MERCEDES-BENZ ML350 1997 Complete Repair Manual

AF80.57-P-6406A
Engine sometimes fails to start and fault message "Start Error" appear in the

instrument cluster
13.8.04

MODEL
163.136 /154 /172 #A as of 145273,

163.136 /154 /172 #X as of 708319,

163.113 /128 /157 /174 /175

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

Category

Op. no.
Operation text

Time
Acc. no.
Code

P
541011
Perform quick test
004 WU
------

P
805030
Replace drive authorization system (DAS [FBS]) control unit

(after check)
006 WU
------

Damage code
Cause
Remedy

82 801 90

When the ignition is switched on (circuit

15), the engine control unit sends a start

enable request to the DAS [FBS] control unit.

If during this request circuit 15 is switched off

or interrupted before the DAS [FBS] control

unit could respond, the variable code sent the

first time is used again the next time circuit 15

is switched on, since the original request is

saved by the DAS [FBS] control.

1
Replace the DAS [FBS] control unit.

AR54.21-P-1300GH


The fault message "Start Error" appears

in instrument cluster.

When ordering a new control unit, please

specify the chassis number.

Parts ordering notes

Part no.

Designation
Quantity

163 545 07 16
FBS control unit
1

Copyright DaimlerChrysler AG 05.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

1998-2005 ENGINE
Engine timing - 163 Chassis
GENERAL INFORMATION
GENERAL NOTES: PASSE NGER CARS: ENGINE TIMING - AH05.00-Z-9999AZ
MODEL all
Loosening and tighten ing regulation for
camshaft bearing capsENGINE 160.921 /922 /923 in MODEL
452.3/4AH05.20-P-
0300-01RR
Loosening and tighten ing regulation for
camshaft bearing capsENGINE 160, 660...AH05.20-P-
0300-01SM
Note concerning adjusting the valve
seat cutterENGINE 160 in MODEL 450.3/4, 452.3/4AH05.30-P-
4520-01A
Note concerning valve seat machiningENGINE 160 in MODEL 450.3/4, 452.3/4AH05.30-P-
4520-02A
Information on application of sealant to
bottom part of camshaft housingENGINE 271AH05.20-P-
6995-01QK
General notes on timing, markingsENGINE 112, 113, 112.951/976AH05.10-P-
1000-01A
Camshaft code number and assignmentENGINE 111.948 /978, 112, 113AH05.20-N-
0100-01A
Camshaft code number and assignmentENGINE 111AH05.20-P-
0100-01AG
Camshaft code number and assignmentENGINE 120AH05.20-P-
0100-01AO
Slackening and tightening instructions
for the camshaft bearing capsENGINE 275AH05.20-P-
0300-01A
Marking of camshaft bearing capsENGINE 266.920 /940 /960 /980AH05.20-P-
6992-01AK
Marking of camshaft bearing capsENGINE 120AH05.20-P-
6992-01AO
Camshaft, code numbers and allocationENGINE 601, 602, 603AH05.20-P-
6992-03HB
Notes on the application of sealing
compound of the camshaft caseENGINE 266.980 in MODEL 169.0 /3,
245.2AH05.20-P-
6995-02BK
Marking of camshaft bearing capsENGINE 668.914 /940 /941 /942AH05.20-P-
6992-01GD
Marking on camshaft bearing capsENGINE 611,
646.8 /951 /961 /962 /963 /966AH05.20-P-
6992-04HB
Marking of camshaft bearing capsENGINE 613, 648AH05.20-P-
6992-04HD
Loosening and tighten ing regulation for ENGINE 601.943, AH05.20-N-

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.
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Saturday, October 02, 2010 3:39:41 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.

GENERAL NOTES ON TIMING, MARKINGS - AH05.10-P-1000-01A
Engine 112, 113
Shown on engine 112
Fig. 1: Identifying Timing, Markings
- Shown On Engine 112
The four copper plates for the timin
g chain facilitate assembly when putting on timing chain. Every copper
camshaft bearing caps602.980 /983 /981 /984 /985, 601.942 /9700300-01B
Identification of camshaft bearing capsENGINE 111 /948 /978AH05.20-N-
6992-01A
Notes on installing camshaft bearing
bridgeENGINE 112, 113...AH05.20-P-
2000-01AV
Notes on installing camshaft bearing
bridgeENGINE 113.960 with CODE (479)
Cylinder shutoffAH05.20-P-
2000-01BV
Notes on coupling rocker armENGINE 113.960 with CODE (479)
Cylinder shutoffAH05.20-P-
3000-01AV
Marking of camshaft bearing capsENGINE 166AH05.20-P-
6992-01GF
Marking of camshaft bearing capsENGINE 612 /965 /966, 647.961AH05.20-P-
6992-04HC
Marking of camshaft bearing capsENGINE 628, 629 ...AH05.20-P-
6992-04HE

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 2 © 2006 Mitchell Repair Information Company, LLC.

plate (1) must coincide with one of the markings. Due to unequal length of timing chai n paths, the engine must be cranked up to 14 times until the copper
plates are matched again with the markings.
CAMSHAFT CODE NUMBER AND ASSIGNMENT - AH05.20-N-0100-01A
Engine 111, 112, 113
Inspection data of camshaft code numbers
Inspection data for camshaft code numbers
Inspection data for camshaft code numbers
Engine 112, 113
The camshaft code number is located at the flange for the camshaft sprockets (arrow).
Shown on camshaft for engine 112.
NumberDesignationEngine 111.948Engine 111.978
BE05.20-N-1001-
01ACamshaft code
numbersIntake1616
Exhaust2417
BE05.20-N-1002-
01ACamshaft code
numbers repair
camshaftIntake1919
Exhaust2520
NumberDesignationEngines
113.940//
941/942943Engine
113.944Engine
113.960 with
code 479
Engine 113.960
without Code 479
BE05.20-P-
1001-01GLeft camshaft
code number04/28/34/52413206/10/29/36/54
BE05.20-P-
1002-01GRight camshaft
code number05/30/35/53403307/11/31/37/55
NumberDesignationEngines
113.961/962/963Engines
113.980/981/984Engine
113.987/988/98
9/990/991
BE05.20-P-1001-
01GLeft camshaft code
number06/10/29/36/543961
BE05.20-P-1002-
01GRight camshaft
code number07/11/31/37/553860

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 3 © 2006 Mitchell Repair Information Company, LLC.

Fig. 2: Locating Camshaft Code Number - Shown On Camshaft For Engine 112
NOTES ON INSTALLING CAMSHAFT BEARING BRIDGE - AH05.20-P-2000-01AV
Engines 112, 113 except 113.960, 113.960 except cylind er shutoff codes 479, 113.962/982/993, 112.951/976
Pay attention to the following notes before installing the camshaft bearing bridges:
Lubricate the camshaft bearings.
Due to tolerance reasons, the camshafts must not be replaced individually.
If the camshaft bearing bridge is damaged, replace th e cylinder head complete with the camshaft bearing
bridge.
It not permitted to reuse the bolts M7 X84; these must always be replaced.
Pay attention to tightening torque, slackening di agram and tightening diagram of the bolts M7x84.
Shown on engine 112
Fig. 3: Identifying Camshaft Bearings Bridge Bolts

BASIC KNOWLEDGE
DESIGN OF CHAIN TENS IONER - GF05.10-P-7801-01A

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 4 © 2006 Mitchell Repair Information Company, LLC.

Engines 112, 113
Shown on engine 112
Fig. 4: Identifying Desi gn Of Chain Tensioner
- Engines 112, 113
TIMING CHAIN DRIVE, GENERAL - GF05.10-P-9611-01C
Engine 112, 113
Shown on engine 112

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 5 © 2006 Mitchell Repair Information Company, LLC.

Fig. 5: Identifying Timing, Markings - Shown On Engine 112
Engine timing
The basic setting is 40° after TDC.
At 40° after TDC the grooves (6) in th e left and right camshafts point in the direction of the inner V and are
centered on the parting surface of the cylinder head cover. The copper-plated lugs (1) and marks on the
camshaft sprockets (4 and 5) coincide.
The groove in the crankshaft (2) and the mark on the ba lance shaft sprocket (3) point toward one anther and
both coincide with the copper-plated lugs (1).
Rubber-coated sprockets
In order to improve the noise characteristic of the timing case drive the chain sprockets on the crankshaft,
balance shaft and camshafts are rubber-coated.
Only on engine 112
6 mm dia. locating holes (a) are located coinciding with one anther in the rear balancing weight on the balance
shaft and rear of the crankcase.
Repair note
Due to the difference in the timin
g chain paths it may be necessary to crank the engine up to 14 times before the

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 6 © 2006 Mitchell Repair Information Company, LLC.

marks on the camshafts coincide again.
Fig. 6: Identifying Holes
- Only On Engine 112
Only on engine 112
Checking the balance shaft with engine assembled
Two marks, one at the front of the crankcase and the ot her on the end of the balancing weight, point toward one
anther and can be seen through the left timing case shaft approx. 22 cm. below the parting surface of the
cylinder head cover when the cylinder head cover is removed.
Fig. 7: Identifying Two Mark s On Front Of Crankcase

SAFETY PRECAUTIONS
SAFETY INFORMATION: ENGI NE TIMING - AS05.00-Z-9999ZZ
MODEL all

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 7 © 2006 Mitchell Repair Information Company, LLC.

RISK OF EXPLOSION AND PO ISONING - AS05.30-Z-0001-01A
Do not open sodium-filled valves. Wear protectiv e gloves and safety glasses when handling damaged
valves.
Exhaust valves fill ed with sodium
Potential risks
Risk of explosion
Explosion may occur when melting down sodium-filled va lves. Sodium has a very low self-ignition temperature
(121 °C) and may spontaneously ignite in moist air.
Improper disposal may lead to fires due to moisture in scrap containers.
Risk of poisoning
The inhalation of toxic vapors causes severe irritation, shortness of breath, headaches, nausea and vomiting.
Risk of injury
Leaked sodium that comes into contact with moist body tissue (perspiration on hands, tears) may undergo a
severe, explosive reaction and generate heat. This may lead to skin ir ritation and burns, and to corneal damage
with possible blinding.
Safety instructions/precautions
Keep water and sources of heat and ignition away from sodium.
When handling damaged, sodium-filled valves, wear su itable protective gloves and safety glasses, if
necessary.
Never machine sodium-filled valves.
Do not open sodium-filled valves.
Observe all additional safety requireme nts and regulations in your country.
First aid measures
Skin and eye contact
Remove sodium, treat the injured area with an oily solution, e.g. Biseptol and consult a physician.

Risk of explosion and poisoning caused by the melting down
or improper handling of sodium-f illed valves. Risk of injury
caused by skin contact with s odium resulting in heat or
chemical burns.ENGINE 111, 112, 113,
137, 155, 156, 166, 266,
646, 647, 648 ...AS05.30-Z-
0001-01A

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 8 © 2006 Mitchell Repair Information Company, LLC.

Ingestion
Do not give the affected person a nything to drink, consult a physician.
Vapor inhalation
Move the victim out of the risk area.
If victim has the urge to vomit, give him/her oxygen.
In the event of respiratory failure, administ er artificial respiration and notify a physician.
TESTING & REPAIR
REMOVE/INSTALL HYDRAULIC VALVE CLEARANC E COMPENSATION ELEMENTS - AR05.00-P-2011B
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 112 in MODEL 129, 163, 170, 202, 203, 208, 209, 210, 220
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113 in MODEL 129, 163, 202, 203, 208, 209, 210, 215, 220, 230.474 /475
ENGINE 112.913 in MODEL 211.061/261
ENGINE 112.949 in MODEL 211.065/265
ENGINE 113.967 in MODEL 211.070/270
ENGINE 113.982 in MODEL 463.243/246
ENGINE 113.990 in MODEL 211.076/276

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 9 © 2006 Mitchell Repair Information Company, LLC.