designation
Engine

112 except

112.945/951/

960/961

BA07.52-P-1001-01A
Fuel feed line on fuel distributor
Nm
38

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

Fuel rail

Number

Designation
Engines

113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/988/

BA07.52-P-1001-01A
Fuel feed line on fuel distributor
Nm
38


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

163.174

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liters
728393

Reserve capacity
Liters
101212

220 589 00 99 00

Electrical connection set

Pressure hose

119 589 04 63 00

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

AR47.10-P-4100GH
Remove fuel tank
10.3.97

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 ENGINE 112.942

MODEL
163.157 with ENGINE 112.970

MODEL
163.172 with ENGINE 113.942

MODEL
163.175 with ENGINE 113.965

P47.10-0407-06

1
Left side paneling cover

2
Filler cap

3
Bayonet lock

4
Filler cap attachment

5
Rubber seal

B4/3 Fuel tank pressure sensor

X36/4
Fuel tank filler neck/ground screw

connection

P47.10-0413-09

77
Activated charcoal canister

77/1
Fine venting connection

77/2
Regeneration connection

77/3
Spring chamber venting connection
80/19

Mounting screw

90/11
Fuel return line

90/12
Fuel feed line

B4/3 Fuel tank pressure sensor

77/4

Frischluftanschluss

80
Fuel tank

80/2
Tensioning straps

80/18
Longitudinal strut for tensioning

straps

Modification notes
7.11.00

Figure modified from 170 Nm auf 200 Nm
Value in BA35.10-P-1001-01C changed for

model 163

*BA35.10-P-1001-01C

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

Remove, Install


Danger!
Risk of explosion
from fuel igniting,
risk of

poisoning
from inhaling and swallowing fuel

as well as
risk of injury
to eyes and skin

from contact with fuel.
Fire, sparks, open flames or smoking

forbidden.

Pour fuels only into suitable and appropriately

marked containers.

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

1
Drain fuel tank

Via fuel pump. NOT for model 163.113/128.

AR47.10-P-4001GH

If fuel pump faulty, and model 163.113/128.

AR47.10-P-4000GH


*BF47.10-P-1001-01A

2
Unscrew filler cap (2) and detach from filler

cap attachment (4)

3.1
Remove left seat of 3rd seat row

If installed. See owner's manual

4
Unclip cover of left-hand side panel (1)

5.1
Detach fuel lines of expansion reservoir and

separate from filler neck

As of VIN A289565. NOT for model

163.113/128.

6
Detach fuel filler neck from guide funnel


Installation:
Check O-ring and replace if

necessary. Ensure that the bayonet-lock
remains above
the pressure sensor.

Ensure it is correctly located when installed.

Open bayonet lock (3) to do this.

7
Pull filler neck through toward interior

Screw on cap again in order to avoid fuel

flowing out.

8.1
Remove fuel tank pressure sensor (B4/3)

Only USA version

AR47.10-P-8022GH
9.1
Detach bolted connection of fuel tank filler

neck/ground (X36/4) from filler neck

NOT for model 163.113/128.

10.1
Cut cable strap for retaining clips of fuel lines
at filler neck and remove retaining clips

As of VIN A289565. NOT for model

163.113/128.


Danger!
Risk of fatal accident
from vehicle slipping

or toppling off the lift platform
Align vehicle between the columns of lifting
platform and position the four support plates


below the support strongpoints specified by

the vehicle manufacturer.

AS00.00-Z-0010-01A

11
Place the vehicle on lifting platform

AR00.60-P-1000GH

12
Separate rubber seal (5) from underside of

vehicle and remove filler neck from interior

Do not damage fuel lines at filler neck.

13
Remove left rear wheel

e

Removing and installing wheels, rotating if

necessary

AP40.10-P-4050GH

14
Remove spare wheel and spare wheel carrier

complete

NOT in the case of spare wheel

holder/spare wheel, code 849.

15
Cut a large safety cable strap for filler neck at

bracket on longitudinal frame member

16
Remove bracket from longitudinal frame

member

17
Disconnect connection for regeneration (77/2)

and fresh air connection (77/4) on activated

charcoal canister (77)


Installation
: Connect up lines as per

connection diagram:

#

Engine 111

AR47.30-P-8212-01GJ

Engines 112, 113

AR47.30-P-8212-01GI

Engines 112, 113 version
I

AR47.30-P-8212-01GH

Charcoal canister and fuel tank form a

single unit.

NOT for model 163.113/128.

18
Detach vent hose

At rear differential to rear of activated

charcoal reservoir.

19
Remove rear exhaust system heat shield.

Do not damage boot at rear axle shaft.

20
Disconnect rear propeller shaft at differential


Installation:
Install new self-locking bolts.


Tie up propeller shaft e.g. using welding

wire

Heat bolts with hot air fan to facilitate

removing. Mark propeller shaft and differential

gear flange for correct installed position.


*BA41.10-P-1002-01C

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

AR47.10-P-8022GH
Remove/install fuel tank pressure sensor
18.3.97

MODEL
163.154 with ENGINE 112.942 with CODE (494a) USA version

MODEL
163.157 with ENGINE 112.970 with CODE (494a) USA version

MODEL
163.172 with ENGINE 113.942 with CODE (494a) USA version

MODEL
163.174 with ENGINE 113.981 with CODE (494a) USA version

MODEL
163.175 with ENGINE 113.965 with CODE (494a) USA version

P47.10-0390-02

B4/3Fuel tank pressure sensor

Arrow
Socket


Remove, Install


Danger!
Risk of explosion
if ignition takes place,
risk

of poisoning
caused by inhaling fuel vapors

or swallowing fuel as well as
risk of injury
to

skin and eyes exposed to fuel.
Fire, sparks, open flames or smoking

forbidden.

Pour fuels only into suitable and appropriately

marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1
Unscrew filler cap and remove securing tab

2
Unclip left side trim cover

3
Detach fuel filler neck from guide funnel


Installation:
Check O-ring and replace if

necessary. Ensure it is correctly located when

installed.

To do this, open bayonet lock.

4
Disconnect coupling (arrow) for fuel tank

pressure sensor (B4/3)

5
Unscrew fuel tank pressure sensor (B4/3)

from fuel tank filler neck

6
Install in the reverse order

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

Overview of authorized reworking on wiring harnesses
into the body
Lines get pinched in clamps
or trim parts
Fatigue Lines routed or secured
incorrectly
Excessive stress
Open circuit in wiring
Corrosion Due to contact with acids or
aggressive fluids (e.g. brake
fluid, antiseize, coolant
additives, fuels, lubricants),
water penetration due to
defective seals, use of high
pressure cleaner
Wiring harness covered in
paint after paint repair
Hardening of insulation due
to contact with an
incompatible agent (e.g.
solvent)
Line open circuit, contact
pairing not longer conductive
(transition resistances)
Insulation and wires
damaged
Lines or connections to
contacts
High line resistance
Components with sharp
edges
Corrosion
Assembly fault Use of incorrect tools, e.g.
wrong crimper or wrong
release tool
Damaged contacts or lines
through use of unsuitable test
tools (e.g. probes)
Lines pinched or screwed in
Loose contacts in plug
connections
Wrong contacts crimped
Undesirable transition
resistances
Open circuit in wiring, short-
circuit
Insulation damaged
Type of faultRemedial action
Faulty contact part
Contact part
missing
wrong part
deformed
Install new contact part
Contact part not engaged properlyLatch contact part, then check, and replace if
necessary
Not all individual wires are crimpedCut off contact part and install new part
Insulation also crimpedCut off contact part and install new part
Conductor not far enough in contact partCut off contact part and install new part

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 22 © 2006 Mitchell Repair Information Company, LLC.

CHECK ALL VISIBLE PARTS FOR SIGNS OF LEAKS AND DAMAGE - AP00.20-P-0053GH
MODEL 163.113 /128 /136 /154 /157 /172 /174 /175
INSPECTING CHASSIS AND LOAD-BEARING BODY PARTS FOR DAMAGE AND CORROSION - AP00.20-P-0090GH
MODEL 163
with Code Z04/Z07
Model 230AP00.20-P-0001L
Model 414AP00.20-L-0001A
Taxi serviceModels 202, 210AP00.20-P-0007A
Model 203AP00.20-P-0007C
Remove
Detach lower engine
compartment panelingModels 163.172/174/175AR61.20-P-1105GH
Remove noise
encapsulationModel 163.113/128AR94.30-P-5400GH
Check

2If traces of fluid are noted
(e.g. oil), then determine
and correct the cause (on a
separate work order).
Check for leaksEngine:
Transmission
Transfer case
Front axle
Rear axle
Pressure oil pump
3Check for leaks and fixingShock absorbers,
suspension struts
4Inspect for leaks and
conditionRubber boots of front axle
shafts
5Inspect lines and hoses for
leaks and condition, pay
attention to chafing points
and routingRadiator
Fuel system
Exhaust system
Clutch actuation
Automatic transmission
Power steering
Brake system
Install
Install lower engine
compartment paneling.Models 163.172/174/175AR61.20-P-1105GH
Install noise encapsulationModel 163.113/128AR94.30-P-5400GH
1Visual inspectionControl arm mountings and
control arms of front axle

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:52 PMPage 404 © 2006 Mitchell Repair Information Company, LLC.