MERCEDES-BENZ ML350 1997 Complete Repair Manual

163 589 00 91 00

Extraction hose

Adapter hose

Pliers

163 589 00 37 00 168 589 00 90 00

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e.g.)
Order number

WH58.30-Z-1001-16A
Suction master M2P 20 B
Ecco GmbH

Vonkeln 17

D-42349 Wuppertal
9749 5000 50

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Page 3

AP18.00-P-0101AR
Engine - oil and filter change
20.1.99

ENGINE
612

Modification notes

12.9.02

Engine oil level modified
Step 9:

Only Model 203:

Up to engine end number: 134 163 oil level
MAX. 135
mm,
MIN 110
mm.

As of engine end number: 134 164 oil level

MAX. 124,5
mm,
MIN 99,5
mm.


Remove

Danger!

Risk of death
cased 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


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


Change the engine oil only when the engine

is at operating temperature

1
Remove trim panel of cylinder head cover

AR01.20-P-5014-02B

2
Replace oil filter element, drain oil filter

Model 203: Remove clamp attaching fuel

line in order to insert wrench socket.

AP18.00-P-0101-06EG

*BA18.20-P-1002-01G

Socket wrench bit

*103589020900

3.1
Suction off engine oil

AP18.00-P-0101-02Z
4.1
Remove rear left frame cross brace

Only necessary when draining engine oil

at oil drain plug.

MODEL 163

f

Model 203 except 203.018/218/718, 209
AR94.30-P-5300P

Model 210

AR94.30-P-5300AB

4.2
Detach lower engine compartment paneling

Only necessary when draining engine oil

at oil drain plug.

f

Only Model 203.018/218/718

AR61.20-P-1105P

5.1
Unscrew oil drain plug, drain engine oil


Install

6.1
Screw in oil drain plug

Replace sealing ring, in order to avoid

leakage.


*BA01.45-P-1003-01A

7
Pour in engine oil
Note specified and approved quality

grades and viscosity classes conforming to

SAE at enduring ambient temperatures.

*BE18.00-P-1001-02B


*BF18.00-P-1001-01A

g

Viscosity classes of engine oils (car engines)
Sheet 224.1

BB00.40-P-0224-01A

8
Run engine and inspect for leaks

9
Switch off engine

10.1
Fit on bottom part of noise encapsulation

Only necessary when draining engine oil

at oil drain plug.

f

Model 210

AR94.30-P-5300AB

MODEL 203, 209

AR94.30-P-5300P

MODEL 163

10.2
Install lower engine compartment paneling.

Only necessary when draining engine oil

at oil drain plug.

f

Only Model 203.018/218/718

AR61.20-P-1105P

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11
Check oil level approx. 5 min. after switching

off warm engine

Insert oil dipstick up to the stop and keep

to a residence time of at least 3 seconds.

Model 163, 210 with Engine 612
*BE18.00-P-1001-02B
Model 203, Model 209 with Engine 612

On Model 203, Model 209 after oil level

check pay attention to correct seating of the
cap, otherwise it could result in engine

damage.

Only Model 203:

Up to engine end number: 134 163 oil level

MAX. 135
mm,
MIN 110
mm.

As of engine end number: 134 164 oil level

MAX. 124,5
mm,
MIN 99,5
mm.

Measuring rod


*120589072100

12
Install trim panel of cylinder head cover

AR01.20-P-5014-02B


*BA01.20-P-1002-01A


*BA01.20-P-1003-01A

Test values for engine lubrication - general

Number

Designation
Engine

612.961
Engine

612.963

BE18.00-P-1001-02B
Dipstick marking

Color red
t
1

Color black
t
2

Color green
t
3

Color gentian blue
t
4

Numbers on handle
Number
6020760206

Round handle
Color
--

Bottle opener-shaped

handle
Color
11

Designation
Engine

612.961/962/

963/965/966,

613.961
Engine

612.967
Engine

612.990

BA01.45-P-1003-01A
Oil drain plug at oil pan
M12
Nm
---

M14
Nm
303030


Engine lubrication, oil filter

Number

Designation
Engine

612.961/962/
963/967/990,

613.960/961

BA18.20-P-1002-01G
Screw cap at oil filter
Nm
25

Crankcase ventilation, cylinder head cover

Number

Designation
Engine

612.961/

962/967
Engine

612.963
Engine

612.990

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Page 2

BA01.20-P-1002-01A
Screw of trim panel of cylinder head cover

to cylinder head cover
Nm
1010
8

BA01.20-P-1003-01A
Screw attaching cover panel to charge air

distribution pipe
Nm
1010
-

Designation
Engine

612.961
Engine 612.962/

967
Engine

612.963/966

BF18.00-P-1001-01A
Engine oil
Filling capacity

(oil and filter change)
Liter
7,06.57.5

Specifications for Operating

Fluids
SheetBB00.40-P-0228-01ABB00.40-P-0228-01ABB00.40-P-0228-01A
SheetBB00.40-P-0228-03ABB00.40-P-0228-03ABB00.40-P-0228-03A
SheetBB00.40-P-0228-05ABB00.40-P-0228-05ABB00.40-P-0228-05A
SheetBB00.40-P-0229-01ABB00.40-P-0229-01ABB00.40-P-0229-01A
SheetBB00.40-P-0229-03ABB00.40-P-0229-03ABB00.40-P-0229-03A
SheetBB00.40-P-0229-05ABB00.40-P-0229-05ABB00.40-P-0229-05A


Engine lubrication system

Number

Designation
Engine 612.990

BF18.00-P-1001-01A
Engine oil
Filling capacity

(oil and filter change)
Liter
6.5

Specifications for Operating

Fluids
SheetBB00.40-P-0228-01A
SheetBB00.40-P-0228-03A
SheetBB00.40-P-0228-05A
SheetBB00.40-P-0229-01A
SheetBB00.40-P-0229-03A
SheetBB00.40-P-0229-05A

120 589 07 21 00

Measuring rod

Socket wrench bit

103 589 02 09 00

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e. g.)
Order number

WH58.30-Z-1007-16A
Engine oil extractor
Deutsche Tecalemit

Am Metallwerk 11

33659 Bielefeld

1.386950.2

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AR61.20-P-1105GH
Remove/install bottom engine compartment paneling
22.6.00

MODEL
163.172 with ENGINE 113.942

MODEL
163.174 with ENGINE 113.981

MODEL
163.175 with ENGINE 113.965

P61.20-2017-12
1
Engine compartment paneling

2
Grub screw

3
Plastic clips


Remove/Install

1
Remove grub screws (2) of plastic clips (3)

6 grub screws pins.


Installation:
Check grub screws, replace

if necessary.

2
Pull out plastic clips (3)


Installation:
Check plastic clips, replace

if necessary.

3
Remove engine compartment panel (1)


Installation:
Ensure that engine

compartment panel is positioned correctly.

4
Install in the reverse order

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Page 1

GF00.20-P-2009A
Engine oil monitor function
24.10.96

MODEL
129 with ENGINE 112, 113

MODEL
163 with ENGINE 112, 113, 612

MODEL
168 with ENGINE 166, 668

MODEL
202 with ENGINE 112, 611

MODEL
208 up to 31.7.99 with ENGINE 112, 113

MODEL
210 up to 30.6.99 with ENGINE 112, 113, 611

General

The oil level is constantly monitored by the oil sensor, and the

appropriate data transmitted to the processor by the ASSYST.

Oil replenishments are detected automatically and result in a bonus,

which extends the service interval accordingly.

An excess oil level or insufficient oil level appears in the display

together with the oil can symbol.

Display of low oil level at maximum:
D
at driver request

Display of warnings: D
automatically, at the earliest 60 s after engine start and oil

temperature greater than 60°C:

D
if oil level too high: the oil can symbol appears together

with the readout "OIL LEVEL ABOVE MAX". In addition, a

brief warning signal sounds. (On models not fitted with

multifunction displaly, "HI" appears flashing.)

D
if oil level too low: the oil can symbol appears together with

the readout "OIL LEVEL BELOW MIN". In addition, a brief

warning signal sounds. (On models not fitted with multifunction

display, the oil level warning lamp (A1e12) comes on and the

readout "-2L" appears flashing.)

-----------------------------------------------------------------------------------------
D

if oil at minimum: the oil can symbol appears together with

the readout "OIL LEVEL MINIMUM". In addition, a brief

warning signal sounds. (On models not fitted with multifunction

display, the oil level warning lamp (A1e12) comes on.)

D
automatically 13 s after ignition ON:

D
if
no oil
is in engine: the oil can symbol appears together

with the readout "OIL LEVEL BELOW MIN". In addition, a

warning signal sounds. (On models not fitted with multifunction

display, the oil level warning lamp (A1e12) comes on and the

readout "-2L"appears flashing. In addition a brief warning

signal sounds.)

The missing oil quantity displayed no longer changes during the

display. In other words, any change in oil level cannot be observed

directly at the display. The new oil level is only displayed once the

conditions described below exist.

Display of oil quantity at driver request

The text "DISPLAY OIL LEVEL?" appears 10 s after the start switch

has been turned into position "2" (on models not fitted with

multifunction display, the oil can and the clock symbol are displayed).

If the reset button of the trip counter is pressed twice within one sec.

during this readout, for example, "add 1.0L oil" (or "-1.0L")

-----------------------------------------------------------------------------------------

appears in the display if oil level too low. The readout appears only

after the elapse of a waiting time after engine OFF. The waiting time

depends on the engine oil temperature.

It is

D
up to 20°C
30 minutes

D
from 60°C
1 minute

D
The waiting time is between these two limits at other engine oil

temperatures.

Possible readouts are (text in parenthesis relates to models not fitted

with multifunction display.):
D
"OIL LEVEL OKAY" ("o.k."),

D
1.0L, 1.5L, 2L,

D
"Overfilling" ("HI"),

D
"OBSERVE WAITING TIME" (clock symbol flashing and oil can

symbol),

D
"DISPLAY OIL LEVEL" (clock and oil can symbols.)

If there is a fault at the oil sensor (oil level/temperature/quality, B40)

the oil can symbol and the text "OIL LEVEL SENSOR FAULTY"

appears only 30 s after the fault has occurred.

(On models not fitted with multifunction display, the oil level warning

lamp (A1e12) comes on accordingly.)

For diagnosis, read also the injection system control module (N3)

with the HHT. (The instrument cluster (A1) receives the sensor data

through the CAN from the injection system control module (N3)).

-----------------------------------------------------------------------------------------
Oil change

The ASSYST has to be reset each time the oil is changed. Resetting

ASSYST also resets the remaining time and the remaining distance.

Resetting can be performed at the instrument cluster or using the

HHT.

The following data are stored when the system is reset:

D
current kilometer reading rounded off to 100,

D
total oil replenishments in the last interval,

D
remaining distance,

D
remaining time,

D
product of the quality factors,

D
the data of the last 5 resettings in 5 data sets

These data can only be read with the HHT!

If the specified quantity of oil is not replenished when the oil is

changed, the (internal) start distance is reduced.

Detecting oil replenishments
D
With the
HHT
it is possible to retrieve the last 10 oil

replenishments and the corresponding kilometer readings of

the current interval.

D
In the normal case, detection of an oil replenishment is

displayed by the remaining distance in the instrument cluster

being extended

-----------------------------------------------------------------------------------------

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Oil replenishments are always only detected once the following

conditions are met:

D
the replenished quantity is
at least 1 l

D
after replenishing the oil, the car must be driven a distance of
at

least 5 km
under
normal driving conditions
at an
oil

temperature of at least 60 °C
.

There are instances, however, in which the readout of the remaining

distance nevertheless appears implausible after replenishing oil;

according to the display, no bonus or only a small bonus has been

issued. This is caused by the fact that the remaining distance is

always only displayed within a range from 15 000 km up to 30 000

km (or 20 000 km up to 40 000 km in the case of engine 668), but

internally the system calculates with the actual values which may also

be beyond this range. These internal values can only be displayed

with the HHT.
In the charts overleaf, a number of examples of this are presented.
The horizontal (x) axis represents the service interval and the vertical

(y) axis is the remaining distance in each case in km.

The readout of ASSYST in the instrument cluster always moves

within the light range.

The remaining distance calculated internally may also, however, be

within the two dark ranges. These internal values can only be

displayed with the HHT.

All examples relate to gasoline engines fitted with an oil sensor.

P00.20-0201-06

Example 1 :

Sufficient oil was added during the oil change.

This means that the starting distance is 15

000 km.

After 10 000 km oil is topped up under normal

driving conditions (a). The bonus (B1) is

issued and displayed. What this means is that

when the remaining distance is retrieved, a

greater remaining distance is displayed.

(Provided the aforementioned conditions for

detecting the oil replenishment are met.)

Oil is topped up again after a further

5 000 km (b). In this case also a bonus (B2) is

issued and displayed.

If, after this, no further oil is topped up and

the car continues to be driven in the same

manner, a service interval of about

24 000 km is thus achieved.

In this example, the curve moves at all points

within the light range of the chart;

consequently, all the oil replenishments are

displayed by increasing the remaining

distance.

P00.20-0204-06

Example 2:

The specified quantity of oil was added when

the oil was changed.

The car is driven under very favorable

conditions and oil is topped up after

10 000 km (a). Internally, the bonus B1 is

issued, the service interval is extended

accordingly by enlarging the remaining

distance. However, as the curve is sometimes

within the shaded area, only the part of B1

which is within the light area, is at first

displayed as an extension of the remaining

distance. (Provided the aforementioned

conditions for detecting oil replenishment are

met.)

Oil is topped up once again at 18 000 km (b).

In view of the fact that the maximum service

interval of 30 000 km was exceeded, the

bonus B2 is not initially displayed as an

extension. The entire service interval in this

case is 30 000 km.

If, from point b, the car continues to be driven

under less favorable conditions, it may still

also be possible now to achieve the maximum

service interval of 30 000 km because of the

internal bonus B2.

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P00.20-0202-06

Example 3:

When the oil was changed, the quantity

added was less than the specified quantity.

Consequently, the start distance is less than

15 000 km.

If oil is now topped up after 5 000 km (a), the

remaining distance displayed is not extended

as the curve is within the shaded area. The

bonus B1 is nevertheless added internally

and results in an extension of the service

interval to slightly more than

15 000 km - provided the driving conditions

remain the same or are more favorable.

(The service interval of 15 000 km is always

reached, however, even if the internal value

were less.)

P00.20-0203-06

Example 4:

Oil has been topped up after 5 000 km under

unfavorable driving conditions (a) and the oil

replenishment (bonus B1) detected internally.

We now have two cases to consider:

D
If the car continues to be driven under

the same conditions (unbroken line), the

remaining distance displayed is not

extended as the curve is within the

shaded area.

The service interval in this case is

nevertheless 15 000 km although the

internal value is less. (The remaining

distance displayed can always only be

within the light area.)

D
If the car continues to be operated

under more favorable conditions

(broken line), the value of the internal

remaining distance slowly moves into

the light area. Consequently, the service

interval may be greater than

15 000 km.


Active service system survey of display

facilities

GF00.20-P-0003-04A


Active service system technology/ influencing

variables

GF00.20-P-0003-05A


Active service system survey

model/engine/sensor/instrument cluster

GF00.20-P-0003-06A


Active service system (ASSYST) operating

instructions, resetting

GF00.20-P-0003-01A

Oil sensor position/task/function
Oil sensor position, task, function

GF18.40-P-4111A

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Page 3

AF07.00-P-9000B
Engine runs rough, surges or does not turn over
29.4.02

ENGINE
611 in MODEL 203, 202, 210

ENGINE
612 in MODEL 163, 203, 210, 209

ENGINE
613 in MODEL 210, 220

ENGINE
628 in MODEL 163, 220, 211

ENGINE
646 in MODEL 203, 211

ENGINE
647 in MODEL 211

ENGINE
648 in MODEL 220, 211

ENGINE
668 in MODEL 168

ENGINE
612, 628 in MODEL 463

Modification notes

23.3.01

Supersedes STIP 07.16-014 dated 11.12.00

Damage code
Cause
Remedy

07 206 D5
High-pressure pump

To verify whether high pressure pump is

damaged.

#

High pressure pump of common rail

injection system is damaged mechanically.

1
Remove/install/replace high pressure

pump.

When the high pressure pump of the common

rail injection system is damaged metal chips

and/or damage to the pump drive (timing

drive) can occur due to contamination of the

injection system components.
2
Turn high pressure pump by hand with

driver.

If mechanical resistance can be felt,

perform the following tests. Clarify additional

work with ESKULAB by specifying repair work:

#
3
Check driver of high pressure pump or

mount in sprocket for damage (visual

check).

If high pressure pump is locked:
#
4
Check timing

5
Check timing drive for damage.

In each case:
#
6
Remove/install/replace timing chain.

If timing deviates by a crankshaft angle of

more than 20 degrees (corresponding to one

tooth skipped):

#
7
Check pressure loss.

8
Open low pressure connection on high

pressure pump return (plastic line in

area of pressure regulator valve) and

check connection point in rail for chips.

If chips are present when checking

injection system:

#
9
Thoroughly clean all fuel low pressure

lines as well as feed and return lines.

Flush and blow out with compressed air.

10
Remove fuel preheater and fuel filter

with filter housing, replace.

Fuel preheater is only installed in models

202, 203 and 163.

11
Remove/install/replace fuel cooler at

vehicle and engine end.

Not installed in model 210 up to 6/99 and

model 168.

12
Remove fuel tank, replace.

On engine 628:
#

13
Remove/install/replace electric supply

pump.

14
Remove/install/replace injectors, rail

(including pressure regulation valve and

rail pressure sensor), high pressure

lines and injector leak oil rail.*

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Fuel pump (gear pump) and electric

shutoff valve can remain on engine.

15
Check injection system for leakage.

16
Check with HHT/DAS for proper

function (check actual value).

17
Read DTC memory and erase after
checking.

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Page 2