cooling MERCEDES-BENZ ML320 1997 Complete Service Manual

P01.30-0299-06

20
Bolts cylinder head
!
timing case cover

21
Cylinder head bolts

22
Cylinder head left

23
Cylinder head right

24
Left cylinder head gasket

25
Right cylinder head gasket

26
Dowel sleeves


Remove/Install

Notes on self-locking nuts and bolts
All models

AH00.00-N-0001-01A


External torx set

*001589760900

Torx bit set

*000589011000


Danger!

Risk of explosion
caused by oxyhydrogen

gas.
Risk of poisoning and caustic burns


caused by swallowing battery acid.
Risk of

injury caused by burns to skin and eyes from

battery acid or when handling damaged lead-

acid batteries
No fire, sparks, open flames or smoking.

Wear acid-resistant gloves, clothing and

safety glasses. Pour battery acid only into

suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1
Disconnect battery ground cable


Installation:
After connecting, read out

fault memory, encode radio and normalize

power windows.

Vehicles with stationary heater: Set time on

timer for stationary heater
AR54.10-P-0003A

Notes on battery
All models

AH54.10-P-0001-01A

Danger!

Risk of death

caused 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

2
Place the vehicle on lifting platform

AR00.60-P-1000GH
3.1
Remove air guide (1)


Only with engine 113.942

Danger!

Risk of injury
to skin and eyes suffering

scalding from contact with hot coolant spray.
Risk of poisoning
from 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 bottles.

Wear protective gloves, protective clothing

and eye protection.
AS20.00-Z-0001-01A

4
Drain coolant

Remove coolant hose at bottom on

radiator.

AR20.00-P-1142HA

5
Remove engine cover

6.1
Remove viscous fan (2)

All except model 163.174 /175 with

engine 113.981 /965.

Right-hand thread!

AR20.40-P-5660C

7.1
Remove the fan shroud (3).

Only model 163.154 /157 /172. Unscrew

bolts (4) from bottom of fan shroud

7.2
Remove electric fan

Only model 163.174/ 175.

AR20.40-P-5000GH

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

29
Slacken cylinder head bolts (21) in stages,

unscrew

Loosen cylinder head bolts according to
loosening schematic only after engine has

cooled down to prevent cylinder head from

distorting.

AR01.30-P-5800-09B


Installation:
Observe tightening pattern

and tightening instructions of cylinder head

bolts.
Oil thread and head contact surface of

cylinder head bolts.
AR01.30-P-5800-07B

Screwdriver insert

*000589031000

Screwdriver insert

*000589041000


*BA01.30-P-1001-01D

30
Remove cylinder head


Installation:

On Engine 112/113 observe

porous points in the left and right cylinder

head. If porous points are present, sealant

must be applied to the cylinder head gasket.


Notes on application of sealant to cylinder

head gasket.
Engine 112, 113

AH01.30-P-1000-04VA

The sealant must be applied within

10 minutes.

Loctite 5900 sealant.

*BR00.45-Z-1015-01A

31
Inspect version of cylinder head gasket
Assignment of cylinder head gasket


Information for assigning the cylinder head

gaskets
Engine 112, 113

AH01.30-P-1000-06V

32
Check cylinder head bolts (21)


AR01.30-P-5800-03B

*BE01.30-P-1001-04B

33
Clean sealing surfaces, inspect for cracks,

shrink holes and flatness, clean threaded

holes.

Pay attention to dowel sleeves (26) for

locating the cylinder head.

Sealing surfaces of crankcase and

cylinder head are provided with an 0.8 mm

thick silicone layer during series production.

At the time of repair installation, silicone

sealant is applied to the sealing area only in

case of any shrink holes.

The sealant must be applied within

10 minutes.

Loctite 5900 sealant.

*BR00.45-Z-1015-01A

34
Install in the reverse order

Danger!

Risk of accident
caused by vehicle starting

off by itself when engine is running.
Risk of

injury
caused by contusions and burns when

working in engine during starting procedure
Secure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.

Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

35
Run engine and inspect for leaks

36
Inspect cooling system for leaks

Warm up engine to operating temperature

and then inspect cooling system or leaks.

AR20.00-P-1010HA

37
Read out and erase fault memory

Stored faults which can result from cables

being disconnected or from simulation during

removal and installation or test work, have to

be processed and erased in the fault

memories after completing the work:

#

Diagnosis Manual Volume 2 Index 0:

Connecting and using test equipment.

Cylinder head/cylinder head bolts

Number

Designation
Engine

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
Engine

113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/987/
988/990/991/

992/993

BE01.30-P-1001-04B
Cylinder head bolt
Thread diameter
M
1111

Length (L) when new
mm
141.5141.5

Length (L)
mm
T
144.5
T
144.5

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 5

2001 MERCEDES-BENZ
ML320 & ML430
BUZZERS, RELAYS & TIMERS
BUZZERS, RELAYS & TIMERS LOCATION
ComponentComponent Location
Alarm Horn RelayIn left side of engine compartment, in fuse & relay
box.
Blower Motor RelayIn left side of engine compartment, in fuse & relay
box.
Central Locking (All Doors Lock Relay)In left side of engine compartment, in fuse & relay
box.
Central Locking (Left Front Door & Fuel Filler Flap
Unlock Relay)In left side of engine compartment, in fuse & relay
box.
Central Locking (Right Front Door & Rear Doors
Unlock Relay)In left side of engine compartment, in fuse & relay
box.
Central Locking (Tailgate Unlock Relay)In left side of engine compartment, in fuse & relay
box.
Circuit 15 RelayIn left side of engine compartment, in fuse & relay
box.
Circuit 15 RelayIn right front footwell fuse & relay box.
Circuit 15 Delayed RelayIn left side of engine compartment, in fuse & relay
box.
Circuit 58 RelayIn left side of engine compartment, in fuse & relay
box.
Circuit 58L Relay (W/ DRL)In left side of engine compartment, in fuse & relay
box.
Circuit 58R Relay (W/ DRL)In left side of engine compartment, in fuse & relay
box.
Circulation Pump RelayIn left side of engine compartment, in fuse & relay
box.
Convenience RelayIn left side of engine compartment, in fuse & relay
box.
Differential Lock Vacuum Pump RelayIn left side of engine compartment, in fuse & relay
box.
Engine Cooling Fan Stage 1 RelayIn left side of engine compartment, in fuse & relay
box.
ESP Stoplight Suppression RelayIn left side of engine compartment, in fuse & relay
box.
Front Foglight RelayIn left side of engine compartment, in fuse & relay
box.
Front Wiper Motor RelayIn left side of engine compartment, in fuse & relay

2001 Mercedes-Benz ML320
2001 MERCEDES-BENZ ML320 & ML430

2001 Mercedes-Benz ML320
2001 MERCEDES-BENZ ML320 & ML430
me
Saturday, October 02, 2010 3:21:17 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.
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CONTROL UNITS
CONTROL UNITS LOCATION
MOTORS
MOTORS LOCATION
Fig. 1 .
ComponentComponent Location
Acoustimass Bass ModuleUnder driver's seat. See Fig. 1 .
All Activity Module (AAM)In left side of engine compartment, in E-box. See
Fig. 1
.
ASR/ETS/ESP Hydraulic UnitIn left side of engine compartment, below washer
bottle.
Electronic Selector Lever Control ModuleUnder center console, at base of selector lever
assembly.
Engine Control Module (ME-SFI)In left side of engine compartment, in E-box. See
Fig. 1
.
ESA Control Module (Right/Left)Under respective front seat.
ESP/SPS/BAS Control ModuleIn left side of engine compartment, in E-box. See
Fig. 1
.
ETC Control ModuleBehind center of dash. See Fig. 1 .
Extended Activity Module (EAM)Behind left side of dash.
Global Positioning System (GPS) Control ModuleBehind center of dash.
MB-Immobilizer Control ModuleIn top right side of steering column. See Fig. 1 .
Restraint System Control ModuleUnder center console.
SRS Control ModuleBelow front of center console. See Fig. 1 .
Suction Cooling Fan Control ModuleAt front of engine compartment.
Trailer Turn Signal Control ModuleIntegral to trailer harness.
Transfer Case Control ModuleBelow center console, behind shift assembly. See
Fig. 1
.
Trip Computer Control ModuleIn front of roof.
Xenon Headlamp Control Module (Left/Right)Behind respective headlamp.
Xenon Headlamp Ignition Module (Left/Right)Behind respective headlamp.
ComponentComponent Location
Blend Air Flap Actuator MotorBehind right side of dash.
Blower MotorUnder right side of dash.
Coolant Circulation PumpIn right rear of engine compartment.
Differential Lock Vacuum PumpOn left side of engine compartment.
Electric Air PumpOn front center of engine.
Filler Flap CL Actuating MotorIn left rear cargo area, behind trim.

2001 Mercedes-Benz ML320
2001 MERCEDES-BENZ ML320 & ML430
me
Saturday, October 02, 2010 3:21:17 PMPage 3 © 2006 Mitchell Repair Information Company, LLC.

The sealing compound must only be applied to the speci fied surfaces in the form of a bead of 2.0 mm ± 0.5
mm in diameter.
The sealing compound must be processe d within 10 min. The sealing compound bead must not be spread. Only
the sealing compound listed in the s ection Repair products may be used.
TROUBLE DIAGNOSIS
GURGLING NOISE IN HEA TER HOUSING - AF01.30-P-1000AG
ENGINE 113.##### up to 286599 in MODEL 129, 163, 202, 208, 210, 215, 220
ENGINE 113.### ## up to 286599 in MODEL 463
Modification notes
17.1.01Replaces STIP 20.10-004 dated 17.01.2001
Damage
codeCauseRemedy
01 243 B2
Heater return duct in cylinder
head clogged with casting
crust
Before working on the cooling system,
coolant pump, heater housing, etc.:?
1 Remove left cylinder head
ENGINE 113 in MODEL 210, 208, 202, 129AR01.30-P-
5800B
ENGINE 113 in MODEL 220AR01.30-P-
5800BA
ENGINE 112.945, 113.962 in MODEL 463AR01.30-P-
5800GV
ENGINE 113.942 in MODEL 163.172
ENGINE 113.981 in MODEL 163.174AR01.30-P-
5800MV

2 Check coolant duct, if necessary, remove
possible casting crust
As of engine end number 285600 (as of
beginning of 01/2001) there is no casting crust
at this point.


2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 23 © 2006 Mitchell Repair Information Company, LLC.

Fig. 15: Locating Casting Crust In Cooling Duct
COOLANT TEMPERATURE HIGHER THAN NORMAL - AF01.30-P-8000A
ENGINE 113.##### up to 286599 in MODEL 129, 163, 202, 208, 210, 215, 220
ENGINE 113.### ## up to 286599 in MODEL 463
Modification notes
17.1.01Supersedes STIP 20.10-004 dated 17.01.2001
Damage
codeCauseRemedy
01 243 B2
Cylinder head with
casting crust in
coolant duct
Before performing work on cooling system, coolant
pump, heater housing, etc.: ?
1. Remove left cylinder head

ENGINE 113 in MODEL 210, 208, 202, 129AR01.30-P-
5800B
ENGINE 113 in MODEL 220AR01.30-P-
5800BA
ENGINE 112.945, 113.962 in MODEL 463AR01.30-P-
5800GV
ENGINE 113.942 in MODEL 163.172AR01.30-P-
5800MV
ENGINE 113.981 in MODEL 163.174

2 Check coolant duct, if necessary, remove possible casting
crust As of engine end number (as of beginning of
01/2001) there is no casting crust at this point.


2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 24 © 2006 Mitchell Repair Information Company, LLC.

Fig. 16: Locating Casting Crust In Cooling Duct
TESTING & REPAIR
INSPECTING CY LINDERS WITH LIGHT PROBE - AR01.00-P-0200AU
ENGINE 112, 137, 275, 285, 112.945, 113.962/982
ENGINE 113 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 25 © 2006 Mitchell Repair Information Company, LLC.

Fig. 30: Identifying Components For Inspecting Cylinders For Leaks
Shown on Engine 112
Remove, Install

1Risk of accident from
vehicle starting off by
itself when engine
running. Risk of injury
suffered in the form of
bruises or burns to the
hands when reaching in
while the engine cranks
or runs
Bring engine to operating
temperature (approx. 80 °
C)Secure vehicle to prevent it
from moving off by itself.
Wear closed and close-
fitting work clothes.
Do not grasp hot or rotating
parts.
Check the cylinder for
leaks only when the engine
is at normal operating
temperature.AS00.00-Z-0005-01A

Risk of injury to skin
and eyes suffering
scalding from contact
with hot coolant spray.
Risk of poisoning from
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
bottles.
Wear protective gloves,
protective clothing and eye
protection.
AS20.00-Z-0001-01A
2Open cap (2) of
expansion reservoirIn Model 463 with Engine
112, 113, a cap (2) with a
detent is built-in
Turn cap carefully up to the
first pre-detent, relieve the
pressure and then unscrew
the cap (2).
A 1-stage cap is fitted to
Model 163 with Engine
112, 113.
Turn the 1-stage and 2-
stage cap half a revolution
counterclockwise, relieve
the pressure, then unscrew
the 1-stage or 2-stage cover.
3Remove a spark plug
(19) from each cylinder
Model 202, 208, 209, 210
with Engine 112, 113.AP15.10-P-1580A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 40 © 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.

two bottom bolts at transmission bell.
*BA27.40-P-
1008-01A
34Unscrew nuts (18)
for engine mount Before unscrewing left engine mount, press
oil line of power stee ring out of fixture.

*BA22.10-P-
1001-01L
35Unscrew oil filler
pipe (automatic
transmission) at right
cylinder head cover
36Attach engine hoist
to engine lifting eyes Use engine removal device!
*WE58.40-Z-
1012-11A
*WE58.40-Z-
1020-11A
37Raise engine Ensure that engine and its detachable
components are not lying against the body!
38Insert transmission
support (22) The transmission support is inserted onto
crossmember and into recess of transmission.
The transmission support prevents the
torque converter being pulled out. At the same
time, the transmission is fixed in place with the
transmission support when installing the
engine.
*WE58.40-Z-
1036-11A
?
*WE58.40-Z-
1036-11A
39Unscrew two top
bolts (engine 112) or
two bottom bolts
(engine 113) of
transmission bell Ensure that engine does not hit at front
against radiator or condenser damaging them
40Pull engine out
toward front and lift
out
41Install in the reverse
order
42Inspect cooling
system for leaks If fitting new cylinder head gaskets, bring
engine to operating temperature beforehand.AR20.00-P-
1010HA

43Risk of accident
caused by vehicle
starting off by itself Secure vehicle to prev ent it from moving by
itself.
Wear closed and snug-fitting work clothes. 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 57 © 2006 Mitchell Repair Information Company, LLC.