MERCEDES-BENZ ML350 1997 Complete Repair Manual

CONNECT COMPRESSION TESTER INFORMATION ON PR EVENTING DAMAGE TO ELECTRONIC COMPONENTS
DUE TO ELECTROSTATIC DI SCHARGE - AR01.10-P-0010-01V
Fig. 36: Identifying Compression Recorder (001 589 76 21 00)
4
right major assemblies
compartment (W16/6) of
engine wiring harness

5Remove electrical line (5) at
positive lead (4)
6Disconnect positive cable (4) at
battery
7Take off bracket (3) of positive
cable (4) Bracket next to coolant circulation pump.
8
Separate connector of engine
compartment and engine (X22)
in fuse and relay module

9
Separate connectors of motor
electronics control module
(n3/10)
Release locking arm, separate plug connection
10
Unscrew ground strap of
engine/body (W11/5) to
vehicle frame

11Install in the reverse order
12
Read out and erase diagnostic
trouble code memory with
HHT or STAR DIAGNOSIS
After completion of the work, it is necessary to
process and erase the DTCs stored in the DTC memory
during assembly and testing work due to disconnected
lines and simulation. Diagnosis Manual Volume 2 Index
0: Connecting and using test equipment


2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 45 © 2006 Mitchell Repair Information Company, LLC.

Fig. 37: Identifying Electrical Connection Set (201 589 00 99 00)
1. Remove cover on fuse and relay module.
2. Clip connection terminal (A) of compression tester onto circuit 30, 15, 61 terminal block (3-pin)
(X12/3).
3. Pull starter relay (2) out of the fuse module (relay place 8).
4. Connect adapter line (1)w ith terminal 87 in relay place 8 of the fuse module.
5. Connect adapter line (1) to the cable of the compression tester.
Fig. 38: Identifying Star ter Relay & Fuse Module

CRANKING ENGINE WITH STARTER. - AR01.10-P-0110V
ENGINE 112 in MODELS 129, 163, 170, 202, 208, 210, 211, 220, 230
ENGINE 113 in MODELS 129, 163, 202, 208, 210, 211, 215, 220, 230
ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250
ENGINE 137 in MODELS 215, 220
ENGINE 285 in MODEL 240
ENGINE 113.962 in MODELS 463.206 / 240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODELS 463.243 /246

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 46 © 2006 Mitchell Repair Information Company, LLC.

ENGINE 275 in MODELS 215, 220, 230
Shows model 202
Fig. 39: Identifying Cranking Engine With Starter
- Shows Model 202
Remove/install

Danger!
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
1Switch off ignition
Vehicles with Keyless-Go Code
889: press Start/Stop button
repeatedly until ignition is switched
off.

Model 129AR01.10-P-
0010-01AV
Model 163.1AR01.10-P-
0010-01V
Model 170AR01.10-P-
0010-01CA
Model 210 with engine 112 up to
production date 1.3.1997AR01.10-P-
0010-01B
Model 210 with engine 112 from
production date 2.3.1997,AR01.10-P-
0010-01E
Models 202, 208 with engine 112,
Models 210, 202, 208 with engine

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 47 © 2006 Mitchell Repair Information Company, LLC.

Fig. 40: Identifying Electrical Connection Kit (220 589 00 99 00)
2Connect compression recorder (01)
113
Model 211AR01.10-P-
0010-01T
Model 215, model 220AR01.10-P-
0010-01L
Model 230AR01.10-P-
0010-01R
Model 240AR01.10-P-
0010-01H
Model 463.2AR01.10-P-
0010-01GV
Compression recorderFig. 21
Electrical connection setFig. 40
Adapter cableFig. 42
3Crank engine
Press contact switch (02) on
compression recorder (01) for this
step.
Do not crank engine via
ignition/starter switch (8), EIS [EZS]
control unit or Start-Stop button.

4Install in the reverse order
5Read out fault memory and erase if
necessary
If the ignition was switched on
during the process: ?
Stored faults which may be caused
by removal and installation or test
operations, must be erased from the
diagnostic trouble code memories
after completing the work.
STAR DIAGNOSIS di agnosis system
Handheld tester (HHT)
*WH58.30-
Z-1048-13A
*WH58.30-
Z-1036-13A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 48 © 2006 Mitchell Repair Information Company, LLC.

Fig. 41: Identifying Compression Recorder (001 589 76 21 00)
Fig. 42: Identifying Adapter Cable (124 589 36 63 00)

Commercially available tools
REMOVE/INSTALL ENGINE - AR01.10-P-2400CA
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
Illustrated on model 112.942
NumberDesignation
WH58.30-Z-1036-13AHandheld tester (HHT)651 100 01 99
WH58.30-Z-1048-13ASTAR DIAGNOSIS diagnosis
system, Compact Passenger Car6511 1801 00

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 49 © 2006 Mitchell Repair Information Company, LLC.

Fig. 43: Identifying Engine Remove/Install Components - Illustrated On Model 112.942
Shown on engine 112.942
Fig. 44: Identifying Engine Remove/Install Component
- Shown On Engine 112.942

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 50 © 2006 Mitchell Repair Information Company, LLC.

Shown on engine 112.942
Fig. 45: Identifying Torque Converter
- Shown On Engine 112.942
Shown on engine 112.942
Fig. 46: Identifying Starter Ring Gear
- Shown On Engine 112.942
Shown on engine 112.942

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 51 © 2006 Mitchell Repair Information Company, LLC.

Fig. 47: Identifying Transmission Support - Shown On Engine 112.942
Modification notes
13.1.06Bolt, torque converter to drive plateTransmission 722.6*BA27.20-P-1002-01C
Remove/install
Risk of death caused
by vehicle slipping
or toppling off the
lifting platform.Align vehicle between columns of lifting
platform and position f our support plates at
lifting platform suppor t points specified by
vehicle manufacturer.AS00.00-Z-0010-
01A
Notes on self-locking
nuts and boltsAll modelsAH00.00-N-0001-
01A
External Torx setFig. 49
Torx bit setFig. 48
6 mm socket hexagon*WH58.30-Z-
1001-06A
7 mm socket hexagon*WH58.30-Z-
1002-06A
1Remove engine trim
panel
2
Inspect both rear
engine lifting eyes
for marking
Engine suspensi on lugs without
identification must be replaced.


Rear lifting eyes of
engine reinforced
BT01.00-P-0001-01A
Risk of explosion
caused by
oxyhydrogen gas.
Risk of poisoning
and caustic burns
caused by No fire, sparks, open fl ames or smoking. Wear
acid-resistant gloves, clothing and glasses.
Only pour battery acid into suitable and
appropriately marked containers.AS54.10-Z-0001-
01A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 52 © 2006 Mitchell Repair Information Company, LLC.

swallowing battery
acid. Risk of injury
caused by burns to
skin and eyes from
battery acid or when
handling damaged
lead-acid batteries
3Disconnect battery
ground cable The battery is located in the right of the
engine compartment.AR54.10-P-
0003A
Notes on batteryAll modelsAH54.10-P-0001-
01A
Installation: After connecting, read out
fault memory, encode radio and normalize
power windows.Vehicles with
stationary heater:
adjust time
display on
stationary heater.
4.1Remove air guide
(23) Engine 113.942 only.
Risk of injury to
skin and eyes caused
by scalding from
contact with hot
coolant spray. Risk
of poisoning caused
by 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 containers.
Wear protective gloves, pr otective clothing and
safety glasses.AS20.00-Z-0001-
01A
5Drain coolant from
radiator Remove coolant pump line --> (16) from
coolant pump.AR20.00-P-
1142HA
6Drain and collect
engine oil *BA01.45-P-
1003-01B
*BF18.00-P-
1001-01H
7.1Remove viscous fan
(1)All except model 163.174 with engine 113.981
and 163.175 with engine 113.965.
Right-hand thread!AR20.40-P-
5660C
8.1Remove fan shroud
(2). Unscrew bolts at bottom of fan shroud
8.2Remove electric fan Only model 163.174 with engine 113.981
and 163.175 with engine 113.965.AR20.40-P-
5000GH
9Attach guard plate
for radiator /
condenser
Guard plate for
radiator / condenserEngine 606 in MODEL 124,
Engine 606.961 in MODEL 140,
Engine 112, 113, 604, 605, 611.960 in MODEL WF58.50-P-0110-
01A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 53 © 2006 Mitchell Repair Information Company, LLC.

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. /605 /701 /703/705/801 /803/805
Engine 646.982 in model
639.601 /603 /605 /701 /703 /705
10Remove expansion
reservoir (13)
11Remove air filter
housing (7).
12Remove resonance
tube (8) and
resonance unit (9) Separate plug connection of hot film mass
air flow sensor (HFM) for this step and unbolt
resonance pipe at cy linder head cover.
The resonance pipe is attached at rear at
intake manifold with a plastic plate.
Do not damage plastic strap.
Engine 112.942/970.AR07.07-P-
1454A
Engine 113.942/965/981.AR07.07-P-
1454MV
13Remove coolant
pump line(15)from
coolant pump.
14Remove thermostat

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 54 © 2006 Mitchell Repair Information Company, LLC.