spark plugs replace MERCEDES-BENZ ML320 1997 Complete Repair Manual

Fig. 45: Identifying Harmonics - Positive Diode Defective
Fig. 46: Identifying Diode Harmonics OK

REPLACE SPARK PLUGS - AP15.10-P-1580GH
ENGINE 112.942 in MODEL 163.154
ENGINE 112.970 in MODEL 163.157
ENGINE 113.942 in MODEL 163.172
ENGINE 113.981 in MODEL 163.174
ENGINE 113.965 in MODEL 163.175

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 71 © 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.

Models 211.061/065/070AR54.10-P-0003T
Model 215, 220AR54.10-P-0003I
Model 230.474 /475AR54.10-P-0003R
All models 463 except
463.241/248 with code 979.AR54.10-P-0003G
Model 463.241 with code
979AR54.10-P-0003PV
Model 463.248 with code
979AR54.10-P-0003PM
Notes on batteryAll modelsAH54.10-P-0001-01A
2Remove spark plugsTo ensure that the engine
can be easily cranked when
drawing in the timing chain,
and to avoid the timing
chain jumping across.
Remove only once spark
plug of each cylinder.
Replace spark plugsModel 163AP15.10-P-1580GH
Models 220, 230.474/475AP15.10-P-1580AB
Models 210, 208, 202AP15.10-P-1580A
Models 203, 170, 209, 211
with engine 112
Models 209, 211 with
engine 113
3Remove cylinder head
coversAir filter mounted on
vehicleAR01.20-P-5014B
Air filter mounted on
engineAR01.20-P-5014BV
4.1Remove fan shroud Not models
211.061/065/070, 230.475
Models 220, 230.474
AR20.40-P-6800AB
4.2Remove electric fanModel 170AR20.40-P-5000SV
Models 203, 209AR20.40-P-5000PV
Model 163.174AR20.40-P-5000GH
5Position engine to 40°
after TDC of first
cylinder. Engine must not be
cranked backwards. 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 AR05.20-P-6020AU

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 29 © 2006 Mitchell Repair Information Company, LLC.

Intake manifold
211.061/065/070, 230.475
Models 220, 230.474
22.2Install electric fanModel 170AR20.40-P-5000SV
Models 203, 209AR20.40-P-5000PV
Model 163.174AR20.40-P-5000GH
23Install cylinder head
coversAir filter locat ed at vehicle
side.AR01.20-P-5014B
Air filter locat ed on engine
side.AR01.20-P-5014BV
24Install spark plugs
Replace spark plugsModels 220, 230.474/475AP15.10-P-1580AB
Models 210, 208, 202AP15.10-P-1580A
Models 170, 203, 209, 211
with engine 112
Models 209, 211 with
engine 113
Model 163AP15.10-P-1580GH
25Connect ground cableModel 203AR54.10-P-0003P
Models 129, 163, 170, 202,
208, 210AR54.10-P-0003A
Model 209AR54.10-P-0003Q
Models 211.061/065/070AR61.20-P-1105T
Model 215, 220AR54.10-P-0003I
Model 230.474/475AR54.10-P-0003R
All models 463 except
463.241/248 with code 979AR54.10-P-0003G
Model 463.241 with code
979AR54.10-P-0003PV
Model 463.248 with code
979AR54.10-P-0003PM
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
26Run engine and inspect
for leaks
NumberDesignationEngines 112, 113

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 32 © 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.

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.

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.

AR07.16-P-1100MM
Remove, install fuel cooler
5.11.99

ENGINE
612.963 in MODELS 163.113

P47.00-2042-12

1
Fuel feed hose

2
Fuel drain hose

3
Coolant feed hose

4
Coolant return flow hose

5
Fuel cooler

7
Bolts of fuel cooler

Operation no. of operation texts or standard texts and flat rates
Category

Op. no.
Operation text

P
075890
REMOVING AND INSTALLING FUEL COOLER

P
075895
REPLACE FUEL COOLER


Remove, Install


Danger!
Risk of injury
to
fingers being jammed or

squeezed
when removing and installing or

aligning hoods, doors, tailgate/tailgate and

sliding roof.
When moving components ensure that no

body parts or limbs are in the area of motion.

AS00.00-Z-0011-01A


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


Danger!
Risk of explosion
from fuel igniting,
risk of

poisoning
from inhaling and swallowing fuel

as well as
risk of injury
to eyes and skin

from contact with fuel.
No fire, sparks, naked flames or smoking.

Pour fuels only into suitable and appropriately

marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1
Open engine hood and raise to vertical position


Have second person secure hood.

AR88.40-P-1000GI

2
Remove trim panel of cylinder head cover

AR01.20-P-5014-02B


*BA01.20-P-1002-01A
*BA01.20-P-1003-01A

3
Drain coolant

At radiator.

AR20.00-P-1142M

4
Close fuel feed hose (1) at the fuel cooler (5)

Set of plugs

*129589009100

*WH58.30-Z-1001-06A
*WH58.30-Z-1002-06A

5
Detach fuel outlet hose (2)

Clamp

*000589543700

Set of plugs

*129589009100

*WH58.30-Z-1001-06A
*WH58.30-Z-1002-06A

6
Disconnect coolant return flow hose (4) to

thermostat housing

Hose clamp pliers (length 210 mm;

adjustment range 80 mm)

*WH58.30-Z-1026-02A

7
Unscrew bolts (7) at fuel cooler

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

AP15.10-P-1580GHReplace spark plugs
1.7.97

ENGINE
112.942 in MODEL 163.154

ENGINE
112.970 in MODEL 163.157

ENGINE
113.942 in MODEL 163.172

ENGINE
113.981 in MODEL 163.174

ENGINE
113.965 in MODEL 163.175

P15.10-0221-06

Shown on engine 112

R4
Spark plugs

T1/4
Ignition coil cylinder 4


Remove/install and replacing


Danger!

Risk of death
caused by contact with parts

conducting high voltages.
Do not touch parts which conduct high

voltages. Persons who wear electronic

implants (e.g. heart pacemakers) must not

carry out work on the ignition system.

AS15.10-Z-0001-01A


Notes on avoiding damage to ignition system
Engine 104, 111, 112, 113, 119, 120, 271

AH15.10-P-0002-01D

1
Remove/install air filter upper section

2
Removing and installing ignition coils

AR15.12-P-2003A

3
Disconnect spark plug connectors

Prise over cylinder head cover.


Double open-ended wrench

*110589010100

4
Remove/install spark plugs (R4)


*BA15.10-P-1001-01A

Spark plug wrench

*112589010900


Spark plugs

Number

Designation
Engines

104, 110, 111,

113.940/941/942/943/
944/948/960/961/962/
963/965/966/967/968/
969/980/981/982/984/

986/992/993,

115, 117, 119, 120
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

BA15.10-P-1001-01A
Spark plugs
Nm
2828

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1