MERCEDES-BENZ ML350 1997 Complete Repair Manual
Manufacturer: MERCEDES-BENZ, Model Year: 1997, Model line: ML350, Model: MERCEDES-BENZ ML350 1997Pages: 4133, PDF Size: 88.89 MB
Page 2081 of 4133
AR15.12-P-2133A
Remove/install crankshaft position sensor
5.7.96
ENGINE
112.910 in MODEL 202.026 /086
ENGINE
112.920 in MODEL 202.029 /089
ENGINE
112.921 in MODEL 210.063 /081 /263 /281
ENGINE
112.922 in MODEL 220.063
ENGINE
112.923 in MODEL 129.059
ENGINE
112.940 in MODEL 208.365 /465
ENGINE
112.941 in MODEL 210.065 /082 /265 /282
ENGINE
112.942 in MODEL 163.154
ENGINE
112.943 in MODEL 129.064
ENGINE
112.944 in MODEL 220.065 /165
ENGINE
113.940 in MODEL 210.070 /270
ENGINE
113.941 in MODEL 220.070 /170
ENGINE
113.960 in MODEL 215.375, 220.075 /175
ENGINE
113.961 in MODEL 129.068
ENGINE
112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE
113.944 in MODEL 202.033 /093
ENGINE
113.980 in MODEL 210.074 /274
ENGINE
113.943 in MODEL 208.370 /470
ENGINE
113.984 in MODEL 208.374
ENGINE
113.981 in MODEL 163.174
ENGINE
112.912 in MODEL 203.061 /261, 209.361 /461
ENGINE
112.946 in MODEL 203.064 /264
ENGINE
112.947 in MODEL 170.465
ENGINE
112.960 in MODEL 170.466
ENGINE
113.942 in MODEL 163.172
ENGINE
112.961 in MODEL 203.065 /265
ENGINE
113.965 in MODEL 163.175
ENGINE
113.963 in MODEL 230.475
ENGINE
112.913 in MODEL 211.061
ENGINE
112.949 in MODEL 211.065
ENGINE
113.967 in MODEL 211.070
ENGINE
113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE
113.982 in MODEL 463.243 /246
ENGINE
112.955 in MODEL 209.365 /465
ENGINE
112.916 in MODEL 203.081 /281
ENGINE
112.953 in MODEL 203.084 /284
ENGINE
112.973 in MODEL 230.467
ENGINE
112.972 in MODEL 220.067 /167
ENGINE
112.970 in MODEL 163.157
ENGINE
112.975 in MODEL 220.087 /187
ENGINE
113.948 in MODEL 220.083 /183
ENGINE
113.966 in MODEL 220.084 /184
ENGINE
112.917 in MODEL 211.080 /280
ENGINE
112.954 in MODEL 211.082 /282
ENGINE
113.969 in MODEL 211.083 /283
P15.12-0275-11
Shown on Engine 113 in Model 220
L5
Crankshaft position sensor
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Page 1
Page 2082 of 4133
Remove/Install
1.1
Remove engine compartment cover with
integrated air cleaner
All except Engine 112.960 in Model 170.466,
Engine 112.961 in Model 203.065/ 265
Remove air cleaner by lifting vertically up
and away from the cylinder head covers.
Installation:
With sliding compound,
slightly moisten the rubber retainers on the
cylinder head covers and the sealing ring of
the hot film mass air flow sensor in the air
cleaner housing.
1.2
Remove air cleaner housing
Engine 112.960 in Model 170.466
Engine 112.961 in Model 203.065/265
AR09.10-P-1150SVK
2
Remove crankshaft position sensor (L5)
*BA15.10-P-1001-03A
3
Install in the reverse order
4.1
Reinitialize crankshaft position sensor (L5)
using STAR DIAGNOSIS
If the crankshaft position sensor (L5) was
replaced, a re-initialization must be carried
out with STAR DIAGNOSIS in the "Control
unit adaptations" menu item.
Diagnosis system STAR DIAGNOSIS
*WE58.40-Z-1013-06A
Position sensor
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/
948/960/961/
962/963/965/
966/967/968/
969/980/981/
982/984/986/
992/993
BA15.10-P-1001-03A
Crankshaft position sensor to engine block
Nm
88
Workshop equipment/MB testers
(see Workshop Equipment Manual)
WE58.40-Z-1013-06A
Compact STAR DIAGNOSIS system for passenger cars, order number 6511 1801 00
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Page 2
Page 2083 of 4133
Page 2084 of 4133
AR62.30-P-2300GH
Removing and installing front end cross member
15.4.97
MODEL
163
P62.30-0350-06
1
Upper frame cross member
2
Screws
3
Engine hood control cable
4
Engine hood lock
E1 Left headlamp unit
E2
Right headlamp unit
Operation no. of operation texts or of standard texts and flat rates
Division
Operation
no.
Operation text
P
621300
REPAIRING FRONT REINFORCEMENT BETWEEN WHEELHOUSES
P
621304
REPLACING FRONT LEFT AND CENTER REINFORCEMENT BETWEEN WHEELHOUSES
P
621305
REPLACING FRONT LEFT AND CENTER REINFORCEMENT BETWEEN WHEELHOUSES (WHEN REPLACING
WHEELHOUSE TOGETHER WITH LONGITUDINAL MEMBER)
P
621311
REPLACING FRONT RIGHT AND CENTER REINFORCEMENT BETWEEN WHEELHOUSES
P
621312
REPLACING FRONT RIGHT AND CENTER REINFORCEMENT BETWEEN WHEELHOUSES (WHEN REPLACING
WHEELHOUSE TOGETHER WITH LONGITUDINAL MEMBER)
P
621315
REPLACING FRONT CENTER REINFORCEMENT BETWEEN WHEELHOUSES
P
621320
COMPLETELY REPLACING FRONT REINFORCEMENT BETWEEN WHEELHOUSES
P
621321
COMPLETELY REPLACING FRONT REINFORCEMENT BETWEEN WHEELHOUSES (WHEN REPLACING
WHEELHOUSE TOGETHER WITH LONGITUDINAL MEMBER)
P
882302
REMOVING AND INSTALLING FRONT END CENTER SECTION
Removal, installation
1
Remove headlamp unit on left (E1) and right
(E2)
AR82.10-P-4730GH
2
Remove upper frame cross member (1)
Unscrew screws (2).
3
Remove engine hood control cable (3) from
engine hood lock (4)
For this purpose turn upper frame cross
member over.
Unhook engine hood control cable and pry
catch out of upper frame cross member.
4
Remove upper frame cross member (1)
5
Install in opposite order
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Page 1
Page 2085 of 4133
AR01.30-P-5800MV
Remove/install cylinder head
22.7.98
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
P01.30-2032-06
Shown on model 163.154 with engine 112
1
Air baffle
2
Viscous fan
3
Fan shroud
4
Bolts
5
Air cleaner housing
6
Air intake manifold
7
Resonance unit
8
Poly-V-belt
9
Fender liner
10
Shield
11
Exhaust bracket
P01.30-2033-06
12
Right and left ignition coils
13
Left and right cylinder head covers
14
Intake manifold
15
Camshaft position sensor
16
Coolant line
17
Chain tensioner
18
Oil filter housing
19
Camshaft sprockets
28
Camshaft bearing bridges
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Page 1
Page 2086 of 4133
P01.30-0299-06
20
Bolts cylinder head
!
timing case cover
21
Cylinder head bolts
22
Cylinder head left
23
Cylinder head right
24
Left cylinder head gasket
25
Right cylinder head gasket
26
Dowel sleeves
Remove/Install
Notes on self-locking nuts and bolts
All models
AH00.00-N-0001-01A
External torx set
*001589760900
Torx bit set
*000589011000
Danger!
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 batteries
No fire, sparks, open flames or smoking.
Wear acid-resistant gloves, clothing and
safety glasses. Pour battery acid only into
suitable and appropriately marked containers.
AS54.10-Z-0001-01A
1
Disconnect battery ground cable
Installation:
After connecting, read out
fault memory, encode radio and normalize
power windows.
Vehicles with stationary heater: Set time on
timer for stationary heater
AR54.10-P-0003A
Notes on battery
All models
AH54.10-P-0001-01A
Danger!
Risk of death
caused 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
2
Place the vehicle on lifting platform
AR00.60-P-1000GH
3.1
Remove air guide (1)
Only with engine 113.942
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
4
Drain coolant
Remove coolant hose at bottom on
radiator.
AR20.00-P-1142HA
5
Remove engine cover
6.1
Remove viscous fan (2)
All except model 163.174 /175 with
engine 113.981 /965.
Right-hand thread!
AR20.40-P-5660C
7.1
Remove the fan shroud (3).
Only model 163.154 /157 /172. Unscrew
bolts (4) from bottom of fan shroud
7.2
Remove electric fan
Only model 163.174/ 175.
AR20.40-P-5000GH
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Page 2
Page 2087 of 4133
8
Attach guard plate for radiator/condenser
y
Guard plate for radiator/condenser
Engine 606 in model 124,
Engine 606.961 in model 140,
Engine 112, 113, 604, 605, 611.960 in model
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 639.601/
603 /605 /701 /703 /705 /801 /803 /805
Engine 646.982 in model 639.601/ 603/ 605/
701 /703 /705
WF58.50-P-0110-01A
9
Remove air cleaner housing (5)
10
Remove air intake pipe (6) with resonance
tube (7)
Separate connector of hot film mass air
flow sensor (HFM) for this step and unbolt air
intake pipe at cylinder head cover
The air intake pipe is attached at the rear
at the intake manifold with a plastic plate.
Do not damage the plastic strap.
Engine 112.942/ 970
AR07.07-P-1454A
Engine 113.942/ 965/ 981
AR07.07-P-1454MV
Danger!
Risk of explosion
caused by fuel igniting,
risk of poisoning
caused by inhaling and
swallowing fuel as well as
risk of injury
to
eyes and skin caused by contact with fuel.
No fire, sparks, open flames or smoking.
Pour fuels only into suitable and appropriately
marked containers.
Wear protective clothing when handling fuel.
AS47.00-Z-0001-01A
11
Disconnect fuel line at fuel rail
Release fuel pressure at service valve!
Collect fuel!
Engine 112:
#
*BA07.52-P-1001-01A
Engine 113:
#
*BA07.52-P-1001-01A
Pressure hose
*119589046300
12
Remove right and left ignition coils (12)
AR15.12-P-2003A
13
Remove right and left cylinder head covers (13)
AR01.20-P-5014B
14
Remove the 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.
AR09.20-P-1310A
The intake manifold system must not be
disassembled.
Remove intake manifold with fuel distributor
15.1
Remove camshaft position sensor (15)
Only necessary if the right cylinder head is
removed.
AR15.10-P-2000A
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Page 3
Page 2088 of 4133
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
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Page 4
Page 2089 of 4133
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
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Page 2090 of 4133
Fig., see
AR01.30-P-5800-03BAR01.30-P-5800-03B
Cylinder head
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/
948/960/961/
962/963/965/
966/967/968/
969/980/981/
982/984/986/
992
BA01.30-P-1001-01D
Bolt of cylinder head to
crankcase
1st stageNm
1010
2nd stage
Nm
3030
3rd stage
(°
9090
4th stage
(°
9090
Crankcase, timing case cover, end cover
Number
Designation
Engine
112
except
112.951
Engine
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/992
BA01.40-P-1002-01C
Bolt, cylinder head to timing case cover
Nm
2020
Camshaft
Number
Designation
Engine
112
except 112.951
Engine
113.940/941/
942/943/944/
948/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/992
BA05.20-P-1001-01B
Bolt of camshaft sprocket
M12 x 45
1st stageNm
5050
2nd stage
(°
9090
Fuel rail
Number
Designation
Engine
112 except
112.945/951/
960/961
BA07.52-P-1001-01A
Fuel feed line to fuel rail
Nm
38
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Page 6