1997 MERCEDES-BENZ ML500 tow

AR68.20-P-2020GI
Remove/install rear center console
18.5.01

MODEL
163.113 /154 /174 #A as of 289565,
163.113 #X as of 754620,

163.128 /157 /175

P68.20-2493-06

1
Armrest cover

2
Bolts

3
Ashtray paneling

4
Clips

5
Bolts

6
Rear section of center console


Remove/install

1
Remove armrest lid (1)

AR68.20-P-2370GH

2
Remove stowage box on center console

Press center pin approx. 4 mm down,

then remove rivet upward

3
Remove bolts (2) from beverage holder

4
Remove ashtray inner section

5
Remove ashtray paneling (3)

Danger of breaking clips (4).
Loosen clips (4) and pull bottom edge of

cover toward rear and remove upward

6
Remove bolts (5)

7
Unclip rear center console (6) at top (arrows).

Long wedge

*115589035900

8
Remove rear center console (6) from center

console

9
Disconnect connector from rear control panel

control module and ashtray

Disconnect connector for rear ashtray

from ashtray housing

10
Install in the reverse order

Long wedge

115 589 03 59 00

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR68.20-P-2400GH
Removing and installing ashtray housing from front center console
11.2.97

MODEL
163.113 /136 /154 /172 /174 up to 31.8.01

P68.20-0455-01

1
Cover on gearshift lever

2
Ashtray housing

P68.20-0454-01


Remove/install

1
Remove cover on gearshift lever (1)

AR68.20-P-2310GH

2
Remove ashtray housing (2) toward rear

Installation:
Slide ashtray housing into

mount and catch.

3
Install in the reverse order

Copyright DaimlerChrysler AG 10.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR68.20-P-2310GH
Removing and installing cover at gearshift lever
4.2.97

MODEL
163.113 /136 /154 /172 /174 up to 31.8.01

P68.20-0434-06

1
Plastic frame

2
Covering in front stowage compartment

3
Center console insert

4
Cover

5
Connectors

S21
Center console switch group

Operation no. of operation texts or standard texts and flat rates
Range

Op. no.
Operation text

P
683450
REMOVING AND INSTALLING COVER FOR SHIFT LEVER

P
683455
REPLACING COVER FOR GEARSHIFT LEVER

Remove/install

1
Remove plastic frame (1) upward


*115589035900

2
Remove covering in stowage

compartment (2)

Fastened with pin.

3
Remove center console insert (3)

Remove screws (2 each) from insert floor

4
Press cover (4) out of catch in center console

at rear and sides with long wedge

*115589035900

5
Disconnect connectors (5) from center

console switch group (S21)

6
Install in the reverse order

Long wedge

115 589 03 59 00

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR68.20-P-2370GH
Remove/install armrest lid on center console
15.4.97

MODEL
163.113 /128 /136 /154 /157 /172 /174 /175

P68.20-0461-06

Illustrated on model 163 up to 31.08.01

1
Stowage compartment

2
Screws

3
Stowage box

4
Screws

5
Armrest cover

P68.20-2544-04

Illustrated on model 163 as of 01.09.01

4
Bolts

5
Armrest cover

6
Access openings

Removing, installing

1.1
Remove storage compartment (1)

Up to 31.08.01: Unclip stowage

compartment (1) from stowage box (3)

2.1
Unscrew screws (2) and remove stowage box

(3)

up to 31.08.01

3
Unscrew screws (4).

4
Remove armrest lid (5)

As of 01.09.01: Insert long wedge into

access openings (6) and loosen retaining lugs.

Long wedge

*115589035900

5
Install in the reverse order

Assembly wedge

115 589 03 59 00

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

connector (1) and electrical line circuit 61 (D+) (2). Remove 2 generator bolts (3). Remove generator. See Fig.
15 . To install, reverse removal procedure. Using STAR scan tool, perform electrical operational check.
Fig. 15: Removing Generator

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
VOLTAGE REGULATOR
Removal & Installation (Compact Generator)
Disconnect and shield negative battery cable. Remove generator from vehicle. See GENERATOR . Remove 3
screws (1). Unclip cover (2) by pushing apart retaining lugs (3) and remove. Remove 2 screws (4). Remove
regulator (5) toward side. See Fig. 16
. To install, reverse removal procedure. When inserting regulator (5),
ensure
ground lug (6) makes contact with regulator.
NOTE: Numbers in text refer to numbers in figures.

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Generators & Regulators - 163 Chassis
me
Saturday, October 02, 2010 3:20:32 PMPage 23 © 2006 Mitchell Repair Information Company, LLC.

AR91.12-P-1100GH
Remove and install cover on bottom of rear seat
22.2.00

MODELS
163.136 /154 /172 as of 1.9.99,

163.113 /128 /157 /174 /175

P91.12-2189-09

Arrows
Pushing directions for releasing

the locating tabs


Remove


Risk of breakage! Carefully press covers off

with a short screwdriver or suitable long

wedges.

1
Remove rear cargo space floor flaps

See Operating Instructions

2Remove rear cover (A)

Pull front outer edges of the cover

upwards in order to release the locating tabs

(1). Press outer locating tabs (2) outwards. In

the center of the cover, press locating tab (3)

to the right and locating tab (4) forwards. In

order to release the locating tabs (5), press

the cover down and remove to the rear.

3
Remove curtain at front 40 % bench

4
Remove outer cover (B) from 40 % bench

Press the cover in and pull upwards at

locating tab (6). Pull outwards at locating tabs

(7, 8). Press the cover forwards in order to

release the locating tab (9). At locating tab

(10), press down with a long wedge between

the covers. Guide the cover past the lateral

curtain.

5
Remove inner cover (C) from 40 % bench

Pull the outer rear corners of the cover up

in order to release the rear locating tabs (11).

In order to release the locating tabs (12),

press the cover forwards and remove to the

front.

6
Remove curtain at front 60 % bench

7
Remove outer cover (D) from 60 % bench

Push locating tab (13) up and turn cover

out and up at locating tab (14). Pull outwards

at locating tabs (15). Press the cover

forwards in order to release the locating tabs

(16). At locating tab (17) press down with a

long wedge between the covers. Guide the

cover past the lateral curtain.

8
Remove inner cover (E) from 60 % bench

Press locating tabs (18) in. Pull the outer

rear corners of the cover up in order to

release the rear locating tabs (19). In order to

release the locating tabs (20), press the cover

forwards, rotate counterclockwise and remove
past the springs towards the rear.


Install

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

Crankshaft Position Sensor DIY


hopefully this will help others with what appears to be a common stalling issue in the ML series.


Location:


--------


It's on the rear of the engine where the engine mates with the tranny on the driver's side. There are 2

types. Be sure to get the correct one


Here it is:


1) Get
CPS
at dealer, its a VIN specific part. $125 from my local stealer.


2) Tools needed: Socket screwdriver, Good lighting (portable) shop lights, size 8 outside torx socket,
maybe a ratche
t and extentions depending on your flexibility, magnetic part retrieval tool (skip this at

your peril), bath towel, and long sleeve shirt, step stool, blue thread locker (optional)


3) Open hood and remove engine cover, it just pulls off and on


4) Set wor
k light(s) toward back of engine, lighting behind drivers cylinder head


5) Set bath towel on front of ML to kneel on of your knees will die, wearing long sleeve shirt or your

wrists will be cut.


6) Climb up on towel and look behind engine from above and
right (see .jpg), finding torx attachment
holding your
CPS
.

7) Remove torx screw and pull out
CPS
, disconnect one way connector (wiring)


8) Replace with new (leaving wire detached for now)


9) This is the hardest step by far, and requires patience and fl exibility. Apply some thread locker and

insert screw and start the threads. Tighten with torx on socket screwdriver. This step took about 1/2

hour and numerous dropped screws and retrievals with mag tool.


10) Attach wiring to
CPS


11) Reinstall engine cov
er


12) Clean up tools, towel and lights and everything


13) Drink beer and toast yourself for saving yourself at least $100 and a day of your time dropping off

and picking up cars at shop


Hope this helps someone in the community.


Dickie


00 ML 32
0

16
Remove poly V-belt (8)


Installation:
Lock tensioning device with

a drift or pin (diameter 5 mm).

Model 163.154 /157 /172.

AR13.22-P-1202B

Model 163.174 /175.

AR13.22-P-1202BA

17
Detach the coolant line (16) at the cylinder

head on the left

6 mm socket hexagon

*WH58.30-Z-1001-06A

7 mm socket hexagon

*WH58.30-Z-1002-06A

18.1
Remove fender liner (9)

Only with engine 113.113.942 /965 / 981.

AR88.10-P-1300GH

19.1
Remove shield (10)

Only with engine 113.942 /965 /981.

20.1
Remove exhaust bracket (11)

Only with engine 113.942 /965 /981.

Support exhaust system.

21
Detach exhaust system at exhaust manifold


Installation:
On vehicles with engine

damage, the exhaust system must be

examined for swarfs before assembling and

any swarfs present must be removed, in order

to avoid consequential damage.


*BA14.10-P-1002-01B

22
Position crankshaft to 40° after ignition TDC

on cylinder 1


The engine must not be turned back;

otherwise the timing chain can get jammed.

AR05.10-P-6858V

Rotate engine at the crankshaft in running

direction until scribe mark 40° on pulley/

vibration damper corresponds with scribe

mark on timing case.

The grooves on the camshafts must be

pointing toward the inner V.

23
Lock camshafts with locating plates

Locating plate

*112589003200

Locating plate

*112589013200

24
Remove chain tensioner (17)
Model 163.154 /157 with engine 112.942/

970, model 163.172 with engine 113.942.
AR05.10-P-7800C

Model 163.174 /175 with engine 113.981/ 965.
AR05.10-P-7800CA

25.1
Remove oil filter housing (18) together with oil-

water heat exchanger
Engine 113.942.

AR18.20-P-3471B

Engine 112.942/970.

AR18.20-P-3471BA

26
Unscrew camshaft sprockets (19)

If camshaft sprockets are removed,

engine must no longer be cranked, otherwise

timing chain might jam.

Engine 113.942 /965 /981:
#

Tie timing chain tight on both camshaft

sprockets with tie straps.

Engine 112.942 /970:

#

Right-hand camshaft sprocket:

Tie timing chain tight on camshaft sprocket

with tie strap.

Left-hand camshaft sprocket:
Mark camshaft sprocket to timing chain and

remove camshaft sprocket.

It is not possible for the timing chain to

jump across at the crankshaft and balancing

shaft.

After installation:
#

Inspect basic position of camshafts.

AR05.10-P-6858V

If necessary after checking:
#

Set the basic position of camshafts

AR05.20-P-6020AU

Open-end wrench

*112589000100

Insertion tool

*112589010300

Torque wrench

*001589722100


*BA05.20-P-1001-01B

27
Remove camshaft bearing bridges (28)

Pay attention to slackening and tightening

pattern!

AR05.20-P-7103AU

28
Unscrew bolts, cylinder head
!
timing case

cover (20)


*BA01.40-P-1002-01C

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 4