engine MERCEDES-BENZ ML320 1997 Complete Repair Manual

340 IndexUseful features 164
Ashtrays and cigarette lighter 168
Cup holder 166
Electrical outlet 170
Garage door opener 180
Interior storage spaces 164
Programming or reprogramming the in-
tegrated remote control 182
Tele Aid* 171
Telephone* 170
Trip computer* 186
V
Vehicle
Locking 28
Locking in an emergency 262
Lowering 276
Proper use of 17
Service battery 278
Towing 283
Unlocking 28
Unlocking in an emergency 261
Vehicle and trailer weights and
ratings 207
Vehicle battery 278Vehicle care
Cup holder 238
Engine cleaning 236
Gear selector lever 238
Hard plastic trim items 238
Headlamps 236
Instrument cluster 238
Leather upholstery 239
Light alloy wheels 238
MB Tex upholstery 239
Ornamental moldings 236
Paintwork 235
Parktronic* system sensor 237
Plastic and rubber parts 239
Power washer 235
Seat belts 238
Steering wheel 238
Tail lamps 236
Tar stains 235
Turn signals 236
Upholstery 239
Vehicle washing 236
Window cleaning 237
Wiper blades 237Vehicle identification number (VIN) 292
Vehicle jack 258
Vehicle lighting
Checking 216
Vehicle tool kit 257
Vehicle with CD-changer* 258
Vehicle washing 236
VIN (Vehicle Identification Number) 292,
315
Voice control system* 315
W
Warning indicators
Parktronic* 155
Warning sounds
Drivers seat belts 64
Parking brake 48
Warranty coverage 291
Washer fluid see Windshield washer fluid
Washing the vehicle 234

1998-2005 ENGINE
Air Intake, Turbo Charging - 163 Chassis
BASIC KNOWLEDGE
AIR INTAKE, FUNCTION - GF09.00-P-3000A
ENGINE 112 (except 112.960 /961) without supercharger
Fig. 1: Identifying Air Intake Components
- Without Supercharger
INTAKE MANIFOLD, LOCATION - GF09.20-P-3102-01A
Shown on ENGINE 113
PurposeReducing intake noises
Design/function
A Helmholtz resonator (branching filter) with a volume of about 0.6 liters, is installed
to reduce the intake noises. This is active in the engine speed range from approx. 3500
- 4500 rpm. As a side effect the air flow in this engine speed range is improved at the
hot film mass air flow sensor and the measurement of the air mass is thus more
accurate.


2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:57 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.
me
Saturday, October 02, 2010 3:17:00 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.

Fig. 2: Identifying Variable Intake Manifold - Shown On Engine 113
INTAKE MANIFOLD, FUNC TION - GF09.20-P-3102-02A
Engine 112, 113
Section through variable intake manifold in cylinder plane
Fig. 3: Identifying Intake Manifold Function
- Section Through Variable Intake Manifold In Cylinder
Plane
When the engine is started and at low engine speeds the variable flaps are open. The intake air flows along the
shortest path and thus reaches the cylinder with low friction losses from the distributor volume.
At an en
gine load of more than 50% from approx. 1750 rp m up to approx. 3900 rpm the variable flaps are

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:57 PMPage 2 © 2006 Mitchell Repair Information Company, LLC.

closed. The intake air must flow through the whole intake pipe. Its length is selected in such a way that the
pressure waves, produced by the inducting pistons, arrive at the right moment at the open intake valves for the
next induction stroke. The result is improved cylinder charge and thus an increase in torque.
At higher engine speeds (e.g. from 3900 rpm) the actuation to the variable intake manifold switchover valve is
interrupted - the variable flaps open as a result of the spring force. Through the shortened route the pressure
waves arrive in time even at higher rotational speeds before the closing of the intake valves to the combustion
chamber.
INTAKE MANIFOLD, DESIGN - GF09.20-P-3102-03A
Shown on ENGINE 112
Fig. 4: Identifying Intake Manifold Components
- Shown On Engine 112
The intake manifold is assembled out of several magnesium pressure castings. When fitted together, they
produce the individual intake manifolds and the air collecting volume. The parts are sealed off to each other by
plastic. The intake manifold cannot be disassembled.
The individual intake manifolds each approx. 800 mm long, are arranged in a spiral shape around the air
collecting volume. A single intake manifold is assigned to each cylinder.
Each single intake manifold has a further opening to the air collecting volume in the middle. These can be
opened or closed by means of variable flaps which pivot through approx. 60°.
The variable flaps are attached to steel shafts. One shaft is installed for each bank of c
ylinders. The

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:57 PMPage 3 © 2006 Mitchell Repair Information Company, LLC.

interconnected flap shafts are closed by means of vacuum by the intake manifold switchover diaphragm unit.
When the variable intake manifold switchover valve is open, the vacuum is supplied from a vacuum reservoir
with check valve in the intake manifold. The reservoir volume is designed for about 5 operations without
renewed evacuation.
The variable flaps open by means of spring force.
INTAKE MANIFOLD, LOCATION/TASK/DESIGN/FUNCTION - GF09.20-P-3102A
ENGINE
112.910 /911 /912 /913 /914 /916 /917 /920 /921 /922 /923 /940 /941 /942 /943 /944 /946 /947 /949 /953 /954 /9
5
ENGINE 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /967 /966 /968 /969
Fig. 5: Identifying Intake Manifold Design/Function

Intake manifold,
location GF09.20-P-3102-
01A
Intake manifold, taskOptimizing engine torque curve by means of two different
intake manifold lengths
Intake manifold,
design GF09.20-P-3102-
03A
Intake manifold,
function GF09.20-P-3102-
02A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:57 PMPage 4 © 2006 Mitchell Repair Information Company, LLC.

TESTING & REPAIR
INTAKE MANIFOLD CONNECTION DIAGRAM - AR09.20-P-1310-01A
Connection schema intake manifold Engine 112
Fig. 6: Intake Manifold Connection Diagram
- Connection Schema Intake Manifold - Engine 112
INTAKE MANIFOLD CONNECTION DIAGRAM - AR09.20-P-1310-01AA
Connection diagram of intake manifold engine 112 with USA version code 494a

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:57 PMPage 5 © 2006 Mitchell Repair Information Company, LLC.

Fig. 7: Intake Manifold Connection Diagram - Connection Diagram Of Intake Manifold - Engine 112
With USA Version Code 494a
INTAKE MANIFOLD CONNECTION DIAGRA M - AR09.20-P-1310-01AC
Shown on engine 113 with USA version code 494a

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:57 PMPage 6 © 2006 Mitchell Repair Information Company, LLC.

Fig. 8: Intake Manifold Connection Diagram -Shown On Engine 113 With USA Version Code 494a
INTAKE MANIFOLD CONNECTION DIAGRAM - AR09.20-P-1310-01AU
Shown on engine 113
Fig. 9: Intake Manifold Connection Diagram
- Shown On Engine 113
REMOVE/INSTALL INTAKE MANIFOLD - AR09.20-P-1310A
ENGINE 112.910 in MODEL 202.026/086
ENGINE 112.920 in MODEL 202.029/089
ENGINE 112.921 in MODEL 210.063/081 /263 /281
ENGINE 112.922 in MODEL 220.063/163
ENGINE 112.923 in MODEL 129.059
ENGINE 112.940 in MODEL 208.365/465
ENGINE 112.941 in MODEL 210.065/082/265/282
ENGINE 112.942 in MODEL 163.154

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:57 PMPage 7 © 2006 Mitchell Repair Information Company, LLC.

ENGINE 112.943 in MODEL 129.064
ENGINE 112.944 in MODEL 220.065/165
ENGINE 113.940 in MODEL 210.070/270
ENGINE 113.941 in MODEL 220.070/170
ENGINE 113.960 in MODEL 215.375, 220.075/175
ENGINE 113.961 in MODEL 129.068
ENGINE 113.944 in MODEL 202.033/093
ENGINE 113.942 in MODEL 163.172
ENGINE 113.980 in MODEL 210.074/274
ENGINE 113.943 in MODEL 208.370/470
ENGINE 113.984 in MODEL 208.374
ENGINE 113.981 in MODEL 163.174
ENGINE 112.912 in MODEL 203.061/261, 209.361 /461
ENGINE 112.946 in MODEL 203.064/264
ENGINE 112.947 in MODEL 170.465
ENGINE 113.963 in MODEL 230.475
ENGINE 113.968 in MODEL 209.375/475
ENGINE 112.913 in MODEL 211.061/261
ENGINE 112.949 in MODEL 211.065/265
ENGINE 113.967 in MODEL 211.070/270
ENGINE 113.987 in MODEL 209.376/476
ENGINE 112.955 in MODEL 209.365/465
ENGINE 112.916 in MODEL 203.081/281

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:57 PMPage 8 © 2006 Mitchell Repair Information Company, LLC.

ENGINE 112.953 in MODEL 203.084/284
ENGINE 112.970 in MODEL 163.157
ENGINE 112.972 in MODEL 220.067/167
ENGINE 112.973 in MODEL 230.467
ENGINE 113.965 in MODEL 163.175
ENGINE 112.975 in MODEL 220.087/187
ENGINE 113.948 in MODEL 220.083/183
ENGINE 113.966 in MODEL 220.084/184
ENGINE 112.917 in MODEL 211.080/280
ENGINE 112.954 in MODEL 211.082/282
ENGINE 113.969 in MODEL 211.083/283
ENGINE 113.988 in MODEL 203.076/276
ENGINE 113.989 in MODEL 171.473
Shown on engine 112

2001 Mercedes-Benz ML320
1998-2005 ENGINE Air Intake, Turbo Charging - 163 Chassis
me
Saturday, October 02, 2010 3:16:57 PMPage 9 © 2006 Mitchell Repair Information Company, LLC.