MERCEDES-BENZ ML350 1997 Complete Repair Manual

112.910 /911 /912 /913 /914 /916 /917 /920 /921 /922 /923 /940 /941 /942 /943 /944 /946 /947 /949 /953 /954 /95
ENGINE 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /966 /967 /968 /969
ENGINE 166.940 /960 /990 /995
Fig. 19: Identifying Knock Sensors

STARTER CONTROL, FUNCTION - GF15.30-P-3000GA
ENGINE 111.921 /942 as of 1.9.98,
111.943 /944 /946 /947 /973 with CODE (423a) 5-speed automatic transmission (new-generation)
ENGINE 111.945
in MODEL 208.335 /435 as of 1.6.98,
Knock sensors, locationEngine 104GF15.12-P-4101-01D
Engine 111GF15.12-P-4101-01G
Engine 112GF15.12-P-4101-01A
Engine 113GF15.12-P-4101-01B
Engine 119GF15.12-P-4101-01E
Engine 120GF15.12-P-4101-01F
Engine 166GF15.12-P-4101-01GC
Knock sensors, taskThe knock sensor detects
vibrations at the crankcase.
Knock sensors, designThe knock sensor is a self-
contained system. Inside
the sensor are piezo
crystals. The screened
cable is fitted directly onto
the knock sensor.
Knock sensors, function GF15.12-P-4101-02KE

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
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202.020 /080 as of 1.9.98 with CODE (423a) 5-speed automatic transmission (new-generation)
ENGINE 111.974
with CODE (423a) 5-speed automatic transmission (new-generation)
with CODE (494a) USA version
with CODE (807) Model year 1997
with CODE (808) Model year 1998
ENGINE 111.975 as of 1.8.96 with CODE (423a) 5-speed automatic transmission (new-generation)
ENGINE
112.910 /911 /912 /913 /914 /916 /917 /920 /921 /922 /923 /940 /941 /942 /943 /944 /946 /947 /949 /953 /954 /9
5
with CODE (423a) 5-speed automatic transmission (new-generation)
ENGINE 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /966 /967 /968 /969 with CODE (423a) 5-speed
automatic transmission (new-generation)
ENGINE 120.983 as of 1.6.98
ENGINE 137.970
Fig. 20: Identifying Starter Function Components
- Shown On Engine 111

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
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Task
After engine start speed is reached, interrupt the circuit (circuit 50) M1 to the solenoid switch of the starter.
Design
The solenoid switch of the starter is operated not through the ignition/ start switch S2/1, but in drive position P
or N through the starter relay, by the engine control unit.
The voltage for the starter relay (coil) is supplied through circuit 87. The starter relay is actuated by the engine
control unit through GND.
Function
When the ignition/start switch is operated in the start position, the engine control unit activates an automatic
start control. Once the engine start speed of 400 to 700 rpm is reached, the engine control unit interrupts the
ground actuation to the starter relay and thus the engine start operation.
Once the engine start operation is initiated, shutting off circuit 50 at the ignition/start switch has no effect. The
starter rotates until the specified start speed is reached, or for about 5 seconds at an engine temperature of +80 °
C, for a maximum of 10 seconds if the engine is cold.
SAFETY PRECAUTIONS
SAFETY INFORMATION: ELECTRICAL SYSTEM - ENGINE - AS15.00-Z-9999ZZ
MODEL all
Motor electronics control unit,
location/task/ design/function GF07.61-P-5000F
HFM-SFI control unit,
location/task/design/ function GF07.51-P-4103D
Crankshaft position sensor,
location/task/ design/function GF07.04-P-4116F
Start recognition functionEngine 104,, 111, 112,
113, 137 (via terminal 50)GF07.13-P-3014G
Engine 119, 120 (via
engine speed signal)GF07.13-P-3014F
ETC control unit, location/taskSelector lever position
information P/N and
driving position engaged.
Transmission 722.6GF27.19-P-4012G
Electronic ignition switch
control unit, location/
task/design/functionModel 202 as of 6/97, 208,
210 as of 3/97GF80.57-P-4102A
Model 215, 220GF80.57-P-4102S
Model 203, 209GF80.57-P-4102PP

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
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RISK OF DEATH CAUSED BY CONTACT WITH PARTS CONDUCTING HIGH VOLTAGES. - AS15.10-Z-0001-01A
Do not touch parts which conduct high voltages. Persons who wear electronic implants (e.g. heart
pacemakers) must not carry out work on the ignition system
Risk of death caused by high voltages in the ignition system
Electronic ignition systems operate within a hazardous power range both on the low voltage side (primary
circuit) as well as on the high voltage side (secondary circuit). Contacts with such parts can result in burns,
heart flutter or cardiac arrest.
Fig. 21: High Voltage Warning

Safety instructions/precautions
Persons with heart pacemakers must not perform any work on the ignition system.
Switch ignition off before commencing any work on the ignition system.
Do not touch or dismantle components of ignition system when working on running or rotating engine
with cranking speed.
Wear safety shoes (with rubber soles).
Detach the crankshaft position sensor connection either at the control unit or at the position sensor.
Do not install any electrically conducting, un-insulated adapters or installation sensors into the ignition
cable.
Risk of death caused by
coming into contact with
high-voltage parts although
ignition is turned off.ENGINE 137 ENGINE
275 ENGINE 285AS15.15-Z-0001-01A
Risk of death caused by
contact with parts
conducting high voltages.ENGINE 103, 104, 111,
112, 113, 119, 120, 122,
132, 134, 135, 137, 155,
156, 160, 166, 266, 271,
272, 273, 275, 285, 613,
628, 629, 642, 646, 648,
902, 906...AS15.10-Z-0001-01A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
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TROUBLE DIAGNOSIS
STARTER OCCASIONALLY DOES NOT START - AF15.30-P-6405A
ENGINE 112 in MODEL 129, 163, 170, 202, 208, 210, 220
ENGINE 113 in MODEL 129, 163, 202, 208, 210, 215, 220
ENGINE 119 in MODEL 129, 210
ENGINE 120 in MODEL 129
Modification notes
24.7.00Supersedes STIP 07.60-022
dated 28.2.00Reference link updated.
Damage codeCauseRemedy
15 001 41 Starting operation is
terminated before engine
can start.
When starting tachometer
jumps momentarily in
direction > 2000 rpm.
DTC in ME-SFI
control unit:
No DTC stored.
1 Remove starter.
ENGINE 112, 113 in
MODEL 129AR15.30-P-7100CS
ENGINE 119, 120 in
MODEL 129AR15.30-P-7100EC
ENGINE 112, 113 in
MODEL 210AR15.30-P-7100FF
ENGINE 119.985 129AR15.30-P-7100FAF
ENGINE 112 in MODEL
202AR15.30-P-7100ED
ENGINE 112.940 in
MODEL 208
ENGINE 112.947 170AR15.30-P-7100GA
ENGINE 112.942,
113.942 in MODEL 163AR15.30-P-7100GH
ENGINE 113.960 in
MODEL 215,AR15.30-P-7100I
ENGINE 112, 113 in
MODEL 220
2 Coat teeth on starter
ring gear lightly with
paste
Use only paste
specified in parts note
Ensure that excessive

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1998-2005 ENGINE Electrical System - Engine - 163 Chassis
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Parts ordering notes
TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: ELECTRICAL SYSTEM - ENGINE - AR15.00-Z-9163AA
MODEL 163
REMOVE, INSTALL CAMSHAFT HALL SENSOR - AR15.10-P-2000A
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 112 in MODEL 129, 163, 170, 202, 203, 208, 209.361 /365/461 /465, 210,
211.061 /261 /065 /265 /080 /082 /280 /282, 220, 230.467
ENGINE 113 (except 113.990/991) in MODEL 129, 163, 202, 208, 209.375/475/376/476, 210,
211.070 /270 /083 /283, 215, 220, 230.472 /474 /475
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODEL 463.243/246
quantity of paste is not
applied because this can
interfere with the signal
pickup of position sensor
L5
3 Install starter.
Part no.DesignationQuantity
000 989 76 51Paste (1 kg)1
Servicing wiring harnessMODEL 124, 126, 129,
140, 163, 168, 170, 201,
202, 208, 210, 215, 220AR15.18-P-0500A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
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Fig. 22: Identifying Camshaft Hall Sensor - Shown On Engine 112 In Model 220
Position sensor
TEST ROTORLESS HIGH VOLTAGE DISTRIBUTION - AR15.10-P-3000WA
ENGINE 112.923 /943, 113.961 in MODEL 129
ME-SFI fuel injection and ignition system with engine diagnostic tester Datascope D 980
Fig. item etc.Work instructions
Camshaft Hall sensor to
cylinder head *BA15.10-P-1002-03A
B6/1Camshaft Hall sensor Replace O-ring.
NumberDesignationEngines
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/
973/975/976Engines
113.940/941/
942/943/944/
948/960/961/
962/963/964/
965/966/967/
968/969/971/
980/981/982/
984/986/992/
993/995Engine
113.987/
988/990/
991
BA15.10-P-
1002-03ACamshaft Hall
sensor to
cylinder headNm888

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 33 © 2006 Mitchell Repair Information Company, LLC.

ENGINE 112.942, 113.942/965/981 in MODEL 163
ME-SFI fuel injection and ignition system with engine diagnostic tester Datascope D 980
ENGINE 112.910 /920, 113.944 in MODEL 202
ME-SFI fuel injection and ignition system with engine diagnostic tester Datascope D 980
ENGINE 112.940, 113.943 in MODEL 208
ME-SFI fuel injection and ignition system with engine diagnostic tester Datascope D 980
ENGINE 112.911 /921 /941, 113.940/980 in MODEL 210
ME-SFI fuel injection and ignition system with engine diagnostic tester Datascope D 980
ENGINE 112.922 /944, 113.941 /960 in MODEL 220
ME-SFI fuel injection and ignition system with engine diagnostic tester Datascope D 980
Risk of accident.
Accidents may result if the
vehicle starts off
unintentionally with the
engine running. Risk of
injury as working around
the engine during start-up
or while running may result
in contusions and burnsSecure 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
Risk of death. Death may
result if contact is made
with parts carrying high
voltages.Do not touch parts
carrying high voltages.
Persons who wear
electronic implants (e.g.
heart pacemakers) must
not carry out work on the
ignition system.AS15.10-Z-0001-01A
1Remove air cleaner
2Remove trim panel of
cylinder head cover
3Test ignition circuits Datascope engine
diagnostic tester*WH58.30-Z-1003-13A
General information on
rotorless high voltage
distribution AH15.10-P-1002-01WA
General information on
testing rotorless high AH15.10-P-1003-01W

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1998-2005 ENGINE Electrical System - Engine - 163 Chassis
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Commercially available tools
REMOVE/INSTALL IGNITION COILS - AR15.12-P-2003A
ENGINE 112.910 in MODELS 202.026 /086
ENGINE 112.920 in MODELS 202.029 /089
ENGINE 112.921 in MODELS 210.063 /081 /263 /281
ENGINE 112.922 in MODELS 220.063 /163
ENGINE 112.923 in MODEL 129.059
ENGINE 112.940 in MODELS 208.365 /465
ENGINE 112.941 in MODELS 210.065 /082 /265 /282
ENGINE 112.942 in MODEL 163.154
ENGINE 112.943 in MODEL 129.064
ENGINE 112.944 in MODELS 220.065 /165
ENGINE 112.945 in MODEL 463
ENGINE 113.940 in MODELS 210.070 /270
ENGINE 113.941 in MODELS 220.070 /170
voltage distribution
if necessary: ?
Test secondary side
Secondary adapter
cable in place of kV
clamp.
kV clamp in ignition
coil recess alternately at
ignition coil T1/1-T1/6 or
T1/8
Test primary side
Primary adapter cable
alternatively at ignition
coil T1/1-T1/6 or T1/8
NumberDesignation
WH58.30-Z-1003-13AEngine tester

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1998-2005 ENGINE Electrical System - Engine - 163 Chassis
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ENGINE 113.960 in MODEL 215.375, 220.075 /175 /875
ENGINE 113.961 in MODEL 129.068
ENGINE 113.962 /982 in MODEL 463
ENGINE 113.980 in MODELS 210.074 /274
ENGINE 113.944 in MODELS 202.033 /093
ENGINE 113.942 in MODEL 163.172
ENGINE 113.943 in MODELS 208.370 /470
ENGINE 113.984 in MODELS 208.374
ENGINE 113.981 in MODEL 163.174
ENGINE 112.912 in MODELS 203.061 /261, 209.361 /461
ENGINE 112.946 in MODELS 203.064 /264
ENGINE 112.947 in MODEL 170.465
ENGINE 112.960 in MODEL 170.466
ENGINE 113.986 in MODEL 215.373, 220.073 /173
ENGINE 112.961 in MODELS 203.065 /265
ENGINE 113.965 in MODEL 163.175
ENGINE 113.963 in MODEL 230.475
ENGINE 113.968 in MODEL 209.375 /475
ENGINE 112.913 in MODELS 211.061 /261
ENGINE 112.949 in MODELS 211.065 /265
ENGINE 113.967 in MODELS 211.070 /270
ENGINE 113.992 in MODEL 230.474
ENGINE 113.987 in MODELS 209.376 /476

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 36 © 2006 Mitchell Repair Information Company, LLC.