1997 MERCEDES-BENZ ML430 fuel

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

2001 MERCEDES-BENZ
ML320 & ML430
BUZZERS, RELAYS & TIMERS
BUZZERS, RELAYS & TIMERS LOCATION
ComponentComponent Location
Alarm Horn RelayIn left side of engine compartment, in fuse & relay
box.
Blower Motor RelayIn left side of engine compartment, in fuse & relay
box.
Central Locking (All Doors Lock Relay)In left side of engine compartment, in fuse & relay
box.
Central Locking (Left Front Door & Fuel Filler Flap
Unlock Relay)In left side of engine compartment, in fuse & relay
box.
Central Locking (Right Front Door & Rear Doors
Unlock Relay)In left side of engine compartment, in fuse & relay
box.
Central Locking (Tailgate Unlock Relay)In left side of engine compartment, in fuse & relay
box.
Circuit 15 RelayIn left side of engine compartment, in fuse & relay
box.
Circuit 15 RelayIn right front footwell fuse & relay box.
Circuit 15 Delayed RelayIn left side of engine compartment, in fuse & relay
box.
Circuit 58 RelayIn left side of engine compartment, in fuse & relay
box.
Circuit 58L Relay (W/ DRL)In left side of engine compartment, in fuse & relay
box.
Circuit 58R Relay (W/ DRL)In left side of engine compartment, in fuse & relay
box.
Circulation Pump RelayIn left side of engine compartment, in fuse & relay
box.
Convenience RelayIn left side of engine compartment, in fuse & relay
box.
Differential Lock Vacuum Pump RelayIn left side of engine compartment, in fuse & relay
box.
Engine Cooling Fan Stage 1 RelayIn left side of engine compartment, in fuse & relay
box.
ESP Stoplight Suppression RelayIn left side of engine compartment, in fuse & relay
box.
Front Foglight RelayIn left side of engine compartment, in fuse & relay
box.
Front Wiper Motor RelayIn left side of engine compartment, in fuse & relay

2001 Mercedes-Benz ML320
2001 MERCEDES-BENZ ML320 & ML430

2001 Mercedes-Benz ML320
2001 MERCEDES-BENZ ML320 & ML430
me
Saturday, October 02, 2010 3:21:17 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.
me
Saturday, October 02, 2010 3:21:20 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.

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.

GENERAL NOTES ON CONTACTLESS HIGH VOLTAGE DISTRIBUTION - AH15.10-P-1002-01WA
Engine 112, 113 with ME-SFI fuel injection and ignition system
The ignition system can be tested at the primary side and secondary side. It is only possible to test ignition
circuit a and ignition circuit b one after the other.
The ignition coils are fitted as standard with cast mounts for the secondary adapters (kV pickup C). The primary
i
gnition voltage curve can be plotted with a primary adapter cable (D).
112163 2.0 X
112202 2.0 X
112208 2.0 X
112210 2.0 X
112220 2.0 X
113163 2.0 X
113202 2.0 X
113208 2.0 X
113210 2.0 X
113220 2.0 X
119.982129 1.0 X
119.980140 1.0 X
119.981140 1.0 X
119210 1.0 X
120.983129 1.0 X
120.982140 1.0 X

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 4 © 2006 Mitchell Repair Information Company, LLC.

IGNITION COILS, LOCATION - GF15.10-P-3102-01A
Fig. 5: Identifying Cylinder 1 To 6 Ignition Coil - Location On Engine 112
Spark plugs, locationOne or two spark plugs are
located in the cylinder head
per cylinder.
Spark plugs, taskThe spark plugs ignite the
suctioned and compressed
fuel-air mixture due to arcing
between the electrodes.
Spark plugs, designIn the manufacturer's specific
type symbols, all the spark
plug features are assigned (e.
g. heat rating, shape of
seating, thread, width across
flats, electrode material,
spark position).
Spark plugs, functionThe ignition voltage travels to
the spark plugs from directly
connected ignition coils or
over the ignition lines from
the ignition coils causing
arcing in the air gap between
the center and ground
electrodes.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 8 © 2006 Mitchell Repair Information Company, LLC.