1997 MERCEDES-BENZ ML350 fuel pump

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.

3
Fold 60% bench seat forward into footwell

As of VIN A145273, X708319. See

operator's manual.

4
Pull floor covering below rear seat mounting

bracket (1) of 60% seat forward

Ensure that the floor covering is not torn

when pulled forward.

As of VIN A145273, X708319.

5
Pull floor covering below front corner of trim

panel of C-pillar (2) forward

Ensure that the floor covering is not torn

when pulled forward.

As of VIN A145273, X708319.

6
Cut into floor covering directly behind seat

retaining cable (5)

Ensure that the wiring harness (4) is not

damaged when cutting into floor covering.

As of VIN A145273, X708319. broken line

marks cut-in.

7
Turn back floor covering to gain access to

cap (84)


Do not kink floor covering.

8
Remove cap (84)


Cap (84) is sealed in with body sealer.

Heat with hot air blower to make it easier to

remove.


Installation:
Replace cap and install with

new sealing compound.

9
Detach fuel feed line (90/12) and fuel return

line (90/11) and, if fitted, the fuel line at

connection (90/13)


Do not kink the fuel lines.


If no stationary heater is fitted to vehicle,

do not remove connection (90/13) otherwise

housing will be damaged.

*163589003700

10
Remove nut (89)

*163589010700


*BA47.20-P-1006-01B

11
Remove housing (3)

Fuel lever sensor and housing are a

single part and cannot be removed separately.


Installation:
Re-install nut (89) together

with seal (89/2).

Apply a thin film of oil to seal.

12
Install in the reverse order


Fuel pump

Number

Designation
Engine 612Engine 628

BA47.20-P-1006-01B
Union nut for fuel tank sensor on fuel

tank
Nm
6565


Fuel tank

Number

Designation
Models

163.113/
136/154/

172 up to

31.08.01
Model

163.113/
136/154/

172 as of

01.09.01


Model

163.157/

175
Model

163.128

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liter
728383

Reserve capacity
Liter
101212

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-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 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

P47.20-2076-06

1
Fondsitzkonsole

2
Cover of left C-pillar

3
Seat retaining cable

4
Wiring harness

P47.10-2077-09

84
Closing cover

90/10
Ground line (vacuum unit)

90/11
Fuel return line
90/12

Fuel feed line

90/13
Stationary heater connection

90/14
Extraction hose


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

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

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

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

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

21
Detach rear brake cables

Unclip at underfloor of vehicle and

unscrew brake cable holder on right and left

at frame.

22.1
Unbolt check strap of rear axle carrier from

underfloor of vehicle

As of VIN A145273, X708319.

23
Remove left rear stone shield

24
Remove lower tensioning straps (80/2) and

loosen the upper tensioning straps

Tensioning straps are color-coded and

cannot be mixed up.

Support fuel tank using assembly jack.


*BA47.10-P-1001-01D

25
Remove longitudinal strut for tensioning

straps (80/18)


*BA47.10-P-1002-01D

26.1
Unscrew linkage for headlamp range

adjustment
at the top

If installed.

27
Unscrew nuts on bottom of the shock
absorbers at the transverse control arm


Installation:
Install new self-locking nuts.


*BA32.25-P-1001-03D

28
Unscrew rear axle carrier from floor of vehicle

and lower as far as possible

Support rear axle carrier.


Installation:
Install new self-locking bolts.


*BA35.10-P-1001-01C

29
Lower fuel tank

Support fuel tank.

30
Remove upper tensioning strap
at the rear
The tensioning strap at the top at the front.

31.1
Unclip lines from side of fuel tank

As of VIN A289565, X754620.


Installation:
The lines must not be

damaged.

32
Disconnect fuel pump electrical plug

connection

33
Disconnect fuel feed line (90/12) and fuel

return line (90/11)

Fuel lines must not be bent.

Pliers

*163589003700

34
Remove fuel tank (80)


Installation:
Ensure that the sealing

rubbers (5) seat correctly in the body floor to

prevent water entry.

Do not damage fuel lines at filler neck.

Guide filler neck with its chamfered side

(arrow) through between frame and body.

Filler neck and fuel tank cannot be separated

from each other.

35
Install in the reverse order

36.1
Dispose of fuel tank

Ony when replacing the fuel tank.

o

Disposal of fuel tanks

OS47.10-P-0001-01A


Rear axle carrier

Number

Designation
Model

Series 163

BA35.10-P-1001-01C
Self-locking bolt, rear axle carrier at front and rear

to frame floor
Nm
200


Propeller shaft

Number

Designation
Model

Series 163

BA41.10-P-1002-01C
Self-locking bolt, rear propsharft

at rear axle center section
Nm
50

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 3

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.

Remove/install air outlet
temperature sensorMODEL 163...AR83.30-P-
8087GJ

Remove, install in-car
temperature sensor for aspirator
blower (M9)MODELS 163.113/136/154/172/174 as of 1.9.99 up to
31.8.01AR83.30-P-
8100GH

Remove/install switch
unit/automatic air conditioning
control moduleMODEL 163.113/154 /174 #A as of 289565, 163.113 #X
as of 754620, 163.128 /157 /175AR83.40-P-
6500GH
Remove and install sun sensorMODEL 163...AR83.40-P-
6720GH
Remove/install summer/winter
operation switchMODEL 163, 168, 170, 202, 208 ...AR83.70-P-
0001A
Removing, installing stationary
heater antennaMODEL 163.### 1# Retrofitted stationary heater with
Telestart T60AR83.70-P-
0002B
Remove/install stationary heater
antennaMODEL 163.### 1# Retrofitted stationary heater with
Telestart T70AR83.70-P-
0002BA
Remove/install Telestart
receiverMODEL 163, 168, 170, 202, 208, 210 ...AR83.70-P-
0003BA
Removing and installing
telestart receiverMODEL 163.### 1# Retrofitted telestart T60AR83.70-P-
0003H
Checking Telestart remote
controlMODEL 163, 168, 170, 202, 208, 210 Telestart T60AR83.70-P-
0005A
Check Telestart transmitterMODEL 163, 168, 170, 202, 203, 208, 209,
210,211,220,463...AR83.70-P-
0005IA
Check emission level, adjust if
necessaryMODEL 163, 168, 170, 202, 208, 210 ...AR83.70-P-
1177H
Remove/install heater unitMODELS 163.136/154/157/172/174/175 1# Retrofitted
Thermo Top C stationary heaterAR83.70-P-
5302I
Remove/install heaterMODEL 163.113 1# Retrofitted Thermo Top C stationary
heaterAR83.70-P-
5302IA
Remove/install heaterMODEL 163.128 Retrofitted Thermo Top C stationary
heaterAR83.70-P-
5302IB
Remove/install combustion air
blower unitMODEL 163, 168, 170, 202, 208, 210 ...AR83.70-P-
5555G
Removing and installing fuel
metering pumpMODEL 163.### 1# up to 31.12.99 Retrofitted Thermo
Top C stationary heaterAR83.70-P-
5652G
Remove/install coolant
circulation pumpMODEL 163.### (except 163.128) 1# Retrofitted
Thermo Top C stationary heaterAR83.70-P-
5700E
Remove/install burner insertMODEL 163, 168, 170, 202, 208, 210 ...AR83.70-P-
5772G
Remove/install burner insert
with glow pinMODEL 129, 163, 168, 170, 202, 203, 209, 210, 211,
215, 219, 220, 230, 240 ...AR83.70-P-
5773A
Remove/install timerMODEL 163, 168, 170, 202, 208 ...AR83.70-P-
5892D

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 177 © 2006 Mitchell Repair Information Company, LLC.