MERCEDES-BENZ ML350 1997 Complete Repair Manual

camshafts
The copper plates of the
timing chain must be
aligned with the scribe
marks on the camshaft
sprockets.
Owing to the unevenly long
paths of the timing chain it
may be necessary to crank
the engine as many as 14
times till the copper plates
get aligned with the scribe
marks on the camshaft
sprockets.
On vehicles equipped
with an air pump, the
combination valve must be
unbolted before the right
locking plate is inserted.
Installation: Replace
combination valve gasket.
*BA09.20-P-1001-01D
Locating plateFig. 11
Locating plateFig. 12
Timing chain drive -
generalEngines 112, 113GF05.10-P-9611-01C
6Remove chain tensionerModels 163.174, 215, 220
Models 170, 202, 203,
208.365/465
Models 209, 210,
211061/065/070
Model 230.474 with engine
113.992AR05.10-P-7800CA
7Remove camshaft
position sensor AR15.10-P-2000A
8Crank engine in direction
of rotation until the link
for separating the timing
chain is easily accessible The separation point for
the timing chain is one link
down from the copper tab
(right).
See new timing chain.
9Remove camsha ft bearing
bridge on rightEngine 112, 113AR05.20-P-7103AU
Engine 113.960 with code
(479) Cylinder shutoffAR05.20-P-7103AV
10Install holding bush (3)
onto camshaft on right Only insert bolts (4)
until they make contact. Fig. 40

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 30 © 2006 Mitchell Repair Information Company, LLC.

Holding bush
11Bolt on holding devices
(1, 2) for timing chain at
right and left cylinder
heads RetainerFig. 39
12Disconnect timing chain Cover over timing case
recess with a clean cloth.
Parts which have dropped
into the timing case recess,
must be removed.
To pull out the old
timing chain, connect the
old chain to the new timing
chain.AR05.10-P-7601-01AV
Install
13Draw in new timing chain Pull in the new timing
chain by turning the
crankshaft in its standard
direction of rotation.AR05.10-P-7601-04AV
Assembly linksFig. 32
CaseFig. 16
14Remove retaining devices
(1, 2) for timing chain at
right and left cylinder
head RetainerFig. 39
15Rivet new timing chain AR05.10-P-7601-02AV
16Crank engine in direction
of rotation
17Check timing of engine AR05.10-P-6858V
18Take off holding bush (3)
on right camshaft Holding bushFig. 40
19Install camshaft bearing
bridge on rightEngines 112, 113AR05.20-P-7103AU
Engine 113.960 with code
(479) Cylinder shutoffAR05.20-P-7103AV
20Install camshaft position
sensor AR15.10-P-2000A
21Installing chain tensionerModels 163.174, 215, 220
Models 170, 202, 203,
208.365/465
Models 209, 210,
211061/065/070
Model 230.474 with engine
113.992AR05.10-P-7800CA
22.1Install fan shroud Not model AR20.40-P-6800AB

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 31 © 2006 Mitchell Repair Information Company, LLC.

Intake manifold
211.061/065/070, 230.475
Models 220, 230.474
22.2Install electric fanModel 170AR20.40-P-5000SV
Models 203, 209AR20.40-P-5000PV
Model 163.174AR20.40-P-5000GH
23Install cylinder head
coversAir filter locat ed at vehicle
side.AR01.20-P-5014B
Air filter locat ed on engine
side.AR01.20-P-5014BV
24Install spark plugs
Replace spark plugsModels 220, 230.474/475AP15.10-P-1580AB
Models 210, 208, 202AP15.10-P-1580A
Models 170, 203, 209, 211
with engine 112
Models 209, 211 with
engine 113
Model 163AP15.10-P-1580GH
25Connect ground cableModel 203AR54.10-P-0003P
Models 129, 163, 170, 202,
208, 210AR54.10-P-0003A
Model 209AR54.10-P-0003Q
Models 211.061/065/070AR61.20-P-1105T
Model 215, 220AR54.10-P-0003I
Model 230.474/475AR54.10-P-0003R
All models 463 except
463.241/248 with code 979AR54.10-P-0003G
Model 463.241 with code
979AR54.10-P-0003PV
Model 463.248 with code
979AR54.10-P-0003PM
Risk of accident caused
by vehicle starting off by
itself when engine is
running. Risk of injury
caused by contusions and
burns during starting
procedure or when
working near the running
engineSecure vehicle to prevent it
from moving by itself.
Wear closed and snug-
fitting work clothes.
Do not grasp hot or rotating
parts.AS00.00-Z-0005-01A
26Run engine and inspect
for leaks
NumberDesignationEngines 112, 113

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
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Saturday, October 02, 2010 3:39:37 PMPage 32 © 2006 Mitchell Repair Information Company, LLC.

Fig. 37: Identifying Locating Plate (112 589 0032 00)
Fig. 38: Identifying Locating Plate (112 589 01 32 00)

Fig. 39: Identifying Retainer (112 589 04 40 00)

Fig. 40: Identifying Holding Bush (112 589 05 40 00)
BA09.20-P-1001-
01DBolt, intake manifold
to cylinder headM8Nm20

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 33 © 2006 Mitchell Repair Information Company, LLC.

Fig. 41: Identifying Asse mbly Links (602 589 02 40 00)
Fig. 42: Identifying Case (602 589 00 98 00)

REPLACING TIMING CHAIN - AR05.10-P-7601AV
ENGINE 112
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODEL 463.243/246
ENGINE 113 (except 113.995) in MODEL 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 34 © 2006 Mitchell Repair Information Company, LLC.

Fig. 43: Identifying Timing Chain Components
Removing
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 batteriesNo fire, sparks, open
flames or smoking. Wear
acid-resistant gloves,
clothing and safety
glasses. Only pour battery
acid into suitable and
appropriately marked
containers.AS54.10-Z-0001-01A
Notes on batteryAll models.AH54.10-P-0001-01A
1Disconnect ground cableModel 463 except code
(979) Special protection
versionAR54.10-P-0003G
Model 463.241 with code
(979) Special protection
version.AR54.10-P-0003PV
Model 463.248 with code
979AR54.10-P-0003PM
Models 129, 208, 210.AR54.10-P-0003A

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 35 © 2006 Mitchell Repair Information Company, LLC.

2Remove spark plugs To ensure that the
engine can be easily
cranked when drawing in
the timing chain, and to
avoid the timing chain
jumping across.
Remove only one spark
plug at each cylinder.

Replace spark plugsModel 463.AP15.10-P-1580GA
Model 129.AP15.10-P-1580A
Models 202, 208, 210 with
engine 112.
Models 163.AP15.10-P-1580GH
3Remove cylinder head
coversAir filter locat ed at vehicle
side.AR01.20-P-5014B
Air filter located on
engine side.AR01.20-P-5014BV
4Remove viscous-drive fan. Right-hand thread!AR20.40-P-5660C
5Remove fan shroud On model 163 unscrew
bolts at bottom of fan
shroud.
Model 463.AR20.40-P-6800V
6Position engine at a 40°
crank angle before
ignition TDC of cylinder
1. Engine must not be
cranked back.
The notches of the
camshafts must be
pointing in the direction of
the inner V.
It must be possible to
easily insert the two
locking plates.
If this is not possible: ?
Set the basic position of
camshafts.AR05.20-P-6020AU
The copper tabs of the
timing chain must be
aligned with the markings
on the camshaft sprockets.
Because of the unevenly
long travel of the timing
chain it may be necessary
to crank the engine as
much as 14 times until the
copper tabs are aligned
with the markings on the

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 36 © 2006 Mitchell Repair Information Company, LLC.

camshaft sprockets. On
vehicles equipped with an
air pump, the combination
valve must be unbolted
before the right locking
plate is inserted.
Installation : Replace
Gasket of combination
valve.
*BA09.20-P-1001-01D
Locating plateFig. 11
Locating plateFig. 12
Timing chain drive -
general GF05.10-P-9611-01C
7Remove chain tensioner AR05.10-P-7800C
8Remove camshaft position
sensor AR15.10-P-2000A
9Crank engine in direction
of rotation until the link
for separating the timing
chain is easily accessible The separation point
for the timing chain is one
link down from the copper
tab (right). See new timing
chain.
10Remove camsha ft bearing
bridge on rightEngine 112, 113.AR05.20-P-7103AU
Engine 113.960 with Code
(479) cylinder shutoff.AR05.20-P-7103AV
11Install holding bush (3)
onto camshaft on right Insert bolts (4) only
until they make contact.
Fig. 40
12Bolt on holding devices
(1, 2) for timing chain at
right and left cylinder
heads Fig. 39
13Separate timing chain Parts which have
dropped into the timing
case recess, must be
removed. Cover over
timing case recess with a
clean cloth.AR05.10-P-7601-01AV
Connect old timing
chain to new timing chain
before pulling out.
Installing
14Draw in new timing chain Pull in the new timing
chain by turning the AR05.10-P-7601-04AV

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

crankshaft in its standard
direction of rotation.
15Remove retaining devices
(1, 2) for timing chain at
right and left cylinder
head Fig. 39
16Rivet new timing chain AR05.10-P-7601-02AV
17Crank engine in direction
of rotation
18Check timing of engine AR05.10-P-6858V
19Take off holding bush (3)
on right camshaft Fig. 40
20Install camshaft bearing
bridge on rightEngines 112, 113.AR05.20-P-7103AU
Engine 113.960 with code
(479) Cylinder shutoff.AR05.20-P-7103AV
21Install camshaft position
sensor AR15.10-P-2000A
22Installing chain tensioner AR05.10-P-7800C
23Install fan shroudModel 463.AR20.40-P-6800V
24Install viscous-drive fan Right-hand thread!AR20.40-P-5660C
25Install cylinder head
coversAir filter locat ed at vehicle
side.AR01.20-P-5014B
Air filter located on
engine side.AR01.20-P-5014BV
26Install spark plugs
Replace spark plugsModel 463.AP15.10-P-1580GA
Model 129.AP15.10-P-1580A
Models 202, 208, 210 with
engine 112.
Models 163.AP15.10-P-1580GH
27Connect ground cableModel 463 except code
(979) Special protection
versionAR54.10-P-0003G
Models 463.241 with code
(979) Special protection
version.AR54.10-P-0003PV
Model 463.248 with code
979AR54.10-P-0003PM
Models 129, 208, 210.AR54.10-P-0003A
Risk of accident caused
by vehicle starting off by
itself when engine is
running. Risk of injury
caused by contusions and Secure vehicle to prevent
it from moving by itself.
Wear closed and snug-
fitting work clothes.
Do not grasp hot or AS00.00-Z-0005-01A

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 38 © 2006 Mitchell Repair Information Company, LLC.

Intake manifold
Fig. 44: Identifying Locating Plate (112 589 00 32 00)

Fig. 45: Identifying Locating Plate (112 589 01 32 00)

Fig. 46: Identifying Retainer (112 589 04 40 00)
burns during starting
procedure or when
working near the running
enginerotating parts.
28Run engine and inspect
for leaks
NumberDesignationEngines 112,113
BA09.20-P-1001-
01DBolt, intake manifold
to cylinder headM8Nm20

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 39 © 2006 Mitchell Repair Information Company, LLC.