spark plugs MERCEDES-BENZ ML320 1997 Complete User Guide

Fig. 45: Identifying Harmonics - Positive Diode Defective
Fig. 46: Identifying Diode Harmonics OK

REPLACE SPARK PLUGS - AP15.10-P-1580GH
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

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 71 © 2006 Mitchell Repair Information Company, LLC.

Fig. 47: Identifying Spark Plugs And Cylinder 4 Ignition Coil

Remove/install and
replacing

Risk of death due to
contact with high-voltage
conductive partsDo not touch parts which
conduct high voltages.
Persons who are carriers
of electronic implants
(e.g. cardiac pacemaker)
may not carry out any
work on the ignition
systemAS15.10-Z-0001-01A
Notes on avoiding damage
to ignition systemEngine 104, 111, 112,
113, 119, 120,271AH15.10-P-0002-01D
1Remove/install air filter
upper section
2
Remove ignition coils
Remove/install ignition
coils
AR15.12-P-2003A
3Disconnect spark plug
connectors Prise over cylinder
head cover.
Double open-ended
wrenchFig. 24
Checking
4Check spark plug Replace, if necessary.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 72 © 2006 Mitchell Repair Information Company, LLC.

Spark plugs
Fig. 48: Identifying Spark Plug Wrench (112 589 01 09 00)

Fig. 49: Identifying Open
-End Wrench, Double (110 589 01 01 00)
connectors, ignition coil
connectors and ignition
lines for damage,
deformation and crack
formation
5Remove/install spark plugs
(R4) *BA15.10-P-1001-01A
Spark plug wrenchFig. 48
NumberDesignationEngine
104,110,111,
113.940/941/942/943/
944/948/960/961/962/
963/964/965/966/967/
968/969/971/980/981/
982/984/986/992/993/
995,115,117,119,
120Engines
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/
973/975/976
BA15.10-P-1001-
01ASpark plugsNm2828

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 73 © 2006 Mitchell Repair Information Company, LLC.

Models 211.061/065/070AR54.10-P-0003T
Model 215, 220AR54.10-P-0003I
Model 230.474 /475AR54.10-P-0003R
All models 463 except
463.241/248 with code 979.AR54.10-P-0003G
Model 463.241 with code
979AR54.10-P-0003PV
Model 463.248 with code
979AR54.10-P-0003PM
Notes on batteryAll modelsAH54.10-P-0001-01A
2Remove spark plugsTo ensure that the engine
can be easily cranked when
drawing in the timing chain,
and to avoid the timing
chain jumping across.
Remove only once spark
plug of each cylinder.
Replace spark plugsModel 163AP15.10-P-1580GH
Models 220, 230.474/475AP15.10-P-1580AB
Models 210, 208, 202AP15.10-P-1580A
Models 203, 170, 209, 211
with engine 112
Models 209, 211 with
engine 113
3Remove cylinder head
coversAir filter mounted on
vehicleAR01.20-P-5014B
Air filter mounted on
engineAR01.20-P-5014BV
4.1Remove fan shroud Not models
211.061/065/070, 230.475
Models 220, 230.474
AR20.40-P-6800AB
4.2Remove electric fanModel 170AR20.40-P-5000SV
Models 203, 209AR20.40-P-5000PV
Model 163.174AR20.40-P-5000GH
5Position engine to 40°
after TDC of first
cylinder. Engine must not be
cranked backwards. 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 AR05.20-P-6020AU

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 29 © 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
me
Saturday, October 02, 2010 3:39:37 PMPage 32 © 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.

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.

Fig. 83: Identifying Valve Springs And / Or Valve Stem Seal Components -Shown On Engine 112 (2 Of
2)
Remove/install
1Remove engine cover or
air filterRemove engine trim
panel or air filter by
pulling it vertically up
and off the cylinder head
covers.
2Remove viscous fan (1) Right-hand thread!AR20.40-P-5660C
3Fan shroud (2) On model 163
unscrew bolts at bottom
of fan shroud.
Models 163.AR20.40-P-5000GH
Model 463.AR20.40-P-6800V
4Remove poly-V-belt (3) Installation: Lock
tensioning device with a
drift or pin (diameter 5
mm).AR13.22-P-1202B
5Remove cylinder head
covers (6)Air filter located at
vehicle side.AR01.20-P-5014B
Air filter located on
engine side.AR01.20-P-5014BV
6
Remove spark plugs (8)Only one spark plug at
each cylinder.
Models 163.AP15.10-P-1580GH
Models 129, 202, 208,
210.AP15.10-P-1580A
Model 463.AP15.10-P-1580GA
7Remove intake manifold
(7) The intake manifold
system must not be
disassembled.
Remove intake
manifold together with
fuel rail.
Models 129, 163, 202,
208, 210.AR09.20-P-1310A
Model 463.AR09.20-P-1310AG
8Position crankshaft to 40°
after ignition TDC of
cylinder 1 Engine must not be
cranked back!AR05.10-P-6858V
9Remove chain tensioner
(5) AR05.10-P-7800C
10Remove camshaft AR15.10-P-2000A

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 79 © 2006 Mitchell Repair Information Company, LLC.

Fig. 17: Inspecting Cylinders With Light Probe
Shown on engine 112
Remove/install
Risk of death caused by
contact with parts
conducting high voltages.Do not touch parts which
conduct high voltages.
Persons who have
electronic implants (e.g.
pacemakers) must not
perform any work on the
ignition system.AS15.10-Z-0001-01A
Risk of injury to skin and
eyes caused by handling
hot or glowing objects.Wear safety gloves,
protective clothing and
safety glasses, if necessary.AS00.00-Z-0002-01A
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
1Remove a spark plug from
each cylinderType 208.474
Type 202.088
Model 210.062/262
Replace spark plugsModel 129 with engine
112.923/943, 113.961AP15.10-P-1580AC
Model 163 with engine
112, 113AP15.10-P-1580GH
Model 209, 210 except
210.062 /262, 208 except
208.474, 202 except
202.088 with engine 112,
113
Model 203, 170 with
engine 112AP15.10-P-1580A
Model 215, 220 with
engine 137
Model 215, 220, 230 with
engine 275
Model 215, 220 with
engine 285AP15.10-P-1580L
Model 211 with engine
112, 113
Model 215 with Engine
113 AP15.10-P-1580AB

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 26 © 2006 Mitchell Repair Information Company, LLC.

connection for hot
film mass air flow
sensor (HFM-SFI)
for this step and
unbolt resonance
pipe at cylinder
head cover.

The resonance pipe is
attached to the rear of the
intake manifold with a
plastic bracket.

Do not damage plastic
plate.
5Remove spark plugsRemove only one spark
plug at each cylinder: ?
Models 210, 208, 202
with engine 112
Model 210 with engine
113AP15.10-P-1580A
Model 163 with engines
112, 113AP15.10-P-1580GH
6Crank engine with starter.Do not crank engine at
steering lock but use
contact switch of the
compression recorder.
Crank engine several
times with the starter in
order to eliminate
combustion residues in
the cylinder.AR01.10-P-0110V
Checking
7Insert compression tester
into spark plug bore Fig. 21
8Open throttle valve
9Crank engine with starterDo not crank engine at
steering lock but use
contact switch of the
compression recorder.
To check the
compression pressure,
crank the engine by at AR01.10-P-0110V

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 30 © 2006 Mitchell Repair Information Company, LLC.