engine MERCEDES-BENZ ML320 1997 Complete Repair Manual

Application of sealant to bottom part of oil pan The line drawn F marks the application of sealant.
Fig. 12: Identifying Application Of Sealant To Bottom Part Of Oil Pan
- Engine 112
Clean sealing surfaces, apply sealant only to the sp ecified surfaces with a bead of 2.0 mm ± 0.5 mm.
The sealant must be applied within 10 minutes!
The silicone bead must not be spread. Only the silicone sealant listed in the section Repair products may be
used.
NOTES ON APPLICATION OF SEALING CO MPOUND TO OIL PAN - AH01.45-P-0001-01E
Engines 113.941/942/960/962/965/981/982/993
Application of sealing compound to upper part of oil pan
The line drawn in (F) identifies the course of the sealin
g compound.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Fig. 13: Identifying Application Of Seal ing Compound To Upper Part Of Oil Pan - Engines
113.941/942/960/962/965/981/982/993
The sealing compound must be only applied to the specified
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.
Application of sealing compound to bottom part of oil pan
The line drawn in (F) identifies the course of sealing compound.
Fig. 14: Identifying Application Of Sealin g Compound To Bottom Part Of Oil Pan
- Engines
113.941/942/960/962/965/981/982/993

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
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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
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Fig. 17: Inspecting Cylinders With Light Probe
Shown on engine 112
Remove/install
Risk of death caused by
contact with parts
conducting high voltages.Do not touch parts which
conduct high voltages.
Persons who have
electronic implants (e.g.
pacemakers) must not
perform any work on the
ignition system.AS15.10-Z-0001-01A
Risk of injury to skin and
eyes caused by handling
hot or glowing objects.Wear safety gloves,
protective clothing and
safety glasses, if necessary.AS00.00-Z-0002-01A
Risk of death cased 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
1Remove a spark plug from
each cylinderType 208.474
Type 202.088
Model 210.062/262
Replace spark plugsModel 129 with engine
112.923/943, 113.961AP15.10-P-1580AC
Model 163 with engine
112, 113AP15.10-P-1580GH
Model 209, 210 except
210.062 /262, 208 except
208.474, 202 except
202.088 with engine 112,
113
Model 203, 170 with
engine 112AP15.10-P-1580A
Model 215, 220 with
engine 137
Model 215, 220, 230 with
engine 275
Model 215, 220 with
engine 285AP15.10-P-1580L
Model 211 with engine
112, 113
Model 215 with Engine
113 AP15.10-P-1580AB

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 26 © 2006 Mitchell Repair Information Company, LLC.

Model 220 with engine
112, 113
Model 230 with engine
112, 113
Model 240 with engine
285AP15.10-P-1580H
Model 463 with Engine
112, 113AP15.10-P-1580GA
2.1Remove bottom engine
compartment panelingModel 240AR61.20-P-1105H
3Position piston of cylinder
to be inspected to BDCTo do this, crank the
engine at the central bolt of
the crankshaft in the
direction of rotation of the
engine: ?
Firing orderAR01.00-P-1300-03HA
4Connect cylinder
inspection lamp (05) and
insert the flexible test
probe for the inspection
lamp via the spark plug
bore into the respective
cylinder Cylinder inspection
equipment*WH58.30-Z-1014-05A
Flexible inspection light*WH58.30-Z-1006-05A
Flexible inspection light*WH58.30-Z-1007-05A
Check
5Inspect cylinder walls Normal condition:
Mat-grey surface, no
honing pattern.
If the condition of the
cylinder wall is not clearly
recognizable: ?
Model 129, 163, 170, 202,
203, 208, 209, 210,
215,220,230,463
Remove cylinder head
Model 129 with engine
112, 113AR01.30-P-5800B
Model 202, 208, 210 with
engine 113
Model 163 with engine
112, 113AR01.30-P-5800MV
Model 170, 202, 208, 210
with engine 112AR01.30-P-5800BA
Model 220 with engine
112, 113
Model 230 with engine

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Commercially available tools
TESTING COMPRESSION PR ESSURE - AR01.00-P-1200B
ENGINE 112
Air filter positioned at vehicle side.
ENGINE 113
Air filter positioned at vehicle side.
113
Model 203 with engine
112, 113 except 203.764AR01.30-P-5800PV
Model 209 with engine
112, 113
Type 203.764
Model 215, 220 with
engine 137AR01.30-P-5800L
Model 215, 220 with
engines 275.950/ 980AR01.30-P-5800M
Model 230 with engine
275.951
Model 463 with Engine
112, 113AR01.30-P-5800GV
Model 240AR01.10-P-2400H
Remove engine
General information on
inspecting cylinder wallsEngine 112, 113, 134, 135,
137, 166, 275, 285, 611,
612, 613, 628, 639, 646,
647, 648AH01.00-P-0300-01A
6Inspect the remaining
cylinders following the
same procedure
7Install in the reverse order
NumberDesignation
WH58.30-Z-
1006-05AFlexible endoscope, package contents 1 (c omplete unit), Firma Richard Wolf GmbH D-
75438 Knittlingen Firma Karl Storz GmbH D-78532 Tuttlingen
WH58.30-Z-
1007-05AFlexible endoscope package contents 2 (for workshops which already have an approved
endoscope from the Wolf or Storz comp any), Firma Richard Wolf GmbH D-75438
Knittlingen Firma Karl St orz GmbH D-78532 Tuttlingen
WH58.30-Z-
1014-05ACylinder inspection equipment

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 28 © 2006 Mitchell Repair Information Company, LLC.

Fig. 18: Identifying Compression Recorder Assembly
Remove/install
Risk of accident caused
by vehicle starting off by
itself when engine is
running. Risk of injury
caused by contusions and
burns during starting
procedure or when
working near the running
engineSecure vehicle to prevent
it from moving by itself.
Wear closed and snug-
fitting work clothes.
Do not grasp hot or
rotating parts.AS00.00-Z-0005-01A
1Bring engine to operating
temperature (approx. 80°
C)
Only test compression
when engine is at
operating temperature.
2Remove engine trim
panel
3Remove air filter housing
4Remove resonance pipe
with resonance body
All except model 163
with engine 113.942/981.
Disconnect plug
AR07.07-P-1454A

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1998-2005 ENGINE Complete engine - 163 Chassis
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connection for hot
film mass air flow
sensor (HFM-SFI)
for this step and
unbolt resonance
pipe at cylinder
head cover.

The resonance pipe is
attached to the rear of the
intake manifold with a
plastic bracket.

Do not damage plastic
plate.
5Remove spark plugsRemove only one spark
plug at each cylinder: ?
Models 210, 208, 202
with engine 112
Model 210 with engine
113AP15.10-P-1580A
Model 163 with engines
112, 113AP15.10-P-1580GH
6Crank engine with starter.Do not crank engine at
steering lock but use
contact switch of the
compression recorder.
Crank engine several
times with the starter in
order to eliminate
combustion residues in
the cylinder.AR01.10-P-0110V
Checking
7Insert compression tester
into spark plug bore Fig. 21
8Open throttle valve
9Crank engine with starterDo not crank engine at
steering lock but use
contact switch of the
compression recorder.
To check the
compression pressure,
crank the engine by at AR01.10-P-0110V

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1998-2005 ENGINE Complete engine - 163 Chassis
me
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