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Mercedes-Benz ML320. Service manual - part 396

being jammed or squeezed
when removing and
installing or aligning hoods,
doors, trunk lid/tailgate or
sliding roof.

ensure that no body parts or
limbs are within the operating
range of moving parts.

Open engine hood

Model 163.136/154 /172 #A up
to 145272,
Model 163.136 /154 /172 #X up
to 708318

AR88.40-P-1000GH

Model 163.136 /154 /172 #A as
of 145273,
Model 163.136 /154 /172 #X
from 708319,
Model
163.113/128 /157 /174 /175

AR88.40-P-1000GI

Disconnect battery ground
line

Insulate cable lug of ground

line for protection against
unintentional contact of
disconnected ground line.

AR54.10-P-0003A

Notes on battery

All models

AH54.10-P-0001-
01A

Remove air cleaner housing

Installation: Apply liquid

lubricant to the mounting
rubbers and to the connection to
the air hose.
Lubricant

*BR00.45-Z-1002-
06A

4.1

Remove engine trim panel

Engine 112, 113 only.
Pull the engine cover

vertically upwards and detach it
from the cylinder head covers.

Slacken poly V-belt

Do not remove the poly-V-

belt!
Engine 111

AR13.22-P-1202A

Engine 603.931/972,
Engine 113.942

AR13.22-P-1202B

Engine 113.981/965

AR13.22-P-1202BA

Disconnect electrical line
circuit 30 (B+) (1) and
electrical line circuit 61 (D+)
(2)

On engine 112, 113 take off

cover sleeve (4).

*BA15.40-P-1001-
01A

*BA15.40-P-1002-
01A

Unscrew bolts (3) of the
generator (G2)

*BA15.40-P-1003-
01A

Take out generator (G2)

Install in the reverse

2001 Mercedes-Benz ML320

1998-2005 ENGINE Electrical System - Engine - 163 Chassis

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

Perform 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 procedure

Secure 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

Carry out engine test run

Visual inspection of the poly-

V-belt.

Perform operational check

Number

Designation

Engine 111

Engine
112.91/92/94/953/954/955/96/97,113.94/96/98

BA15.40-P-
1001-01A

Nut of circuit
B+ to generator

Nm 15

BA15.40-P-
1002-01A

Nut of circuit
D+ to
generator

Nm 4

BA15.40-P-
1003-01A

Screw,
alternator

Nm 42

Number

Designation

Order number

BR00.45-Z-1002-06A

Lubricant

A 000 989 01 60

2001 Mercedes-Benz ML320

1998-2005 ENGINE Electrical System - Engine - 163 Chassis

Fig. 33: Identifying Generator, Belt Pulley And Collar Nut

Fig. 34: Identifying Double Hexagon Wrench And Generator

Remove/Install

Remove alternator

Engine 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

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

Unscrew 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 only

WF58.50-P-1540-01I

Engines 111, 112, 113: ?

*BA15.40-P-1004-01A

Engine 166: ?

*BA15.40-P-1003-01B

Remove 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).

Install in the reverse order

Number

Designation

Engine 166.940/ 960

BA15.40-P-1003-01B

Collar nut to poly V-belt
pulley

Nm 80

Number

Designation

Engine 111

Engine 112.91/92/94/
953/954/955/ 96/97,
113.94/96/98

BA15.40-P-1004-
01A

Collar nut to poly
V-belt pulley

Nm 80

2001 Mercedes-Benz ML320

1998-2005 ENGINE Electrical System - Engine - 163 Chassis

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