Mercedes-Benz ML320. Service manual - part 494

 

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Mercedes-Benz ML320. Service manual - part 494

 

 

 

Fuel rail

Number

Designation

Engines
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/988/

BA07.52-P-1001-01A

Fuel feed line on fuel distributor

Nm

38

 

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 
163.174

BF47.10-P-1001-01A

Fuel tank capacity Total capacity

Liters 72

83

93

Reserve capacity

Liters 10

12

12

220 589 00 99 00

Electrical connection set

Pressure hose

119 589 04 63 00

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

Page 2

AR47.10-P-4100GH

Remove fuel tank

10.3.97

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 

163.175 with ENGINE 113.965

P47.10-0407-06

1

Left side paneling cover

2

Filler cap

3

Bayonet lock

4

Filler cap attachment 

5

Rubber seal

B4/3

Fuel tank pressure sensor

X36/4

Fuel tank filler neck/ground screw 
connection

P47.10-0413-09

77

Activated charcoal canister

77/1

Fine venting connection

77/2

Regeneration connection

77/3

Spring chamber venting connection

80/19

Mounting screw

90/11

Fuel return line

90/12

Fuel feed line

B4/3

Fuel tank pressure sensor

77/4

Frischluftanschluss

80

Fuel tank

80/2

Tensioning straps

80/18

Longitudinal strut for tensioning 
straps

Modification notes

7.11.00

Figure modified from 170 Nm auf 200 Nm

Value in BA35.10-P-1001-01C changed for 
model 163

*BA35.10-P-1001-01C

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

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