checking oil MERCEDES-BENZ ML320 1997 Complete Owner's Manual

16
Remove poly V-belt (8)


Installation:
Lock tensioning device with

a drift or pin (diameter 5 mm).

Model 163.154 /157 /172.

AR13.22-P-1202B

Model 163.174 /175.

AR13.22-P-1202BA

17
Detach the coolant line (16) at the cylinder

head on the left

6 mm socket hexagon

*WH58.30-Z-1001-06A

7 mm socket hexagon

*WH58.30-Z-1002-06A

18.1
Remove fender liner (9)

Only with engine 113.113.942 /965 / 981.

AR88.10-P-1300GH

19.1
Remove shield (10)

Only with engine 113.942 /965 /981.

20.1
Remove exhaust bracket (11)

Only with engine 113.942 /965 /981.

Support exhaust system.

21
Detach exhaust system at exhaust manifold


Installation:
On vehicles with engine

damage, the exhaust system must be

examined for swarfs before assembling and

any swarfs present must be removed, in order

to avoid consequential damage.


*BA14.10-P-1002-01B

22
Position crankshaft to 40° after ignition TDC

on cylinder 1


The engine must not be turned back;

otherwise the timing chain can get jammed.

AR05.10-P-6858V

Rotate engine at the crankshaft in running

direction until scribe mark 40° on pulley/

vibration damper corresponds with scribe

mark on timing case.

The grooves on the camshafts must be

pointing toward the inner V.

23
Lock camshafts with locating plates

Locating plate

*112589003200

Locating plate

*112589013200

24
Remove chain tensioner (17)
Model 163.154 /157 with engine 112.942/

970, model 163.172 with engine 113.942.
AR05.10-P-7800C

Model 163.174 /175 with engine 113.981/ 965.
AR05.10-P-7800CA

25.1
Remove oil filter housing (18) together with oil-

water heat exchanger
Engine 113.942.

AR18.20-P-3471B

Engine 112.942/970.

AR18.20-P-3471BA

26
Unscrew camshaft sprockets (19)

If camshaft sprockets are removed,

engine must no longer be cranked, otherwise

timing chain might jam.

Engine 113.942 /965 /981:
#

Tie timing chain tight on both camshaft

sprockets with tie straps.

Engine 112.942 /970:

#

Right-hand camshaft sprocket:

Tie timing chain tight on camshaft sprocket

with tie strap.

Left-hand camshaft sprocket:
Mark camshaft sprocket to timing chain and

remove camshaft sprocket.

It is not possible for the timing chain to

jump across at the crankshaft and balancing

shaft.

After installation:
#

Inspect basic position of camshafts.

AR05.10-P-6858V

If necessary after checking:
#

Set the basic position of camshafts

AR05.20-P-6020AU

Open-end wrench

*112589000100

Insertion tool

*112589010300

Torque wrench

*001589722100


*BA05.20-P-1001-01B

27
Remove camshaft bearing bridges (28)

Pay attention to slackening and tightening

pattern!

AR05.20-P-7103AU

28
Unscrew bolts, cylinder head
!
timing case

cover (20)


*BA01.40-P-1002-01C

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 4

16
Remove poly V-belt (8)


Installation:
Lock tensioning device with

a drift or pin (diameter 5 mm).

Model 163.154 /157 /172.

AR13.22-P-1202B

Model 163.174 /175.

AR13.22-P-1202BA

17
Detach the coolant line (16) at the cylinder

head on the left

6 mm socket hexagon

*WH58.30-Z-1001-06A

7 mm socket hexagon

*WH58.30-Z-1002-06A

18.1
Remove fender liner (9)

Only with engine 113.113.942 /965 / 981.

AR88.10-P-1300GH

19.1
Remove shield (10)

Only with engine 113.942 /965 /981.

20.1
Remove exhaust bracket (11)

Only with engine 113.942 /965 /981.

Support exhaust system.

21
Detach exhaust system at exhaust manifold


Installation:
On vehicles with engine

damage, the exhaust system must be

examined for swarfs before assembling and

any swarfs present must be removed, in order

to avoid consequential damage.


*BA14.10-P-1002-01B

22
Position crankshaft to 40° after ignition TDC

on cylinder 1


The engine must not be turned back;

otherwise the timing chain can get jammed.

AR05.10-P-6858V

Rotate engine at the crankshaft in running

direction until scribe mark 40° on pulley/

vibration damper corresponds with scribe

mark on timing case.

The grooves on the camshafts must be

pointing toward the inner V.

23
Lock camshafts with locating plates

Locating plate

*112589003200

Locating plate

*112589013200

24
Remove chain tensioner (17)
Model 163.154 /157 with engine 112.942/

970, model 163.172 with engine 113.942.
AR05.10-P-7800C

Model 163.174 /175 with engine 113.981/ 965.
AR05.10-P-7800CA

25.1
Remove oil filter housing (18) together with oil-

water heat exchanger
Engine 113.942.

AR18.20-P-3471B

Engine 112.942/970.

AR18.20-P-3471BA

26
Unscrew camshaft sprockets (19)

If camshaft sprockets are removed,

engine must no longer be cranked, otherwise

timing chain might jam.

Engine 113.942 /965 /981:
#

Tie timing chain tight on both camshaft

sprockets with tie straps.

Engine 112.942 /970:

#

Right-hand camshaft sprocket:

Tie timing chain tight on camshaft sprocket

with tie strap.

Left-hand camshaft sprocket:
Mark camshaft sprocket to timing chain and

remove camshaft sprocket.

It is not possible for the timing chain to

jump across at the crankshaft and balancing

shaft.

After installation:
#

Inspect basic position of camshafts.

AR05.10-P-6858V

If necessary after checking:
#

Set the basic position of camshafts

AR05.20-P-6020AU

Open-end wrench

*112589000100

Insertion tool

*112589010300

Torque wrench

*001589722100


*BA05.20-P-1001-01B

27
Remove camshaft bearing bridges (28)

Pay attention to slackening and tightening

pattern!

AR05.20-P-7103AU

28
Unscrew bolts, cylinder head
!
timing case

cover (20)


*BA01.40-P-1002-01C

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 4

NOTES ON AVOIDING DAMAGE TO IGNITION SYSTEM - AH15.10-P-0002-01D
Engine 104, 111, 112, 113, 119, 120, 156, 271
To avoid damage to control unit connect and disconnect the two connectors on control unit only when
ignition is switched off.
Terminal 1 of ignition coils must not be short-circuited to GND, e.g. as anti-theft protection.
Install only original ignition system components.
Do not operate ignition system at starting speed unless all of the ignition cables are connected.
No tests such as holding ignition cable 4 at a distance to GND, unplugging a spark plug connector or
pulling cable 4 out of the ignition coils, may be performed at starting speed or when the engine is
running.
Every high voltage circuit must be loaded with at least 2 kohms (spark plug connector).
If it is necessary to test the ignition spark when providing roadside assistance, this must only be done with
a spark plug at a cylinder ignition cable. Ensure that the spark plug has good contact to ground.
Before working at cranking speed, e.g. checking compression pressure, switch off ignition and disconnect
connector "2" from control unit.
Engine 120 has two fuel injection and ignition systems.
Use of testers
Only connect and disconnect secondary measuring sensor to corresponding ignition cables when vertical
engine and ignition are switched off.
If the shot-circuit protection is operated (cylinder comparison) and the engine stays upright, it is not
possible to conduct the test with this test instrument.
Do not connect test lamp to ignition coil terminals 1 and 15.
NOTES ON IGNITION COIL CHARACTERISTICS OF IGNITION SYSTEMS - AH15.10-P-1001-01A
Engine 104, 111, 112, 113, 119, 120

In the case of the twin-spark ignition coil with kV pickup in ignition systems ME-SFI 2.1 and HFM-SFI, no
measurement facilit
y exists at the ignition coil using the kV pickup although a kV pickup is fitted. It is only
damage to ignition system
Notes on avoiding
damage to ignition systemENGINE 104, 111, 112, 113,
119, 120, 156, 271, 112 mit
Benzin-Einspritz- und
Zundsystem MEAH15.10-P-0002-01D
Notes for ceramic glow
plugsENGINE 646.8, 642AH15.20-P-0001-01A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 2 © 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.

AF07.00-P-9000B
Engine runs rough, surges or does not turn over
29.4.02

ENGINE
611 in MODEL 203, 202, 210

ENGINE
612 in MODEL 163, 203, 210, 209

ENGINE
613 in MODEL 210, 220

ENGINE
628 in MODEL 163, 220, 211

ENGINE
646 in MODEL 203, 211

ENGINE
647 in MODEL 211

ENGINE
648 in MODEL 220, 211

ENGINE
668 in MODEL 168

ENGINE
612, 628 in MODEL 463

Modification notes

23.3.01

Supersedes STIP 07.16-014 dated 11.12.00

Damage code
Cause
Remedy

07 206 D5
High-pressure pump

To verify whether high pressure pump is

damaged.

#

High pressure pump of common rail

injection system is damaged mechanically.

1
Remove/install/replace high pressure

pump.

When the high pressure pump of the common

rail injection system is damaged metal chips

and/or damage to the pump drive (timing

drive) can occur due to contamination of the

injection system components.
2
Turn high pressure pump by hand with

driver.

If mechanical resistance can be felt,

perform the following tests. Clarify additional

work with ESKULAB by specifying repair work:

#
3
Check driver of high pressure pump or

mount in sprocket for damage (visual

check).

If high pressure pump is locked:
#
4
Check timing

5
Check timing drive for damage.

In each case:
#
6
Remove/install/replace timing chain.

If timing deviates by a crankshaft angle of

more than 20 degrees (corresponding to one

tooth skipped):

#
7
Check pressure loss.

8
Open low pressure connection on high

pressure pump return (plastic line in

area of pressure regulator valve) and

check connection point in rail for chips.

If chips are present when checking

injection system:

#
9
Thoroughly clean all fuel low pressure

lines as well as feed and return lines.

Flush and blow out with compressed air.

10
Remove fuel preheater and fuel filter

with filter housing, replace.

Fuel preheater is only installed in models

202, 203 and 163.

11
Remove/install/replace fuel cooler at

vehicle and engine end.

Not installed in model 210 up to 6/99 and

model 168.

12
Remove fuel tank, replace.

On engine 628:
#

13
Remove/install/replace electric supply

pump.

14
Remove/install/replace injectors, rail

(including pressure regulation valve and

rail pressure sensor), high pressure

lines and injector leak oil rail.*

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

Fig. 70: Identifying Heli-Coil Repair Set (102 589 00 99 00)
CHECKING CYLINDER HEAD BOLTS - AR01.30-P-5800-03B
Cylinder head/Cylinder head bolts
Cylinder head/cyl inder head bolts
1. Measure length (L) of cylinder head bolts.
If the length (L) exceeds the maximu m permissible dimension then the cyli nder head bolts must be replaced.
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/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/987/988/
990/991/992/
993/995
BE01.30-P-
1001-04BCylinder head
boltThread diameterM1111
Length (L) when
newmm141.5141.5
Length (L)mm< or = 144.5< or = 144.5
See pictureAR01.30-P-
5800-03B
AR01.30-P-
5800-03B
NumberDesignationEngine 113.989
BE01.30-P-1001-
04BCylinder head boltThread diameterM11
Length (L) when
newmm141.5
Length (L)mm< or = 144.5
See pictureAR01.30-P-5800-
03B

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 77 © 2006 Mitchell Repair Information Company, LLC.

TDC on first cylinder Rotate engine at cra nkshaft in direction of
rotation until 40° marking on belt pulley/
vibration damper is al igned with marking on
timing case cover.
The grooves on the camshafts must be pointing
toward the inner V.
23Lock camshafts with
locating plate Locating plateFig. 85
Locating plateFig. 86
24Remove chain
tensioner (17)Model 163.154 /157 with Engine 112.942 /970,
model 163.172 with Engine 113.942.AR05.10-P-
7800C
Model 163.174/175 with Engine 113.981 /965.AR05.10-P-
7800CA
25.1Remove oil filter
housing (18) with
oil/water heat
exchangerEngine 113.942.AR18.20-P-
3471B
Engines 113.965/981.AR18.20-P-
3471BA
26Remove camshaft
sprockets (19) If the camshaft sprockets are removed, the
engine must no longer be cranked otherwise the
timing chain might jam.
Engines 113.942 /965/981: ?
Tie timing chain tight on both camshaft
sprockets with cable straps.
Engine 112.942 /970: ?
Right-hand camshaft sprocket:
Tie timing chain tight on camshaft sprocket
with cable strap.
Left-hand camshaft sprocket:
Mark camshaft sprocket to timing chain and
remove camshaft sprocket.
It is not possible for the timing chain to
jump across at the crankshaft and balancing
shaft.
After installation: ?

Inspect basic positi on of camshafts.
If necessary after checking: ?AR05.10-P-
6858V
Set the basic position of camshafts.AR05.20-P-
6020AU
Open-end wrenchFig. 87
Insertion toolFig. 88
Torque wrenchFig. 92
*BA05.20-P-
1001-01B
27Remove camshaft
bearing bridges (28) Observe slackening and tightening pattern!AR05.20-P-
7103AU

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 88 © 2006 Mitchell Repair Information Company, LLC.

Engine 113 in model 129, 202, 208, 210
Engine 113 (except 113.965/981) in model 163
24.1Remove oil
reservoir on
power steering
pump (11)Model 163
Removal: Extract oil from rese rvoir. Remove circlip.
Installation: Replace sealing ring. Ch eck that circlip is
correctly seated.
Power steering -
checking and
correcting oil
level AP46.00-P-
4611BB
Hand pumpFig. 95
24.2Detach power
steering pump
(11) with oil
reservoir. Do not disconnect lines.
*BA46.30-P-
1005-01A
*BA46.30-P-
1010-01A
*BA46.30-P-
1010-01C
25.1Detach guide
pulley at timing
case coverModel 230.474
*BA13.25-P-
1008-01D
25.2Take off guide
pulley (15) at
coolant pump Except model 230.474
Take plastic cover off guide pulley.
*BA20.10-P-
1001-01C
*BA20.10-P-
1001-01M
26.1Remove
compressorEngine 112.960 in model 170.466
Engine 113.992 in model 230.474AR09.50-P-
4705SVK
27Remove air pump
(20)Engine 112 (except 112.960) in model 170
Engine 112 in 163, 202, 208, 210
Engines 113 in 163, 202, 208, 210AR14.30-P-
7251A
Engine 112.922 in model 220.063AR14.30-P-
7251AA
Engine 112.923 in model 129.059
Engine 112.943 in model 129.064
Engine 112.944 in model 220.065 /165
Engine 112.972 in model 220.067 /167
Engine 112.975 in model 220.087 /187
Engine 113.941 in models 220.070/170
Engine 113.948 in model 220.083 /183
Engine 113.960 in model 220.075/175
Engine 113.960 in model 215.375
Engine 113.961 in model 129.068
Engine 113.963 in models 230.475
Engine 113.966 in model 220.084 /184

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 103 © 2006 Mitchell Repair Information Company, LLC.

A/C housing. Disconnect control module connector. To install reverse removal procedure. Recode 5-digit radio
security code. Using HHT, check for DTC and erase, and set clock.
A/C PUSH BUTTON CONTROL PANEL
Removal & Installation
1. Obtain 5-digit radio security code from vehicle owner. Disconnect negative battery cable. Using radio
removal plates, remove radio. Disconnect electrical connectors.
2. Remove instrument panel center section. Remove 4 A/C control panel screws and remove control panel.
Release pull cables and disconnect connectors. To install, reverse removal procedure. Recode radio. See
RECODING RADIO
under PROGRAMMING.
BLOWER MOTOR
Removal & Installation
Remove passenger-side instrument panel under cover. Remove blower motor mounting screws from A/C
housing unit. Disconnect blower motor connector and remove blower motor. To install, reverse removal
procedure.
COMPRESSOR
Removal & Installation
1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove accessory
drive belt. Disconnect low pressure refrigerant line from compressor. Discard "O" rings. Plug exposed
openings to protect A/C system from debris and moisture.
2. Disconnect high pressure refrigerant line from compressor. Discard "O" rings. Plug exposed openings to
protect A/C system from debris and moisture. Disconnect electrical connector. Remove compressor
mounting bolts.
3. Raise and support vehicle. Remove compressor from under vehicle without spilling refrigerant oil. To
install, reverse removal procedure. Ensure refrigerant oil quantity in compressor is correct. See
COMPRESSOR REFRIGERANT OIL CHECKING under GENERAL SERVICING. Tighten bolts to
specification. See TORQUE SPECIFICATIONS
.
CONDENSER
Removal & Installation
1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove cooling fans.
See COOLING FANS
. Disconnect refrigerant line from receiver-drier. See Fig. 5 . Discard "O" rings.
2. Plug exposed openings to protect A/C system from debris and moisture. Remove refrigerant line from
condenser. Remove radiator upper rubber seal. See Fig. 6
. Remove condenser upper mounting screws.
Lift condenser upward and remove. NOTE: Each time A/C compressor is removed and installed, receiver-drier must be
replaced.

2001 Mercedes-Benz ML320
2000-01 MANUAL A/C-HEATER SYSTEMS ML 320, ML 430 & ML 55
me
Saturday, October 02, 2010 3:25:10 PMPage 17 © 2006 Mitchell Repair Information Company, LLC.

Fig. 157: Checking Draining, Evacuating And Refilling Air Conditioning Function
Draining

Risk of explosion from welding or
soldering work on closed air conditioning
system. Risk of poisoning . Inhaling
overheated refrigerant vapors may be
toxic. Risk of injury from skin and eye
contact with liquid refrigerant.
Do not carry out any welding work on the
closed air conditioning system or in the
surrounding area. No smoking or open flames.
Wear eye protection and protective gloves.
Work only in well ventilated areas. Carry out
repair work on the air conditioning system
circuit only after the system has been
discharged.
AS83.00-Z-
0001-01A
1
Connect the connector (blue) (3) of the
filling unit (1) to the Schrader valve of
the high-pressure line and the connector
(red) (2) to the Schrader valve of the
suction line.
During all steps, the operating instructions
for the particular filling unit must be
followed.

*WE58.40-
Z-1002-22A
2Discharge air conditioning system
3
Drain separated oil for refrigerant
compressor out of the inspection glass for
the filling unit and determine the quantity
exactly
Drained quantity must be replaced by fresh
oil for refrigerant compressor.
Evacuate
Clean air conditioning system and

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 188 © 2006 Mitchell Repair Information Company, LLC.