engine MERCEDES-BENZ ML320 1997 Complete Repair Manual

Fig. 43: Identifying Timing Chain Components
Removing
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 batteriesNo fire, sparks, open
flames or smoking. Wear
acid-resistant gloves,
clothing and safety
glasses. Only pour battery
acid into suitable and
appropriately marked
containers.AS54.10-Z-0001-01A
Notes on batteryAll models.AH54.10-P-0001-01A
1Disconnect ground cableModel 463 except code
(979) Special protection
versionAR54.10-P-0003G
Model 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

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 35 © 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.

camshaft sprockets. On
vehicles equipped with an
air pump, the combination
valve must be unbolted
before the right locking
plate is inserted.
Installation : Replace
Gasket of combination
valve.
*BA09.20-P-1001-01D
Locating plateFig. 11
Locating plateFig. 12
Timing chain drive -
general GF05.10-P-9611-01C
7Remove chain tensioner AR05.10-P-7800C
8Remove camshaft position
sensor AR15.10-P-2000A
9Crank engine in direction
of rotation until the link
for separating the timing
chain is easily accessible The separation point
for the timing chain is one
link down from the copper
tab (right). See new timing
chain.
10Remove camsha ft bearing
bridge on rightEngine 112, 113.AR05.20-P-7103AU
Engine 113.960 with Code
(479) cylinder shutoff.AR05.20-P-7103AV
11Install holding bush (3)
onto camshaft on right Insert bolts (4) only
until they make contact.
Fig. 40
12Bolt on holding devices
(1, 2) for timing chain at
right and left cylinder
heads Fig. 39
13Separate timing chain Parts which have
dropped into the timing
case recess, must be
removed. Cover over
timing case recess with a
clean cloth.AR05.10-P-7601-01AV
Connect old timing
chain to new timing chain
before pulling out.
Installing
14Draw in new timing chain Pull in the new timing
chain by turning the AR05.10-P-7601-04AV

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

Intake manifold
Fig. 44: Identifying Locating Plate (112 589 00 32 00)

Fig. 45: Identifying Locating Plate (112 589 01 32 00)

Fig. 46: Identifying Retainer (112 589 04 40 00)
burns during starting
procedure or when
working near the running
enginerotating parts.
28Run engine and inspect
for leaks
NumberDesignationEngines 112,113
BA09.20-P-1001-
01DBolt, intake manifold
to cylinder headM8Nm20

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

Fig. 47: Identifying Holding Bush (112 589 05 40 00)
REMOVE/INSTALL CHAIN TE NSIONER - AR05.10-P-7800C
ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250
ENGINE 112 in MODELS 163, 129
ENGINE 113.962 in MODELS 463.206 / 240 /241 /247 /248 /249 /254
ENGINE 113 (except 113.965 /981) in MODELS 210, 208, 202, 163, 129
ENGINE 113.982 in MODELS 463.243 /246
Shown on ENGINE 112 in MODEL 129
Fig. 48: Identifying Chain Tensioner Components
- Shown On Engine 112 In Model 129

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 40 © 2006 Mitchell Repair Information Company, LLC.

Timing chain, chain tensioner
REMOVE/INSTALL CHAIN TE NSIONER - AR05.10-P-7800CA
ENGINE 112 in MODELS 170, 208, 202, 210, 209, 203
Remove/install
1Remove viscous fan (1) Right-hand thread!AR20.40-P-5660C
2Remove fan shroud (2).On model 163 unscrew
bolts at bottom of fan
shroud.
Model 463AR20.40-P-6800V
3Remove poly-V belt (3) Installation: Lock
tensioning device with a
drift or pin (diameter 5
mm).AR13.22-P-1202B
4Remove alternator (4)Model 129AR15.40-P-5032CT
Model 163AR15.40-P-5032GH
Model 208 with engine
113AR15.40-P-5032EB
Model 210 with engine
113AR15.40-P-5032ED
Model 463 with engine
112, 113AR15.40-P-5032GV
5Take chain tensioner (6) off
timing case cover (5) Installation: Replace
seal (7).
*BA05.10-P-1001-01C
Design of chain tensionerEngines 112, 113GF05.10-P-7801-01A
6Install in the reverse order
NumberDesignationEngines
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
BA05.10-P-1001-
01CChain tensioner in
timing case coverNm8080

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 41 © 2006 Mitchell Repair Information Company, LLC.

ENGINE 113 in MODELS 163.174 /175, 209.375 /475
ENGINE 113.987 in MODELS 209.376 /476 up to 23.4.04
Shown on engine 112
Fig. 49: Identifying Chain Tensioner Components
- Shown On Engine 112
Remove/install
1.1Remove fan shroud (2)
together with electric fanModels 208, 210 with engine
112
1.2Remove electric fan (1)Model 170.465 with engine
112.947
Model 170.466 with engine
112.960AR20.40-P-5000SV
Models 203.061 /261 with
engine 112.912
Models 203.064 /264 /764
with engine 112.946
Models 203.065 /265 with
engine 112.961
Models 203.081 /281 with
engine 112.916
Models 203.084 /284 with
engine 112.953 AR20.40-P-5000PV

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 42 © 2006 Mitchell Repair Information Company, LLC.

Models 209.361 /461 with
engine 112.912
Models 209.365 /465 with
engine 112.955
Models 209.375 /475 with
engine 113.968
Models 209.376 /476 with
engine 113.987
Model 163.174 with engine
113.981
Model 163.175 with engine
113.965AR20.40-P-5000GH
2.1Remove alternator (G2) On alternator (G2)only
unscrew upper bolt, slacken
lower bolt. Fold away the
alternator (G2).
Models 202.088,
210.061 /062/261 /262
Models 163.174/175 with
ENGINE 113AR15.40-P-5032GH
Model 170 with Engine 112AR15.40-P-5032G
Models 203.061 /261 with
engine 112.912AR15.40-P-5032P
Models 203.064 /264 /764
with engine 112.946
Models 203.065 /265 with
engine 112.961
Models 209.361 /461 with
engine 112.912
Models 209.365 /465 with
engine 112.955
Models 209.375 /475 with
engine 113.968
Models 209.376 /476 with
ENGINE 113.987
Models
203.081 /084 /281 /284 with
engine 112AR15.40-P-5032PW
Model 202 with engine
112.910 /920, except 202.088
with engine 112AR15.40-P-5032EB
Model 208 with engine
112.940, 113.943 /984
Model 210 with engine
112.921 /941, except AR15.40-P-5032ED

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 43 © 2006 Mitchell Repair Information Company, LLC.

Timing chain, chain tensioner
Fig. 50: Identifying External Torx Set (001 589 76 09 00)

REMOVE/INSTALL SLIDE RAIL IN TI MING CASE COVER - AR05.10-P-8484V
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 112 in MODEL 129, 163, 170, 202, 203, 208, 209, 210, 211, 220
210.061 /062 /261 /262 with
engine 112
Models
210.061 /062/261 /262
Model 202.088
External Torx setFig. 50
3Remove chain tensioner
(6) from timing case cover
(5) Installation: Replace seal
(7).
*BA05.10-P-1001-01C
Design of chain tensionerEngine 112, 113GF05.10-P-7801-01A
4Install in the reverse order
NumberDesignationEngines
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
BA05.10-P-1001-
01CChain tensioner in
timing case coverNm8080

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 44 © 2006 Mitchell Repair Information Company, LLC.