1997 MERCEDES-BENZ ML500 alternator

by vehicle starting off by
itself when engine is
running. Risk of injury
caused by contusions and
burns during starting
procedure or when
working near the running
enginefrom moving by itself.
Wear closed and snug-fitting
work clothes.
Do not grasp hot or rotating
parts.
4Start engine
5Check function of charge
indicator lamp when
engine is idling and with
increasing engine speed
(up to 3000 rpm) Charge indicator lamp
must extinguish.
6Load battery (G1) using a
permanent consumer and
check regulation voltage
of alternator (G2)Engines 111, 112, 113*BE15.40-P-1001-02A
Engines 612, 628*BE15.40-P-1001-02C
Volt ampere tester with
load resistance*WH58.30-Z-1002-09A
Volt ampere tester ETT
011.00*WH58.30-Z-1003-09A
Regulation voltage > 15.0
V: ?
Replace regulator

Engine 628

Engines 111, 112, 113
Replace alternator
(G2)
AR15.40-P-5760GH
Engine 612
Regulation voltage < 13.0
V: ?
Check electrical
connections for
charging system for
transition resistances;
repair if necessary.

Electrical connections OK: ?
AR15.40-P-5032GI
Check alternator (G2)
diodes AR15.40-P-9301-02EA

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 55 © 2006 Mitchell Repair Information Company, LLC.

Check values for regulator
Check values for regulator
Commercially available tools
CHECKING CHARGING CURRENT OF ALTERNATOR - AR15.40-P-5011GH
Engine tester with
oscilloscope
If diodes are faulty: ?
Replace alternator
(G2)
*WH58.30-Z-1046-13A
Engine 111, 112, 113AR15.40-P-5032GH
Engine 612AR15.40-P-5032GI
Engine 628AR15.40-P-5032IA
7Turn off engine
8Disconnect volt ampere
tester (079) Volt ampere tester with
load resistance*WH58.30-Z-1002-09A
Volt ampere tester ETT
011.00*WH58.30-Z-1003-09A
NumberDesignationEngines 103,104,111,
112,113,119, 120,
137, 155, 166, 275
BE15.40-P-1001-
02ARegulating voltage
(at battery)Loading: only on
permanent consumerV13 to 15
Engine speedrpm3000
measured afterminapprox.2
NumberDesignationEngines
601,602,603, 604,
605, 606,
611,613,628, 646,
647, 668Engine 612
except 612.966
BE15.40-P-
1001-02CRegulating
voltage (at
battery)Loading: only on
permanent
consumerV13 to 1513 to 15
Engine speedrpm30003000
measured afterminapprox.2approx.2
NumberDesignation
WH58.30-Z-1002-09AVolt-amp(s) tester with load resistance (no longer
available)
WH58.30-Z-1003-09AVolt ampere tester
WH58.30-Z-1046-13AEngine tester with oscilloscope

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 56 © 2006 Mitchell Repair Information Company, LLC.

ENGINES 111.977, 112.942/970, 113.942/965/981, 612.963, 628.963 in MODEL 163
Fig. 31: Identifying Checking For Alternator Charging Current

Modification notes
18.10.05Charging current of
alternatorEngine 111*BE15.40-P-1001-01A
Checking
Risk of explosion caused
by oxyhydrogen gas. Risk
of poisoning and caustic
burns caused by
swallowing battery acid.
Risk of injury caused by
burns to skin and eyes
from battery acid or when
handling damaged lead-
acid batteriesNo fire, sparks, open flames
or smoking. Wear acid-
resistant gloves, clothing
and goggles. Only pour
battery acid into suitable
and appropriately marked
containers.AS54.10-Z-0001-01A
Notes on battery AH54.10-P-0001-01A
1Check regulation voltage
of alternator AR15.40-P-5010GH
2Connect volt ampere
tester (079) with current
clamp (065) according to Volt ampere tester with
load resistance*WH58.30-Z-1002-09A
Volt ampere tester ETT *WH58.30-Z-1003-09A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 57 © 2006 Mitchell Repair Information Company, LLC.

connection diagram011.00
Risk of accident caused
by vehicle starting off by
itself when engine is
running. Risk of injury
caused by contusions and
burns during starting
procedure or when
working near the running
engineSecure vehicle to prevent it
from moving by itself.
Wear closed and snug-
fitting work clothes.
Do not grasp hot or rotating
parts.AS00.00-Z-0005-01A
3Start engine
4Load battery (G1) with
volt ampere tester (079)
and check charging
current of alternator (G2)
with increased engine
speed Vary load resistance
long enough until the
maximum load current is
achieved; when this is
done, the regulating voltage
must not drop below 12.7
V.
Engines 111, 612*BE15.40-P-1001-01A
Engines 112, 113*BE15.40-P-1001-01K
Engine 628*BE15.40-P-1001-01J
Volt ampere tester with
load resistance*WH58.30-Z-1002-09A
Volt ampere tester ETT
011.00*WH58.30-Z-1003-09A
Charging current below
desired value: ?
Check diodes for
alternator (G2).
AR15.40-P-9301-02EA
Engine tester with
oscilloscope
If diodes are faulty: ?
Replace alternator
(G2)
*WH58.30-Z-1046-13A
Engines 111, 112, 113AR15.40-P-5032GH
Engine 612AR15.40-P-5032GI
Engine 628 with water-
cooled alternator (G2)AR15.40-P-5032IA
Engine 628 with air-cooled
alternator (G2)AR15.40-P-5032GD
5Turn off engine
6Disconnect volt ampere
tester (079) with current Volt ampere tester with
load resistance*WH58.30-Z-1002-09A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 58 © 2006 Mitchell Repair Information Company, LLC.

Check values for alternator
Check values for alternator
Check values for alternator
Commercially available tools
clamp (065) Volt ampere tester ETT
011.00*WH58.30-Z-1003-09A
NumberDesignationEngine 111 in
models 163, 203
Engine 111 in
models 202, 208
with code 910
Bosch/ ValeoEngine 612 in
models 163,203,
209, 210, 463
Delphi
BE15.40-P-1001-
01ACharging current
of alternatormax.A120190
min.A90150
Engine speedrpm25002500
RatioI=2.932.53
NumberDesignationEngine 628.963
in model 163
NF 14V 150AEngine 628.963
in model 163
E10 14V 90-
200A
BE15.40-P-1001-
01JCharging current
of alternatormax.A150200
min.A120160
Engine speedrpm25002500
RatioI=2.82.93
NumberDesignationEngine 112 in
models 163, 170,
202, 203, 208,
209, in model 210
without code 978,
in model 211
without code 910,
Bosch/ValeoEngine 113 in
models
163,171,203,208,
209,210,211,215,
219, 220, 230 except
models 211.076/276,
215.374, 219.376,
220.074/174,
230.472/474 Bosch
BE15.40-P-
1001-01KCharging
current of
alternatormax.A120150
minA90120
Engine speedrpm25002500
RatioI=2.932.93
NumberDesignation
WH58.30-Z-1002-09AVolt-amp(s) tester with load resistance (no longer
available)

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 59 © 2006 Mitchell Repair Information Company, LLC.

Alternator
Repair materials
REMOVE/INSTALL GENERATOR BELT PULLEY - AR15.40-P-5710GF
ENGINE 111.977, 112.942/970, 113.942/965/981 in MODEL 163
ENGINE 166.940 /960 in MODEL 168
ENGINE 112.923 /943, 113.961 in MODEL 129
sequence
10Perform basic programming AR00.19-P-0200GH
Risk of accident caused by
vehicle starting off by itself
when engine is running.
Risk of injury caused by
contusions and burns when
working in engine during
starting procedureSecure vehicle to prevent it from
moving. Wear closed and snug-
fitting work clothes.
Do not grasp hot or rotating
parts.AS00.00-Z-0005-01A
11Carry out engine test run Visual inspection of the poly-
V-belt.
12Perform operational check
NumberDesignationEngine 111Engine
112.91/92/94/953/954/955/96/97,113.94/96/98
BA15.40-P-
1001-01ANut of circuit
B+ to generatorNm1518
BA15.40-P-
1002-01ANut of circuit
D+ to
generatorNm45
BA15.40-P-
1003-01AScrew,
alternatorNm4242
NumberDesignationOrder number
BR00.45-Z-1002-06ALubricantA 000 989 01 60

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 62 © 2006 Mitchell Repair Information Company, LLC.

Fig. 33: Identifying Generator, Belt Pulley And Collar Nut
Fig. 34: Identifying Double He xagon Wrench And Generator

Remove/Install
1Remove alternatorEngine 112, 113 in Model
129.AR15.40-P-5032CT
Engine 166.940 /960 in AR15.40-P-5032GF

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 63 © 2006 Mitchell Repair Information Company, LLC.

Generator
Generator
REMOVE/INSTALL REGULATOR OF ALTERNATOR - AR15.40-P-5760GH
ENGINE 111.977, 112.942/970, 113.942/965/981 in MODEL 163
Model 168.
Engine 111, 112, 113 in
model 163.AR15.40-P-5032GH
2Unscrew collar nut (1) To hold generator shaft
(2), insert screwdriver bit
through double hexagon
wrench (4).
Shorten double hexagon
wrench to remove the belt
pulley Model 163 onlyWF58.50-P-1540-01I
Engines 111, 112, 113: ?

*BA15.40-P-1004-01A
Engine 166: ?

*BA15.40-P-1003-01B
3Remove ribbed V-belt
pulley (3) When replacing
generators after mileages in
excess of
100.000 km simultaneously
also replace the poly-V-
belt
pulley (3).

4Install in the reverse order
NumberDesignationEngine 166.940/ 960
BA15.40-P-1003-01BCollar nut to poly V-belt
pulleyNm80
NumberDesignationEngine 111Engine 112.91/92/94/
953/954/955/ 96/97,
113.94/96/98
BA15.40-P-1004-
01ACollar nut to poly
V-belt pulleyNm8080

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 64 © 2006 Mitchell Repair Information Company, LLC.