Mercedes-Benz ML320. 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

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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.

Page 3