MERCEDES-BENZ ML350 1997 Complete Repair Manual

Fuel rail
Fig. 55: Identifying External Torx Set (001 589 76 09 00)

Fig. 56: Identifying Torx Bit Set (000 589 01 10 00)

Fig. 57: Identifying Double Open
-End Wrench (110 589 01 01 00)
BA07.52-P-
1001-01ADisconnect fuel
feed line at fuel railNm38382435
NumberDesignationEngine
113.987Engines
113.990/
991Engine
113.990/
993/995Engines 113.990/ 942/943/944/
945/946/948/ 960/961/962/
963/964/965/ 966/967/968/
969/971/980/ 981/982/984/ 986/988
BA07.52-P-
1001-01ADisconnect fuel
feed line at fuel
rail
Nm38383838

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 65 © 2006 Mitchell Repair Information Company, LLC.

Fig. 58: Identifying Pressure Hose (119 589 04 63 00)
REMOVE/INSTALL CY LINDER HEAD COVER - AR01.20-P-5014BV
ENGINE 112
Air filter motor page arranged
ENGINE 113 (except 113.995) in MODEL 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230
Air filter motor page arranged
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
Shown on engine 112.945

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 66 © 2006 Mitchell Repair Information Company, LLC.

Fig. 59: Identifying Cylinder Head Cover Remove/Install Component - Shown On Engine 112.945
Remove/install
1.1Remove engine trim panel
with integrated air filter
(1) Unclip covering on front side
of engine. Remove air filter by
pulling vertically up and off the
cylinder head covers.
1.2Remove air filterModel 170.466
Model 203.065/265,
Model 211.076/276,
Models 215.374, 220.074/174,
Model 230.474AR09.10-P-1150SVK
2.1Unscrew the guide tube of
the automatic
transmission oil dipstickexcept models 170
Models 203, 209.375,
Model 208
Models 211.061/065/070,
Model 230.475
3Detach right ignition coils
(4), left ignition coils (5)
on right cylinder head
cover (2) and left cylinder
head cover (3)Except engines
112.911/914/915/917/954,
Engine 113.969AR15.12-P-2003A
*BA01.20-P-1002-01E
4Disconnect spark plug
connectors Installation: Observe
marking for spark plug
connectors on the cylinder head
covers and ignition coils.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 67 © 2006 Mitchell Repair Information Company, LLC.

Double open-ended wrenchFig. 57
5Pull off vent hoses on
right connector (6) and on
left connector (7) of the
right cylinder head cover
(2) and left cylinder head
cover (3)
6Pull off engine vent hose
on left connector (8) of
left cylinder head cover
(3)
Risk of explosion caused
by fuel igniting, risk of
poisoning caused by
inhaling and swallowing
fuel as well as risk of
injury to eyes and skin
caused by contact with
fuel.No fire, sparks, open flames or
smoking.
Pour fuels only into suitable and
appropriately marked containers.
Wear protective clothing when
handling fuel, date service.AS47.00-Z-0001-01A
7.1Disconnect fuel line at
fuel rail Only in case of vehicles with
a non-flexible fuel line and.
Models 211.061/065/
070/076/276,
Model 215.374
Model 220.074
Model 230.474/475
Release fuel pr essure through
service valve!
Engine 112*BA07.52-P-1001-01A
Engine 113*BA07.52-P-1001-01A
Pressure hoseFig. 52
8Remove right cylinder
head cover (2) and left
cylinder head cover (3) Installation: Check cylinder
head covers for leaks, see: ?
Ensure cylinder head cover
gasket is correctly installed.AR01.20-P-5014-01B
*BA01.20-P-1001-01E
9Install in the reverse order

10Risk 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 Secure 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

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 68 © 2006 Mitchell Repair Information Company, LLC.

Crankcase ventilation, cylinder head cover
Fuel rail
Fuel rail
Fig. 60: Identifying Double Open
-End Wrench (110 589 01 01 00)
engine
Run engine and inspect
for leaks
NumberDesignation
Engines 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/ 992/995
Engines
113.987/988/
990/991/993
BA01.20-
P-1001-
01EScrew of
cylinder
head cover
Nm8108
BA01.20-
P-1002-
01E
Bolt of
ignition
coils to
cylinder
head cover
Nm888
NumberDesignationEngine 112 except
112.945/951/ 960/961Engine
112.945Engines 112.960/
961 AMG
BA07.52-P-
1001-01ADisconnect fuel feed
line at fuel railNm383835
NumberDesignationEngine
113.987Engines
113.990/
991Engine
113.992/
993/995Engines 113.940/941/ 942/943/944/
945/946/948/ 960/961/962/
963/964/965/ 966/967/968/
969/971/980/ 981/982/984/ 986/988
BA07.52-P-
1001-01ADisconnect fuel
feed line at fuel
rail
Nm38383838

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 69 © 2006 Mitchell Repair Information Company, LLC.

Fig. 61: Identifying Pressure Hose (119 589 04 63 00)
TAP THREAD IN SPARK PLUG HOLE AND SCRE W IN THREADED INSERT - AR01.30-P-5440-01B
Fig. 62: Identifying Heli-Coil Repair Set (102 589 00 99 00)
1. Remove pilot bushing (1) of tapped hole device .
2. Fill the swarf grooves of the combination tap (4) with grease for bonding the swarfs.
3. Cut combination tap (4) into corresponding spark pl ug thread. Screw in combination tap (4) until the
guide tube (3) is seated and forms a fully compress with the stop ring (2).
Screw out after 5 revolutions on removed cylinder head combination tap (4), clean the swarf grooves
from swarfs and grease, refi ll with grease and finish cutting thread. After cutting.
Blow out spark plu
g thread and cylinder with compressed air.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 70 © 2006 Mitchell Repair Information Company, LLC.

Fig. 63: Identifying Pilot Bushing, Stop Ring, Guide Tube And Combination Tap
4. Select heli-coil threaded inse rt (8) with block length 10.2 mm.
5. Insert threaded insert (8) with primary pump drive pointing in direction of prestessing cartridge (16) in
the installation tool (13) (arrow).
6. Screw in threaded insert (8) flush to prestessing cartridge (16) (arrow).
Fig. 64: Identifying Installation T ool, Threaded Insert And Cartridge

7. Position HC-installat ion tool on tapped hole

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 71 © 2006 Mitchell Repair Information Company, LLC.

8. Hold jacket sleeve (5)
9. Rotate screw-in spindle (6) until the stop ring (7) is pos itioned on the jacket sleeve (5). Slightly turn back
a clamping jacket sleeve when screwing-in.
Fig. 65: Identifying Jacket Sleeve, Spindle And Stop Ring

10. Insert sleeve (9) via primary pum p drive of HELI-COIL insert
11. Guide open pliers to the marking in the sleeve (9) and fix with primary pump drive
12. Close pliers , the serrated lock of pliers must latch.
13. Rotate sleeve (9) toward left as far as the stop and hold
14. Dismount primary pump drive, to do so move pliers slightly up and down.
Remove with a ma
gnet the primary pump drive which had fallen onto the piston crown!

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 72 © 2006 Mitchell Repair Information Company, LLC.

Fig. 66: Identifying Sleeve & Pliers
CAULK THREADED INSE RT - AR01.30-P-5440-02B
Fig. 67: Identifying Heli-Coil Repair Set (102 589 00 99 00)
1. Grease caulk drift, screw into installed HELI-COI L insert and tighten with a torque of approx. 25-30
Nm.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 73 © 2006 Mitchell Repair Information Company, LLC.

Fig. 68: Identifying Caulk Drift
REPAIRING SPARK PLUG THREAD - AR01.30-P-5440BV
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

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 74 © 2006 Mitchell Repair Information Company, LLC.