check oil MERCEDES-BENZ ML320 1997 Complete Manual PDF

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

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
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Page 5

AR72.10-P-1000GH
Remove/install front door liner
11.2.97

MODEL
163.113 /128 /136 /154 /157 /172 /174 /175

P72.10-2161-06

1
Door liner

2
Door handle cover

3
Bolt

4
Cover

5
Clips

6
Bowden cable

7
Sheet metal clip nuts

8
Door foil

9
Entrance lamp

10
Bolt


Remove/install

1
Open crank window

2
Remove cover for door handle (2)

Press cover off using assembly wedge at

bottom.

Assembly wedge

*110589035900

3
Unscrew bolts (3)

4.1
Unclip SRS panel and unscrew screw (10)

As of vehicle identification number

A145273, X708319.

5
Remove cover (4) with installation wedge

Assembly wedge

*110589035900

6
Press door liner (1) off of inner door panel at

bottom, front and rear with assembly wedge

Position assembly wedge directly next to

clips (5).

Assembly wedge

*110589035900

7
Lift door liner (1) up and out

8
Unhook control cable (6) from inner door

actuation

9.1
Remove entrance lamp (9)
As of vehicle identification number

A145273, X708319.

10
Lay down door liner

11
Check sheet metal clip nuts (7) on inner door

panel


Replace damaged sheet metal clip nuts.

12
Check door foil (8) on inner door panel and

clips (5) on door


Replace damaged door foil Replace all

clips.

13
Install in the reverse order

Assembly wedge

110 589 03 59 00

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1

AR72.12-P-1010GH
Remove/install rear door liner
18.2.97

MODEL
163.113 /128 /136 /154 /157 /172 /174 /175

P72.12-2061-09

1
Door handle cover

2
Bolt

3
Door liner
7

Assembly wedge

8
Entrance lamp

9
Bolt

4

Bowden cable

5
Inner lock

6
Clips


Remove/install

1
Open crank window

2
Remove cover for door handle (1)

3
Unscrew screw (2)

4.1
Unclip SRS panel and unscrew screw (9)

As of vehicle identification number

A145273, X708319.

5
Press door liner (3) off of bottom, front and

rear inner door panel with assembly wedge (7)

Position assembly wedge directly next to

clips

Assembly wedge

*110589035900

6
Lift door liner (3) up and out

7
Unhook control cable (4) on inner door

actuating mechanism

8
Unclip inner lock (5) on door liner (3)
9.1
Remove entrance lamp (8)
As of vehicle identification number

A145273, X708319.

10
Lay down door liner

11
Check foil and sheet metal clip nuts on inner

door panel

Replace damaged foil. Replace all clips.

12
Install in the reverse order

Assembly wedge

110 589 03 59 00

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

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.

Engine load
Crankshaft position sensor
Camshaft Hall sensor
Coolant temperature sensor
Intake air temperature sensor/charge air.
Coil ignition: The ME control unit interrupts at the point of ignition timing at the ground end the ignition
coil primary circuit of the ignition coil.
ECI ignition system (engine 137): The ME control unit actuates the output stages in the ECI ignition
modules.

The ignition angle can only be checked with the HHT/STAR DIAGNOSIS.
2.Ignition angle adaptation
2.1 Catalytic converter heating-up (warming-up)
The ignition angle is continuously retarded for about 20 seconds in order to more rapidly warm up the catalytic
converter to its operating temperature if:
coolant temperature at start > 15 °C and < 40 °C
Selector lever position P or N
At the same time idle speed is increased by the idle speed control.
2.2 Idle speed
To assist the idle speed control, the ignition angle can be retarded by as much as 36° crank angle or advanced by
as much as 20° crank angle.
Altering the ignition angle provides a more rapid control than altering the position of the throttle valve (idle
speed control).
2.3 Deceleration fuel shutoff
The ignition angle is briefly retarded when combustion is resumed (fuel injectors actuated) in order to prevent a
sudden increase in torque.
2.4 Intake air temperature/coolant temperature
The ignition angle is retarded under load, as a function of the intake air temperature and coolant temperature, in
order to prevent an
y knocking tendency at high intake air and coolant temperatures. The ignition angle is

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 17 © 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.

11
Check oil level approx. 5 min. after switching

off warm engine

Insert oil dipstick up to the stop and keep

to a residence time of at least 3 seconds.

Model 163, 210 with Engine 612
*BE18.00-P-1001-02B
Model 203, Model 209 with Engine 612

On Model 203, Model 209 after oil level

check pay attention to correct seating of the
cap, otherwise it could result in engine

damage.

Only Model 203:

Up to engine end number: 134 163 oil level

MAX. 135
mm,
MIN 110
mm.

As of engine end number: 134 164 oil level

MAX. 124,5
mm,
MIN 99,5
mm.

Measuring rod


*120589072100

12
Install trim panel of cylinder head cover

AR01.20-P-5014-02B


*BA01.20-P-1002-01A


*BA01.20-P-1003-01A

Test values for engine lubrication - general

Number

Designation
Engine

612.961
Engine

612.963

BE18.00-P-1001-02B
Dipstick marking

Color red
t
1

Color black
t
2

Color green
t
3

Color gentian blue
t
4

Numbers on handle
Number
6020760206

Round handle
Color
--

Bottle opener-shaped

handle
Color
11

Designation
Engine

612.961/962/

963/965/966,

613.961
Engine

612.967
Engine

612.990

BA01.45-P-1003-01A
Oil drain plug at oil pan
M12
Nm
---

M14
Nm
303030


Engine lubrication, oil filter

Number

Designation
Engine

612.961/962/
963/967/990,

613.960/961

BA18.20-P-1002-01G
Screw cap at oil filter
Nm
25

Crankcase ventilation, cylinder head cover

Number

Designation
Engine

612.961/

962/967
Engine

612.963
Engine

612.990

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Page 2

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

i040*WH58.30-Z-
1003-28A
3Place camshaft bearing
bridge on board (4) Fig. 56
4
Remove the rocker arm
spindle (3) by tapping
gently with a hammer If it is tapped very hard, th ere is a danger of distorting the
camshaft bearing bridge and da maging the hollow rocker arm
spindle (3).

Fig. 53
Check
5
Inspect bearing
surfaces of rocker arms
for damage Pay attention to any long score marks caused by the
removal of the rocker arm spindl es (3). Replace the rocker arm
if damaged.

Installing
6
Insert the guide shafts
into the camshaft
bearing bridge. At the same time, preassemble the rocker arm on guide
shaft.
Fig. 54
Fig. 55

Risk of injury to skin
and eyes caused by
handling hot or glowing
objects.
Wear safety gloves, protective cl othing and safety glasses, if
necessary.AS00.00-Z-
0002-01A
7
Heat camshaft bearing
bridge to approx. 150°
C
Heat the camshaft bearing bridge uniformly, but do not
heat it over 160°C; there is a danger of structural changes.
WH58.30-Z-
1001-28A
*WH58.30-Z-
1003-28A
8Cool the rocker arm
spindle (3)
9
Place heated camshaft
bearing bridge on board
(4) Fig. 56
10Install rocker arm
spindle (3)
Insert the rocker arm spindle (3) in the camshaft bearing
bridge by tapping gently with a hammer and simultaneously
remove the guide shaft. Ensure that the rocker arms do not get
jammed.

11Align the rocker arm
spindle (3)
In order to align and secure the rocker arm spindle (3), fit
two screws through the mount ing bores in the camshaft
bearing bridge. The oil supply bores of the rocker arm spindle
(3) point towards the cylinder head.

Engines 112, 113 except engines 113.967 /990 in models 219,
engines 113.964 /971 /989 /993AR05.20-P-
7103AU
Engine 113.993 in model 463AR05.20-P-
7103GX

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 55 © 2006 Mitchell Repair Information Company, LLC.