engine coolant MERCEDES-BENZ ML350 1997 Complete Repair Manual

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. 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

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1998-2005 ENGINE Complete engine - 163 Chassis
me
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CONNECT COMPRESSION TESTER INFORMATION ON PR EVENTING DAMAGE TO ELECTRONIC COMPONENTS
DUE TO ELECTROSTATIC DI SCHARGE - AR01.10-P-0010-01V
Fig. 36: Identifying Compression Recorder (001 589 76 21 00)
4
right major assemblies
compartment (W16/6) of
engine wiring harness

5Remove electrical line (5) at
positive lead (4)
6Disconnect positive cable (4) at
battery
7Take off bracket (3) of positive
cable (4) Bracket next to coolant circulation pump.
8
Separate connector of engine
compartment and engine (X22)
in fuse and relay module

9
Separate connectors of motor
electronics control module
(n3/10)
Release locking arm, separate plug connection
10
Unscrew ground strap of
engine/body (W11/5) to
vehicle frame

11Install in the reverse order
12
Read out and erase diagnostic
trouble code memory with
HHT or STAR DIAGNOSIS
After completion of the work, it is necessary to
process and erase the DTCs stored in the DTC memory
during assembly and testing work due to disconnected
lines and simulation. Diagnosis Manual Volume 2 Index
0: Connecting and using test equipment


2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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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
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202,
Engine 602.983, 612.966 in MODEL 461,
Engine 628.962, 612.965, 606.964, 112.945,
113.962 /982 in MODEL 463,
Engine 111, 112, 611.962, 612.962 in model
203,
Engine 112, 113, 611.961, 612.961, 613.961 in
MODEL 210,
Engine 112 in model 170,
Engine 112 in MODEL 220,
Engine 113 in MODEL 211, 215,220,
Engine 112 in MODEL 208,
Engine 112, 113, 612.963, 628.963 in MODEL
163,
Engine 112.923/943, 113.961 in MODEL 129,
Engine 137, 275 in MODEL 215, 220,
Engine 613.960, 628.960 in MODEL 220,
Engine 113.992 in model 230.474,
Engine 271 in model 209, 203,
Engine 285.950 in model 240.078 /178,
Engine 612.967 in model 209.316,
Engine 648 in model 220
Engine 112.951 in model
639.601/603 /605 /701 /703 /705 /801 /803 /805
Engine 646.983 /984 in model
639. /605 /701 /703/705/801 /803/805
Engine 646.982 in model
639.601 /603 /605 /701 /703 /705
10Remove expansion
reservoir (13)
11Remove air filter
housing (7).
12Remove resonance
tube (8) and
resonance unit (9) Separate plug connection of hot film mass
air flow sensor (HFM) for this step and unbolt
resonance pipe at cy linder head cover.
The resonance pipe is attached at rear at
intake manifold with a plastic plate.
Do not damage plastic strap.
Engine 112.942/970.AR07.07-P-
1454A
Engine 113.942/965/981.AR07.07-P-
1454MV
13Remove coolant
pump line(15)from
coolant pump.
14Remove thermostat

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 54 © 2006 Mitchell Repair Information Company, LLC.

housing coolant line
--> (17) from
thermostat housing
15.1Remove radiator Only engine 113.942 /965 /981.AR20.20-P-
3865HC
16Remove brake
pressure regulator
vacuum line (5) from
brake pressure
regulator at rear of
intake manifold
17Extract power
steering pump (19)
oil Hand pumpFig. 50
18Detach return flow
line and pressure line
of power steering
pump (19) Seal connections!
Set of plugsFig. 51
*BA46.30-P-
1002-01A
*BA46.30-P-
1003-01A
19Remove regeneration
vacuum line (6) from
intake pipe
Risk of explosion
caused by ignition of
flammable products,
risk of poisoning
caused by inhaling
fuel vapors or
swallowing fuel as
well as risk of
injury to skin and
eyes exposed to fuel.No fire, sparks, ope n flames or smoking.AS47.00-Z-0001-
01A
Pour fuels only into suitable and appropriately
marked containers.
Wear protective clothing when handling fuel.
20Disconnect fuel line
(4) Release fuel pressure through service valve!
Collect fuel.
M112: ?
*BA07.52-P-
1001-01A
M113: ?
*BA07.52-P-
1001-01A
Pressure hoseFig. 52
21Detach coolant line
(14)

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 55 © 2006 Mitchell Repair Information Company, LLC.

stationary heater timer.
Notes on batteryAll modelsAH54.10-P-0001-
01A
Risk of death caused
by vehicle slipping
or toppling off of the
lifting platform.Align vehicle between the columns of the
lifting platform and pos ition the four support
plates below the lifti ng platform support points
specified by the vehicle manufacturer.AS00.00-Z-0010-
01A
2Place the vehicle on
lifting platform AR00.60-P-
1000GH
3.1Remove air guide (1) Only for engine 113.942.
Risk of injury to
skin and eyes caused
by 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 containers.
Wear protective gloves, pr otective clothing and
safety glasses.AS20.00-Z-0001-
01A
4Drain coolant Detach coolant hose at bottom of radiator.AR20.00-P-
1142HA
5Remove engine trim
panel
6.1Remove viscous fan
(2) All except model 163.174 /175 with Engine
113.981 /965.
Right-hand thread!AR20.40-P-
5660C
7.1Remove fan shroud
(3) Only model 163.154 /157 /172. unscrew
screws (4) of bottom fan shroud.
7.2Remove electric fan Only models 163.174/ 175.AR20.40-P-
5000GH
8Attach guard plate
for radiator /
condenser
Guard plate for
radiator / condenserEngine 606 in model 124,
Engine 606.961 in model 140,
Engines 112, 113, 604, 605, 611.960 in model
202,
Engines 602.983, 612.966 in model 461,
Engine 628.962, 612.965, 606.964, 112.945,
113.962/982 in model 463,
Engines 111, 112, 611.962, 612.962 in model
203,
Engines 112, 113, 611.961, 612.961, 613.961
in model 210,
Engine 112 in model 170,
Engine 112 in model 220,
Engine 113 in models 211, 215, 220, WF58.50-P-0110-
01A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 85 © 2006 Mitchell Repair Information Company, LLC.

*BA07.52-P-
1001-01A
Pressure hoseFig. 52
12Remove right and
left ignition coils
(12) AR15.12-P-
2003A
13Remove right and
left cylinder head
covers (13) AR01.20-P-
5014B
14Remove intake
manifold (14) Installation: On vehicles with engine
damage, the intake manifold must be examined
for swarfs before assembling and any swarfs
present must be removed, in order to avoid
consequential damage.
The intake manifold system must not be
disassembled.
Remove intake manifold together with fuel
distributor.AR09.20-P-
1310A
15.1Remove camshaft
angle position sensor
(15) Only necessary if right cylinder head is
removed.AR15.10-P-
2000A
16Remove poly-V-belt
(8) Installation: Lock tensioning device with a
drift or pin (diameter 5 mm).
Models 163.154/157/172.AR13.22-P-
1202B
Models 163.174/175.AR13.22-P-
1202BA
17Detach coolant line
(16) at left cylinder
head 6 mm socket hexagon*WH58.30-Z-
1001-06A
7 mm socket hexagon*WH58.30-Z-
1002-06A
18.1Remove inner fender
(9) Only for engine 113.942 /965 /981.AR88.10-P-
1300GH
19.1Remove shield (10) Only for engine 113.942 /965 /981.
20.1Remove exhaust
bracket (11) Only for engine 113.942 /965 /981.
Support exhaust system.
21Detach exhaust
system at exhaust
manifold Installation: On vehicles with engine
damage check exhaust sy stem for chips before
assembly and remove any chips present to
prevent later damage
*BA14.10-P-
1002-01B
22Position crankshaft
to 40° after ignition The engine must not be turned back;
otherwise the timing chain can get jammed. AR05.10-P-
6858V

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Saturday, October 02, 2010 3:17:57 PMPage 87 © 2006 Mitchell Repair Information Company, LLC.

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
1Disconnect
battery ground
cableModels 129, 163, 170, 202, 208, 210AR54.10-P-
0003A
Model 215, 220AR54.10-P-
0003I
Model 230.474 /475AR54.10-P-
0003R
Notes on batteryAll modelsAH54.10-P-
0001-01A
2Remove engine
compartment
panelingModel 129,202,208,210AR61.20-P-
1105AB
Models 163.172/174/175AR61.20-P-
1105GH
Model 170AR61.20-P-
1105A
Model 215, 220AR61.20-P-
1105M
Model 230AR61.20-P-
1105R
Risk of injury to
skin and eyes
caused by
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 containers.
Wear protective gloves, protec tive clothing and safety
glasses.
AS20.00-Z-
0001-01A
3Drain coolant
from radiatorEngine 112, 113 in models 129, 163, 202, 208,
210,215,220AR20.00-P-
1142HA
Engine 113.963 in models 230.475
Engine 112.960 in model 170.466AR20.00-P-
1142RVK
Engine 113.992 in model 230.474

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 98 © 2006 Mitchell Repair Information Company, LLC.

Engine 113 in model 129, 202, 208, 210
Engine 113 (except 113.965 /981) in model 163
Engine 112 in model 202, 208, 210AR13.22-P-
1202BA
Engine 112 in model 220
Engine 113 in model 215.373 /375
Engine 113 in models
220.070 /073 /075 /083 /084 /170 /173 /175 /183 /184 /875
Engine 113.965 in model 163.175
Engine 113.981 in model 163.174
Engine 113.984 in model 208.374 /474
Engine 113.963 in models 230.475AR13.22-P-
1202R
Engine 113.992 in model 230.474
Engine 112.947 in model 170.465AR13.22-P-
1202SV
10Remove cylinder
head covers (6)Engine 112, 113 air filter located on vehicle sideAR01.20-P-
5014B
Engine 112, 113 air filter located on engine sideAR01.20-P-
5014BV
11Detach coolant
line (17, 18) from
coolant pump
(12).
12Detach coolant
line (16) at
thermostat
housing (13).
13Dismount
refrigerant
compressor (A9) Place to the side with lines connected.

*BA83.55-P-
1001-01A
14.1Remove
alternator (G2)Engine 113.963 in models 230.475
Engine 113.992 in model 230.474AR15.40-P-
5032R
15.1Remove ATF line
bracket (23).Model 230
15.2Detach ATF line
from front axle
carrierModel 163
16Remove oil pan
bottom section (9)Engine 112.942 in model 163.154AR01.45-P-
7555V
Engine 112.970 in model 163.157
Engine 113.942 in model 163.172
Engine 113.965 in model 163.175AR01.45-P-
7555VE

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Saturday, October 02, 2010 3:17:57 PMPage 100 © 2006 Mitchell Repair Information Company, LLC.