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2002 MERCEDES-BENZ ML320 CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT MERCEDES-BENZ REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Cabin Air Filter Locations & Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 2002 MERCEDES-BENZ ML320 AUTOMOBILES
Electrical Symbol & Wire Color Code Identification -> Electrical Symbol Identification -> Imported Vehicles
Vehicle: 2002 MERCEDES-BENZ ML320 3.2 V6 GAS
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BRAKE SERVICE PROCEDURES FOR 2002 MERCEDES-BENZ ML320 AUTOMOBILES
Disc Brakes -> Parking Brake Service -> Foot Control Cable, Replace -> Foot Control, Replace -> Hand Lever, Replace -> Parking Brake Rear Control Cable, Replace -> Parking Brake Shoes, Replace -> SLK32, SLK230 & SLK320
Vehicle: 2002 MERCEDES-BENZ ML320 3.2 V6 GAS
Foot Control, Replace
- On SL55, SL500 and SL600 models, remove exhaust system heat shield.
- On E55, E320, E430 and E500 models, remove cover panel under rear squab.
- On CLK55, CLK320, CLK430, CLK500, E55, E320, E430 and E500 models, proceed as follows:
- Turn preloading automatic slack adjuster eccentric pin clockwise approximately one turn using suitable Allen wrench through cover sheet oblong hole.
- At same time, push pin back longitudinal slot until spring-loaded locking eccentric locks into spring clip position with elevation.
- On CL55, CL500, CL600, S55, S430, S500 and S600 models...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2002 MERCEDES-BENZ ML320 AUTOMOBILES
Mercedes-Benz -> Fuel Filter Replacement -> Except 2003-06 E320 & E500 Sedans Less 4 Matic & 2004-06 E Series w/Gasoline Engines -> Fuel System Pressure Relief -> Removal & Installation
Vehicle: 2002 MERCEDES-BENZ ML320 3.2 V6 GAS
Fuel System Pressure Relief
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental fuel spray.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven while it relearns its adaptive strategy.
- Ensure t...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2002 MERCEDES-BENZ ML320 AUTOMOBILES
DRIVESHAFT, Replace -> FRONT -> REAR
Vehicle: 2002 MERCEDES-BENZ ML320 3.2 V6 GAS
FRONT
- Remove propeller shaft to transfer case mounting bolts and washers.
- Remove propeller shaft to front differential carrier mounting bolts.
- Remove propeller shaft from vehicle.
- Reverse procedure to install, noting the following:
- Ensure front differential carrier flange and propeller shaft are perfectly centered.
- Torque propeller shaft to transfer case bolts to 29 ft. lbs.
- Torque propeller shaft to front differential carrier flange to 37 ft. lbs.
REAR
- Remove front propeller shaft to transfer ca...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2002 MERCEDES-BENZ ML320 AUTOMOBILES
Alternator, Replace
Vehicle: 2002 MERCEDES-BENZ ML320 3.2 V6 GAS
- Remove engine compartment bottom cover.
- Remove viscous fan clutch and drive belt.
- Disconnect electrical connecto...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2002 MERCEDES-BENZ ML320 AUTOMOBILES
Cabin Air Filter Service -> Mercedes-Benz -> 1998-2005 ML Class
Vehicle: 2002 MERCEDES-BENZ ML320 3.2 V6 GAS
Under normal operating conditions the cabin air filter should be replaced every 15,000 miles. In dusty areas change the cabin air filter more often.
- Remove the instrument panel righthand lower trim panel.
- Release the three cabin air filter cover retainers securing the cover to the bottom of the AC/hea...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2002 MERCEDES-BENZ ML320 AUTOMOBILES
Mercedes-Benz -> Fuel Reserve & Fuel Cap Placement Warning Lamp ->
Vehicle: 2002 MERCEDES-BENZ ML320 3.2 V6 GAS
The Fuel Reserve and Fuel Cap Placement warning lamp will illuminate when the ignition switch is placed in the On position to indicate the warning system is operational. After the engine has been started, the warning lamp should go off. If the warning lamp is blinking, the fuel tank filler cap is improperly installed or a leak in the fuel system has been detected. Properly install the fuel tank filler cap. If fuel tank filler cap was improperly...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2002 MERCEDES-BENZ ML320 AUTOMOBILES
Radiator, Replace
Vehicle: 2002 MERCEDES-BENZ ML320 3.2 V6 GAS
- Drain cooling system into suitable container.
- Remove viscous fan mounting nut while counterholding pulley socket bolts with suitable wrench. Mounting nut has righthand threads.
- Remove fan shroud metal clamps.
- Remove fan shroud.
- Remove cover strip and headlamps.
- Remove front end crossmember.
- Disconnect coolant hoses at radiator.
- Remove radiator top seal.
- Remove power steering oil cooler lines.
- Disconnect AFT lines at radiator. Plug and sea...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2002 MERCEDES-BENZ ML320 AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2002 MERCEDES-BENZ ML320 3.2 V6 GAS
- Remove viscous fan clutch.
- Swivel tensioning pulley clockw...
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COMPONENT LOCATION DIAGRAMS FOR 2002 MERCEDES-BENZ ML320 AUTOMOBILES
Component location diagrams for most 2002 MERCEDES-BENZ ML320 cars and light trucks sold in the U.S. from 1990+.
Interior, Left Front Seat, Inside Seat Cushion Diagram for 2002 MERCEDES-BENZ ML320 3.2 V6 GAS Components on diagram: |
Interior, C-Pillar Diagram for 2002 MERCEDES-BENZ ML320 3.2 V6 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 2002 MERCEDES-BENZ ML320 AUTOMOBILES
OEM drawn wiring diagrams for most 2002 MERCEDES-BENZ ML320 cars and light trucks sold in the U.S.
2002 MERCEDES-BENZ ML320 3.2 V6 GAS Wiring Diagram Components on diagram: |
2002 MERCEDES-BENZ ML320 3.2 V6 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2002 MERCEDES-BENZ ML320 AUTOMOBILES
OEM TSB listings for most 2002 MERCEDES-BENZ ML320 cars and light trucks sold in the U.S. from 1985+.
Document: Maintenance Systems Overview Vehicle: 2002 MERCEDES-BENZ ML320 3.2 V6 GAS Auto Systems: |
Document: Introduction of Improved Single-Component Windshield/Window Bonding System Vehicle: 2002 MERCEDES-BENZ ML320 3.2 V6 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2002 MERCEDES-BENZ ML320 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2002 MERCEDES-BENZ ML320 cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2002 MERCEDES-BENZ ML320 cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2002 MERCEDES-BENZ ML320 cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2002 MERCEDES-BENZ ML320 cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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