MERCEDES-BENZ ML350 1997 Complete Repair Manual

1
Open cooling system cap (2) on coolant

expansion reservoir (1)

Cap with detent:

Turn cap carefully as far as the first detent,

release pressure, and then unscrew cap.

2-stage and 1-stage cap: Rotate cap half

a revolution in a counterclockwise direction,

release overpressure, then unscrew cap.

2.1Remove engine compartment paneling
Models 129, 202, 208, 210

AR61.20-P-1105AB

Models 163.172/ 174/ 175

AR61.20-P-1105GH

Models 163.113/ 128

AR94.30-P-5400GH

Model 211

AR61.20-P-1105T

Models 215, 220

AR61.20-P-1105M

Model 230

AR61.20-P-1105R

2.2Remove underride guard
Only on model 463

3.1
Remove air guide
Only on model 163 with engine 113.942

4
Drain coolant

Model 163: For draining coolant, detach

bottom coolant line at radiator or at coolant

pump.

Collect coolant Observe regulations for

disposal of coolant.


Installation:
On model 163 replace
radiator connection of hose clamps to coolant

hose, otherwise this can cause a damage to

the bolt/thread.


Hose clamp

*BA20.20-P-1004-01A

Pouring in

5
Pour in coolant

All except engine 137

*BF20.00-P-1001-02K


Engine 137

*BF20.00-P-1001-02M


Notes on coolant level
Engines 112, 113, 137, 275, 285

AH20.00-P-1142-01V


Notes on coolant level
Model 163 with engines 111, 112, 113

AH20.00-P-1142-01GH

6
Bleed cooling system

Let engine run, put heater on full heat

output.

Except stationary heater, code 228

AR20.00-P-1142-06GA

With stationary heater code 228

7
Inspect cooling system for leaks

AR20.00-P-1010HA


Radiator, coolant hoses

Number

Designation
Engines

112.942/

970,

113.942/

965/981

BA20.20-P-1004-01A
Hose clamp
Nm
3

Designation
Engines

112.910 /920

in model 202,

112.940

in model 208
Engines

112.911/921/941

in model 210
Engines

112.922/944/972

in model 220

BF20.00-P-1001-02K
Cooling system
Total capacity
Liters
Y
9.5
Y
10.0
Y
10.5

Capacity of

anticorrosion/antifreeze agent

down to -37°C

Liters

Y
4.75
Y
5.0
Y
5.0

Capacity of anticorrosion/

antifreeze agent down

to -45°C

Liters

Y
5.25
Y
5.5
Y
5.5

Specifications for Operating

Fluids
SheetBB00.40-P-0310-01ABB00.40-P-0310-01ABB00.40-P-0310-01A
SheetBB00.40-P-0325-00ABB00.40-P-0325-00ABB00.40-P-0325-00A

Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

Cooling system

Number

Designation
Engines

112.923/943

in model 129
Engine

112.945 in

models 463.209/

232/233/244/
245/250
Engine 112.942

in models 163,

113.940/980

in models 210,

113.943/984

in model 208,

113.944

in model 202

BF20.00-P-1001-02K
Cooling system
Total capacity
Liters
Y
11.75
Y
11.5
Y
11.0

Capacity of

anticorrosion/antifreeze agent

down to -37°C

Liters

Y
6.0
Y
5.8
Y
5.5

Capacity of anticorrosion/

antifreeze agent down

to -45°C

Liters

Y
6.5
Y
6.4
Y
6.0

Specifications for Operating

Fluids
SheetBB00.40-P-0310-01ABB00.40-P-0310-01ABB00.40-P-0310-01A
SheetBB00.40-P-0325-00ABB00.40-P-0325-00ABB00.40-P-0325-00A


Cooling system

Number

Designation
Engines

112.913/917/
949/954

in model 211
Engines

113.967/969

in model 211
Engine

113.990

BF20.00-P-1001-02K
Cooling system
Total capacity
Liters
Y
9.5
Y
10.75
Y
13.2

Capacity of

anticorrosion/antifreeze agent

down to -37°C

Liters

Y
4.75
Y
5.25

Y
6.6

Capacity of anticorrosion/

antifreeze agent down

to -45°C

Liters

Y
5.25
Y
6.0

Y
7.3

Specifications for Operating

Fluids
SheetBB00.40-P-0310-01ABB00.40-P-0310-01ABB00.40-P-0310-01A
SheetBB00.40-P-0325-00ABB00.40-P-0325-00ABB00.40-P-0325-00A


Cooling system

Number

Designation
Engines

113.941/960

in models 215,

220
Engine

113.961

in model 129
Engine 113.962

in modeld

463.206/

240/241

/247/248 249/254

BF20.00-P-1001-02K
Cooling system
Total capacity
Liters
Y
11.5
Y
12.75
Y
12

Capacity of

anticorrosion/antifreeze agent

down to -37°C

Liters

Y
5.75
Y
6.25
Y6

Capacity of anticorrosion/

antifreeze agent down

to -45°C

Liters

Y
6.25
Y
7.0
Y
6,6

Specifications for Operating

Fluids
SheetBB00.40-P-0310-01ABB00.40-P-0310-01ABB00.40-P-0310-01A
SheetBB00.40-P-0325-00ABB00.40-P-0325-00ABB00.40-P-0325-00A


Cooling system

Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 3

Number
Designation
Engine 113.991

in model 215
Engines

113.960/
986

in model 215
Engine

112.973 in

model 230.467

BF20.00-P-1001-02K
Cooling system
Total capacity
Liters
Y
14.5
Y
11.5
Y
10.8

Capacity of

anticorrosion/antifreeze agent

down to -37°C

Liters

Y
7.3
Y
5.75

Y
5.4

Capacity of anticorrosion/

antifreeze agent down

to -45°C

Liters

Y8Y
6.25

Y6

Specifications for Operating

Fluids
SheetBB00.40-P-0310-01ABB00.40-P-0310-01ABB00.40-P-0310-01A
SheetBB00.40-P-0325-00ABB00.40-P-0325-00ABB00.40-P-0310-01A


Cooling system

Number

Designation
Engines

112.970

113.965

in model 163
ENgines

113.942/981

in model 163
Engine

113.982
in

models

463.241/243/246

BF20.00-P-1001-02K
Cooling system
Total capacity
Liters
Y
12.0
Y
11.5
Y
11.9

Capacity of

anticorrosion/antifreeze agent

down to -37°C

Liters

Y
6.0
Y
5.75
Y
5.95

Capacity of anticorrosion/

antifreeze agent down

to -45°C

Liters

Y
6.75
Y
6.25
Y
6.55

Specifications for Operating

Fluids
SheetBB00.40-P-0310-01ABB00.40-P-0310-01ABB00.40-P-0310-01A
SheetBB00.40-P-0325-00ABB00.40-P-0325-00ABB00.40-P-0325-00A


Cooling system

Number

Designation
Engines

113.986/991

in model 220
Engines

113.948/966

in model 220
Engine

112.975

in model 220

BF20.00-P-1001-02K
Cooling system
Total capacity
Liters
Y
13.5
Y
11.6
Y
10.4

Capacity of

anticorrosion/antifreeze agent

down to -37°C

Liters

Y
6.8

Y
5.8
Y
5.2

Capacity of anticorrosion/

antifreeze agent down

to -45°C

Liters

Y
7.4

Y
6.4
Y
5.7

Specifications for Operating

Fluids
SheetBB00.40-P-0310-01ABB00.40-P-0310-01ABB00.40-P-0310-01A
SheetBB00.40-P-0325-00ABB00.40-P-0325-00ABB00.40-P-0310-01A


Cooling system

Number

Designation
Engine

113.968

in models 209,

211;

engine 113.969

in model 211

BF20.00-P-1001-02K
Cooling system
Total capacity
Liters
Y
11.5

Capacity of

anticorrosion/antifreeze agent

down to -37°C

Liters

Y
5.75

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d by Modification services.
Page 4

Capacity of anticorrosion/

antifreeze agent down

to -45°C

Liters

Y
6.25

Specifications for Operating

Fluids
SheetBB00.40-P-0310-01A
SheetBB00.40-P-0325-00A


Cooling system

Number

Designation
Engine

137.970

BF20.00-P-1001-02M
Cooling system
Total capacity
Liters
Y
12

Capacity of anticorrosion/

antifreeze agent down

to -37°C

Liters

Y6

Capacity of anticorrosion/

antifreeze agent down

to -45°C

Liters

Y
6.6

Specifications for Operating

Fluids
SheetBB00.40-P-0310-01A
SheetBB00.40-P-0325-00A

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Page 5

AR20.00-P-1142M
Drain, pour in coolant
8.11.99

ENGINE
612.963 in MODEL 163.113

P20.20-2083-12

1
Front noise encapsulation bottom part

2
Radiator

3
Radiator drain tap

4
Siphon hose

Draining


Danger!

Risk of injury
to
fingers being jammed or

pinched
when removing, installing or aligning

hoods, doors, trunk lid/tailgate or sliding roof.
When moving components, ensure that no

body parts or limbs are within the operating

range of moving parts.

AS00.00-Z-0011-01A


Danger!
Risk of injury
to skin and eyes suffering

scalding from contact with hot coolant spray.
Risk of poisoning
from swallowing coolant.
Do not open cooling system unless coolant

temperature is below 90 °C. Open cap slowly

and release the pressure. Do not pour coolant

into beverage bottles.

Wear protective gloves, protective clothing

and eye protection.

AS20.00-Z-0001-01A

1
Open engine hood and raise to vertical position


Have assistant secure hood.

AR88.40-P-1000GI

2
Open cap of coolant expansion reservoir

Turn cap half a turn in the anti-clockwise

direction, release pressure, and then unscrew

cap.

3
Remove front noise encapsulation bottom

part (1)

4
Attach siphon hose (4) to drain connection of

radiator

5
Drain coolant at radiator (2) on right

To do this, turn drain tap (3) at radiator (2)

into position "1" (arrow).


Disposal of coolants.

Pay attention to legal provisions or local

wastewater regulations!

Refer to Environmental Protection Catalog

issued by MBVD/PWU for locations in

Germany.

6
Clean cooling and heating system

Clean cooling and heating system in case

of impurities. See

#

Remove oil from cooling and heating system.
AR20.00-P-1250B

Pour in


Notes on coolant
All engines

AH20.00-N-2080-01A

7
Turn drain tap (3) at radiator (2) into position

"0" (arrow)

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Page 1

Danger!

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

8
Pour in coolant

Warm up engine by running at moderate

revs. Top up coolant constantly at coolant

expansion reservoir. Close coolant expansion

tank once

coolant temperature is 60-70 °C.

*BF20.00-P-1001-02E


Note on coolant level
Model 124, 129, 140, 163.113, 168, 170, 202,

208, 210, 220, 463

AH20.00-P-1142-01A

9
Inspect cooling system for leaks

AR20.00-P-1010HA


Cooling system

Number

Designation
Engine

612.963

BF20.00-P-1001-02E
Cooling system
Total capacity
Liter
Y
11.0

Filling capacity of anticorrosion/

antifreeze agent down to

-37 °C
Liter
Y
5.5

Filling capacity of anticorrosion/

antifreeze up to -45 °C
Liter
Y
6.25

Specifications for Operating

Fluids
SheetBB00.40-P-0310-01A
SheetBB00.40-P-0325-00A

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Page 2

GF54.30-P-4103GH
Coolant level switch, location/task/design/function
28.6.99

MODEL
163 as of 1.3.99

P54.30-2690-06

S41
Coolant level indicator electronic switch

The coolant level indicator electronic switch

(S41) is integrated in the coolant reservoir.

Coolant level switch, taskTo record the coolant level:

Coolant level
in order
or
below minimum

Coolant level switch, design
The coolant level indicator electronic switch

(S41) consists of two electrodes which are

permanently cast to the coolant reservoir and

a connector with contacts which have an

electrical connection to the electrodes.

Coolant level switch, function
The two electrodes are either immersed or

not immersed in the coolant depending on the

coolant level. As a result the test current

changes via the coolant level indicator

electronic switch (S41). This change is

evaluated by the instrument cluster (A1).

An alternating current is used so that the

electrodes do not disintegrate.

Copyright DaimlerChrysler AG 04.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1

AR91.12-P-1100GH
Remove and install cover on bottom of rear seat
22.2.00

MODELS
163.136 /154 /172 as of 1.9.99,

163.113 /128 /157 /174 /175

P91.12-2189-09

Arrows
Pushing directions for releasing

the locating tabs


Remove


Risk of breakage! Carefully press covers off

with a short screwdriver or suitable long

wedges.

1
Remove rear cargo space floor flaps

See Operating Instructions

2Remove rear cover (A)

Pull front outer edges of the cover

upwards in order to release the locating tabs

(1). Press outer locating tabs (2) outwards. In

the center of the cover, press locating tab (3)

to the right and locating tab (4) forwards. In

order to release the locating tabs (5), press

the cover down and remove to the rear.

3
Remove curtain at front 40 % bench

4
Remove outer cover (B) from 40 % bench

Press the cover in and pull upwards at

locating tab (6). Pull outwards at locating tabs

(7, 8). Press the cover forwards in order to

release the locating tab (9). At locating tab

(10), press down with a long wedge between

the covers. Guide the cover past the lateral

curtain.

5
Remove inner cover (C) from 40 % bench

Pull the outer rear corners of the cover up

in order to release the rear locating tabs (11).

In order to release the locating tabs (12),

press the cover forwards and remove to the

front.

6
Remove curtain at front 60 % bench

7
Remove outer cover (D) from 60 % bench

Push locating tab (13) up and turn cover

out and up at locating tab (14). Pull outwards

at locating tabs (15). Press the cover

forwards in order to release the locating tabs

(16). At locating tab (17) press down with a

long wedge between the covers. Guide the

cover past the lateral curtain.

8
Remove inner cover (E) from 60 % bench

Press locating tabs (18) in. Pull the outer

rear corners of the cover up in order to

release the rear locating tabs (19). In order to

release the locating tabs (20), press the cover

forwards, rotate counterclockwise and remove
past the springs towards the rear.


Install

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Page 1

9
Install inner cover (E) at 60 % bench

Insert cover past the springs from the rear

and rotate into position in a clockwise

direction. Insert locating tabs (19). Press the

front cover down and reset so that locating

tabs (20) engage. Press rear cover down until

locating tabs (18) engage.

10
Install outer cover (D) at 60 % bench

Guide the cover past the lateral curtain.

Insert locating tab (17), push front cover down

and reset so that locating tabs (16) engage.

Press the outer edge of the cover down and

insert lateral locating tabs (15). Raise rear
cover on the inside, press down until locating

tab (14) and rear locating tab (13) engage.

11
Install curtain at front 60 % bench

12
Install inner cover (C) at 40 % bench

Insert cover from the front and insert

locating tabs (11). Press the front cover down

and reset so that locating tabs (12) engage.

13
Install outer cover (B) at 40 % bench
Guide the cover past the lateral curtain.

Insert locating tab (10), push front cover down

and reset so that locating tab (9) engages.

Press the outer edge of the cover down and

insert lateral locating tabs (8). Insert locating

tab (7), push cover down at locating tab (6)

and engage.

14
Install curtain at front 40 % bench

15
Install rear cover (A)

Insert cover from the rear and press down

and forwards so that locating tabs (5) engage.

Press front ends of the cover down, so that

locating tabs (2, 3, 4) engage. Insert locating

tabs (1) into covers (C, E).

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Page 2

Crankshaft Position Sensor DIY


hopefully this will help others with what appears to be a common stalling issue in the ML series.


Location:


--------


It's on the rear of the engine where the engine mates with the tranny on the driver's side. There are 2

types. Be sure to get the correct one


Here it is:


1) Get
CPS
at dealer, its a VIN specific part. $125 from my local stealer.


2) Tools needed: Socket screwdriver, Good lighting (portable) shop lights, size 8 outside torx socket,
maybe a ratche
t and extentions depending on your flexibility, magnetic part retrieval tool (skip this at

your peril), bath towel, and long sleeve shirt, step stool, blue thread locker (optional)


3) Open hood and remove engine cover, it just pulls off and on


4) Set wor
k light(s) toward back of engine, lighting behind drivers cylinder head


5) Set bath towel on front of ML to kneel on of your knees will die, wearing long sleeve shirt or your

wrists will be cut.


6) Climb up on towel and look behind engine from above and
right (see .jpg), finding torx attachment
holding your
CPS
.

7) Remove torx screw and pull out
CPS
, disconnect one way connector (wiring)


8) Replace with new (leaving wire detached for now)


9) This is the hardest step by far, and requires patience and fl exibility. Apply some thread locker and

insert screw and start the threads. Tighten with torx on socket screwdriver. This step took about 1/2

hour and numerous dropped screws and retrievals with mag tool.


10) Attach wiring to
CPS


11) Reinstall engine cov
er


12) Clean up tools, towel and lights and everything


13) Drink beer and toast yourself for saving yourself at least $100 and a day of your time dropping off

and picking up cars at shop


Hope this helps someone in the community.


Dickie


00 ML 32
0