MERCEDES-BENZ ML350 1997 Complete Repair Manual

AR15.12-P-2133A
Remove/install crankshaft position sensor
5.7.96

ENGINE
112.910 in MODEL 202.026 /086

ENGINE
112.920 in MODEL 202.029 /089

ENGINE
112.921 in MODEL 210.063 /081 /263 /281

ENGINE
112.922 in MODEL 220.063

ENGINE
112.923 in MODEL 129.059

ENGINE
112.940 in MODEL 208.365 /465

ENGINE
112.941 in MODEL 210.065 /082 /265 /282

ENGINE
112.942 in MODEL 163.154

ENGINE
112.943 in MODEL 129.064

ENGINE
112.944 in MODEL 220.065 /165

ENGINE
113.940 in MODEL 210.070 /270

ENGINE
113.941 in MODEL 220.070 /170

ENGINE
113.960 in MODEL 215.375, 220.075 /175

ENGINE
113.961 in MODEL 129.068

ENGINE
112.945 in MODEL 463.209 /232 /233 /244 /245 /250

ENGINE
113.944 in MODEL 202.033 /093

ENGINE
113.980 in MODEL 210.074 /274

ENGINE
113.943 in MODEL 208.370 /470

ENGINE
113.984 in MODEL 208.374

ENGINE
113.981 in MODEL 163.174

ENGINE
112.912 in MODEL 203.061 /261, 209.361 /461

ENGINE
112.946 in MODEL 203.064 /264

ENGINE
112.947 in MODEL 170.465

ENGINE
112.960 in MODEL 170.466

ENGINE
113.942 in MODEL 163.172

ENGINE
112.961 in MODEL 203.065 /265

ENGINE
113.965 in MODEL 163.175

ENGINE
113.963 in MODEL 230.475

ENGINE
112.913 in MODEL 211.061

ENGINE
112.949 in MODEL 211.065

ENGINE
113.967 in MODEL 211.070

ENGINE
113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254

ENGINE
113.982 in MODEL 463.243 /246

ENGINE
112.955 in MODEL 209.365 /465

ENGINE
112.916 in MODEL 203.081 /281

ENGINE
112.953 in MODEL 203.084 /284

ENGINE
112.973 in MODEL 230.467

ENGINE
112.972 in MODEL 220.067 /167

ENGINE
112.970 in MODEL 163.157

ENGINE
112.975 in MODEL 220.087 /187

ENGINE
113.948 in MODEL 220.083 /183

ENGINE
113.966 in MODEL 220.084 /184

ENGINE
112.917 in MODEL 211.080 /280

ENGINE
112.954 in MODEL 211.082 /282

ENGINE
113.969 in MODEL 211.083 /283

P15.12-0275-11

Shown on Engine 113 in Model 220

L5
Crankshaft position sensor

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Page 1

Remove/Install

1.1
Remove engine compartment cover with

integrated air cleaner
All except Engine 112.960 in Model 170.466,

Engine 112.961 in Model 203.065/ 265

Remove air cleaner by lifting vertically up

and away from the cylinder head covers.


Installation:
With sliding compound,

slightly moisten the rubber retainers on the

cylinder head covers and the sealing ring of

the hot film mass air flow sensor in the air

cleaner housing.

1.2
Remove air cleaner housing
Engine 112.960 in Model 170.466

Engine 112.961 in Model 203.065/265

AR09.10-P-1150SVK

2
Remove crankshaft position sensor (L5)


*BA15.10-P-1001-03A

3
Install in the reverse order

4.1
Reinitialize crankshaft position sensor (L5)

using STAR DIAGNOSIS

If the crankshaft position sensor (L5) was

replaced, a re-initialization must be carried

out with STAR DIAGNOSIS in the "Control

unit adaptations" menu item.

Diagnosis system STAR DIAGNOSIS

*WE58.40-Z-1013-06A


Position sensor

Number

Designation
Engine

112.910/911/912/
913/914/915/
916/917/920/
921/922/923/
940/941/942/
943/944/945/
946/947/949/
951/953/954/
955/960/961/

970/972/973/975
Engine

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

992/993

BA15.10-P-1001-03A
Crankshaft position sensor to engine block
Nm
88

Workshop equipment/MB testers
(see Workshop Equipment Manual)

WE58.40-Z-1013-06A
Compact STAR DIAGNOSIS system for passenger cars, order number 6511 1801 00

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Page 2

AR62.30-P-2300GH
Removing and installing front end cross member
15.4.97

MODEL
163

P62.30-0350-06

1
Upper frame cross member

2
Screws

3
Engine hood control cable

4
Engine hood lock

E1 Left headlamp unit
E2
Right headlamp unit

Operation no. of operation texts or of standard texts and flat rates
Division
Operation

no.
Operation text

P
621300
REPAIRING FRONT REINFORCEMENT BETWEEN WHEELHOUSES

P
621304
REPLACING FRONT LEFT AND CENTER REINFORCEMENT BETWEEN WHEELHOUSES

P
621305
REPLACING FRONT LEFT AND CENTER REINFORCEMENT BETWEEN WHEELHOUSES (WHEN REPLACING

WHEELHOUSE TOGETHER WITH LONGITUDINAL MEMBER)

P
621311
REPLACING FRONT RIGHT AND CENTER REINFORCEMENT BETWEEN WHEELHOUSES

P
621312
REPLACING FRONT RIGHT AND CENTER REINFORCEMENT BETWEEN WHEELHOUSES (WHEN REPLACING

WHEELHOUSE TOGETHER WITH LONGITUDINAL MEMBER)

P
621315
REPLACING FRONT CENTER REINFORCEMENT BETWEEN WHEELHOUSES

P
621320
COMPLETELY REPLACING FRONT REINFORCEMENT BETWEEN WHEELHOUSES

P
621321
COMPLETELY REPLACING FRONT REINFORCEMENT BETWEEN WHEELHOUSES (WHEN REPLACING

WHEELHOUSE TOGETHER WITH LONGITUDINAL MEMBER)

P
882302
REMOVING AND INSTALLING FRONT END CENTER SECTION


Removal, installation

1
Remove headlamp unit on left (E1) and right

(E2)

AR82.10-P-4730GH

2
Remove upper frame cross member (1)

Unscrew screws (2).

3
Remove engine hood control cable (3) from

engine hood lock (4)

For this purpose turn upper frame cross

member over.

Unhook engine hood control cable and pry

catch out of upper frame cross member.

4
Remove upper frame cross member (1)

5
Install in opposite order

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Page 1

AR01.30-P-5800MV
Remove/install cylinder head
22.7.98

ENGINE
112.942 in MODEL 163.154

ENGINE
112.970 in MODEL 163.157

ENGINE
113.942 in MODEL 163.172

ENGINE
113.981 in MODEL 163.174

ENGINE
113.965 in MODEL 163.175

P01.30-2032-06

Shown on model 163.154 with engine 112

1
Air baffle

2
Viscous fan

3
Fan shroud

4
Bolts

5
Air cleaner housing

6
Air intake manifold

7
Resonance unit

8
Poly-V-belt

9
Fender liner

10
Shield

11
Exhaust bracket

P01.30-2033-06

12
Right and left ignition coils

13
Left and right cylinder head covers

14
Intake manifold

15
Camshaft position sensor

16
Coolant line

17
Chain tensioner

18
Oil filter housing

19
Camshaft sprockets

28
Camshaft bearing bridges

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Page 1

P01.30-0299-06

20
Bolts cylinder head
!
timing case cover

21
Cylinder head bolts

22
Cylinder head left

23
Cylinder head right

24
Left cylinder head gasket

25
Right cylinder head gasket

26
Dowel sleeves


Remove/Install

Notes on self-locking nuts and bolts
All models

AH00.00-N-0001-01A


External torx set

*001589760900

Torx bit set

*000589011000


Danger!

Risk of explosion
caused by oxyhydrogen

gas.
Risk of poisoning and caustic burns


caused by swallowing battery acid.
Risk of

injury caused by burns to skin and eyes from

battery acid or when handling damaged lead-

acid batteries
No fire, sparks, open flames or smoking.

Wear acid-resistant gloves, clothing and

safety glasses. Pour battery acid only into

suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1
Disconnect battery ground cable


Installation:
After connecting, read out

fault memory, encode radio and normalize

power windows.

Vehicles with stationary heater: Set time on

timer for stationary heater
AR54.10-P-0003A

Notes on battery
All models

AH54.10-P-0001-01A

Danger!

Risk of death

caused by vehicle slipping or

toppling off of the lifting platform.
Align vehicle between the columns of the

hydraulic hoist and position the four support

plates below the hoist support points specified

by the vehicle manufacturer.

AS00.00-Z-0010-01A

2
Place the vehicle on lifting platform

AR00.60-P-1000GH
3.1
Remove air guide (1)


Only with engine 113.942

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

4
Drain coolant

Remove coolant hose at bottom on

radiator.

AR20.00-P-1142HA

5
Remove engine cover

6.1
Remove viscous fan (2)

All except model 163.174 /175 with

engine 113.981 /965.

Right-hand thread!

AR20.40-P-5660C

7.1
Remove the fan shroud (3).

Only model 163.154 /157 /172. Unscrew

bolts (4) from bottom of fan shroud

7.2
Remove electric fan

Only model 163.174/ 175.

AR20.40-P-5000GH

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Page 2

8
Attach guard plate for radiator/condenser

y

Guard plate for radiator/condenser
Engine 606 in model 124,
Engine 606.961 in model 140,

Engine 112, 113, 604, 605, 611.960 in model

202,

Engine 602.983, 612.966 in model 461,

Engine 628.962, 612.965, 606.964, 112.945,

113.962/ 982 in model 463,

Engine 111, 112, 611.962, 612.962 in model

203,

Engine 112, 113, 611.961, 612.961, 613.961

in model 210,

Engine 112 in model 170,
Engine 112 in model 220,

Engine 113 in model 211, 215, 220,

Engine 112 in model 208,

Engine 112, 113, 612.963, 628.963 in model

163,

Engine 112.923 /943, 113.961 in model 129,

Engine 137, 275 in model 215, 220,

Engine 613.960, 628.960 in model 220,

Engine 113.992 in model 230.474,

Engine 271 in model 209, 203,

Engine 285.950 in model 240.078 /178,

Engine 612.967 in model 209.316,

Engine 648 in model 220

Engine 112.951 in model 639.601/603/ 605/

701 /703 /705 /801 /803 /805

Engine 646.983 /984 in model 639.601/

603 /605 /701 /703 /705 /801 /803 /805

Engine 646.982 in model 639.601/ 603/ 605/
701 /703 /705

WF58.50-P-0110-01A

9
Remove air cleaner housing (5)

10
Remove air intake pipe (6) with resonance
tube (7)

Separate connector of hot film mass air

flow sensor (HFM) for this step and unbolt air

intake pipe at cylinder head cover

The air intake pipe is attached at the rear

at the intake manifold with a plastic plate.

Do not damage the plastic strap.

Engine 112.942/ 970

AR07.07-P-1454A

Engine 113.942/ 965/ 981

AR07.07-P-1454MV


Danger!

Risk of explosion
caused by fuel igniting,

risk of poisoning
caused by inhaling and

swallowing fuel as well as
risk of injury
to

eyes and skin caused by contact with fuel.
No fire, sparks, open flames or smoking.

Pour fuels only into suitable and appropriately

marked containers.

Wear protective clothing when handling fuel.
AS47.00-Z-0001-01A

11
Disconnect fuel line at fuel rail

Release fuel pressure at service valve!

Collect fuel!

Engine 112:
#

*BA07.52-P-1001-01A

Engine 113:
#

*BA07.52-P-1001-01A

Pressure hose

*119589046300

12
Remove right and left ignition coils (12)

AR15.12-P-2003A

13
Remove right and left cylinder head covers (13)

AR01.20-P-5014B

14
Remove the intake manifold (14)


Installation:

On vehicles with engine

damage, the intake manifold must be

examined for swarfs before assembling and

any swarfs present must be removed, in order

to avoid consequential damage.

AR09.20-P-1310A

The intake manifold system must not be

disassembled.

Remove intake manifold with fuel distributor

15.1
Remove camshaft position sensor (15)

Only necessary if the right cylinder head is

removed.

AR15.10-P-2000A

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16
Remove poly V-belt (8)


Installation:
Lock tensioning device with

a drift or pin (diameter 5 mm).

Model 163.154 /157 /172.

AR13.22-P-1202B

Model 163.174 /175.

AR13.22-P-1202BA

17
Detach the coolant line (16) at the cylinder

head on the left

6 mm socket hexagon

*WH58.30-Z-1001-06A

7 mm socket hexagon

*WH58.30-Z-1002-06A

18.1
Remove fender liner (9)

Only with engine 113.113.942 /965 / 981.

AR88.10-P-1300GH

19.1
Remove shield (10)

Only with engine 113.942 /965 /981.

20.1
Remove exhaust bracket (11)

Only with engine 113.942 /965 /981.

Support exhaust system.

21
Detach exhaust system at exhaust manifold


Installation:
On vehicles with engine

damage, the exhaust system must be

examined for swarfs before assembling and

any swarfs present must be removed, in order

to avoid consequential damage.


*BA14.10-P-1002-01B

22
Position crankshaft to 40° after ignition TDC

on cylinder 1


The engine must not be turned back;

otherwise the timing chain can get jammed.

AR05.10-P-6858V

Rotate engine at the crankshaft in running

direction until scribe mark 40° on pulley/

vibration damper corresponds with scribe

mark on timing case.

The grooves on the camshafts must be

pointing toward the inner V.

23
Lock camshafts with locating plates

Locating plate

*112589003200

Locating plate

*112589013200

24
Remove chain tensioner (17)
Model 163.154 /157 with engine 112.942/

970, model 163.172 with engine 113.942.
AR05.10-P-7800C

Model 163.174 /175 with engine 113.981/ 965.
AR05.10-P-7800CA

25.1
Remove oil filter housing (18) together with oil-

water heat exchanger
Engine 113.942.

AR18.20-P-3471B

Engine 112.942/970.

AR18.20-P-3471BA

26
Unscrew camshaft sprockets (19)

If camshaft sprockets are removed,

engine must no longer be cranked, otherwise

timing chain might jam.

Engine 113.942 /965 /981:
#

Tie timing chain tight on both camshaft

sprockets with tie straps.

Engine 112.942 /970:

#

Right-hand camshaft sprocket:

Tie timing chain tight on camshaft sprocket

with tie strap.

Left-hand camshaft sprocket:
Mark camshaft sprocket to timing chain and

remove camshaft sprocket.

It is not possible for the timing chain to

jump across at the crankshaft and balancing

shaft.

After installation:
#

Inspect basic position of camshafts.

AR05.10-P-6858V

If necessary after checking:
#

Set the basic position of camshafts

AR05.20-P-6020AU

Open-end wrench

*112589000100

Insertion tool

*112589010300

Torque wrench

*001589722100


*BA05.20-P-1001-01B

27
Remove camshaft bearing bridges (28)

Pay attention to slackening and tightening

pattern!

AR05.20-P-7103AU

28
Unscrew bolts, cylinder head
!
timing case

cover (20)


*BA01.40-P-1002-01C

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29
Slacken cylinder head bolts (21) in stages,

unscrew

Loosen cylinder head bolts according to
loosening schematic only after engine has

cooled down to prevent cylinder head from

distorting.

AR01.30-P-5800-09B


Installation:
Observe tightening pattern

and tightening instructions of cylinder head

bolts.
Oil thread and head contact surface of

cylinder head bolts.
AR01.30-P-5800-07B

Screwdriver insert

*000589031000

Screwdriver insert

*000589041000


*BA01.30-P-1001-01D

30
Remove cylinder head


Installation:

On Engine 112/113 observe

porous points in the left and right cylinder

head. If porous points are present, sealant

must be applied to the cylinder head gasket.


Notes on application of sealant to cylinder

head gasket.
Engine 112, 113

AH01.30-P-1000-04VA

The sealant must be applied within

10 minutes.

Loctite 5900 sealant.

*BR00.45-Z-1015-01A

31
Inspect version of cylinder head gasket
Assignment of cylinder head gasket


Information for assigning the cylinder head

gaskets
Engine 112, 113

AH01.30-P-1000-06V

32
Check cylinder head bolts (21)


AR01.30-P-5800-03B

*BE01.30-P-1001-04B

33
Clean sealing surfaces, inspect for cracks,

shrink holes and flatness, clean threaded

holes.

Pay attention to dowel sleeves (26) for

locating the cylinder head.

Sealing surfaces of crankcase and

cylinder head are provided with an 0.8 mm

thick silicone layer during series production.

At the time of repair installation, silicone

sealant is applied to the sealing area only in

case of any shrink holes.

The sealant must be applied within

10 minutes.

Loctite 5900 sealant.

*BR00.45-Z-1015-01A

34
Install in the reverse order

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

35
Run engine and inspect for leaks

36
Inspect cooling system for leaks

Warm up engine to operating temperature

and then inspect cooling system or leaks.

AR20.00-P-1010HA

37
Read out and erase fault memory

Stored faults which can result from cables

being disconnected or from simulation during

removal and installation or test work, have to

be processed and erased in the fault

memories after completing the work:

#

Diagnosis Manual Volume 2 Index 0:

Connecting and using test equipment.

Cylinder head/cylinder head bolts

Number

Designation
Engine

112.910/911/912/
913/914/915/
916/917/920/
921/922/923/
940/941/942/
943/944/945/
946/947/949/
951/953/954/
955/960/961/

970/972/973/975
Engine

113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/987/
988/990/991/

992/993

BE01.30-P-1001-04B
Cylinder head bolt
Thread diameter
M
1111

Length (L) when new
mm
141.5141.5

Length (L)
mm
T
144.5
T
144.5

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Fig., see
AR01.30-P-5800-03BAR01.30-P-5800-03B

Cylinder head

Number

Designation
Engine

112.910/911/912/
913/914/915/
916/917/920/
921/922/923/
940/941/942/
943/944/945/
946/947/949/
951/953/954/
955/960/961/

970/972/973/975
Engine

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

992

BA01.30-P-1001-01D
Bolt of cylinder head to

crankcase
1st stageNm
1010

2nd stage
Nm
3030

3rd stage
(°
9090

4th stage
(°
9090

Crankcase, timing case cover, end cover

Number

Designation
Engine

112

except

112.951
Engine

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

984/986/992

BA01.40-P-1002-01C
Bolt, cylinder head to timing case cover
Nm
2020


Camshaft

Number

Designation
Engine

112

except 112.951
Engine

113.940/941/
942/943/944/
948/961/962/
963/965/966/
967/968/969/
980/981/982/

984/986/992

BA05.20-P-1001-01B
Bolt of camshaft sprocket
M12 x 45
1st stageNm
5050

2nd stage
(°
9090


Fuel rail

Number

Designation
Engine

112 except

112.945/951/

960/961

BA07.52-P-1001-01A
Fuel feed line to fuel rail
Nm
38

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Page 6