ECU MERCEDES-BENZ ML350 1997 Complete Repair Manual

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

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 40 © 2006 Mitchell Repair Information Company, LLC.

ENGINE 275 in MODELS 215, 220, 230
Shows model 202
Fig. 39: Identifying Cranking Engine With Starter
- Shows Model 202
Remove/install

Danger!
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
1Switch off ignition
Vehicles with Keyless-Go Code
889: press Start/Stop button
repeatedly until ignition is switched
off.

Model 129AR01.10-P-
0010-01AV
Model 163.1AR01.10-P-
0010-01V
Model 170AR01.10-P-
0010-01CA
Model 210 with engine 112 up to
production date 1.3.1997AR01.10-P-
0010-01B
Model 210 with engine 112 from
production date 2.3.1997,AR01.10-P-
0010-01E
Models 202, 208 with engine 112,
Models 210, 202, 208 with engine

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 47 © 2006 Mitchell Repair Information Company, LLC.

two bottom bolts at transmission bell.
*BA27.40-P-
1008-01A
34Unscrew nuts (18)
for engine mount Before unscrewing left engine mount, press
oil line of power stee ring out of fixture.

*BA22.10-P-
1001-01L
35Unscrew oil filler
pipe (automatic
transmission) at right
cylinder head cover
36Attach engine hoist
to engine lifting eyes Use engine removal device!
*WE58.40-Z-
1012-11A
*WE58.40-Z-
1020-11A
37Raise engine Ensure that engine and its detachable
components are not lying against the body!
38Insert transmission
support (22) The transmission support is inserted onto
crossmember and into recess of transmission.
The transmission support prevents the
torque converter being pulled out. At the same
time, the transmission is fixed in place with the
transmission support when installing the
engine.
*WE58.40-Z-
1036-11A
?
*WE58.40-Z-
1036-11A
39Unscrew two top
bolts (engine 112) or
two bottom bolts
(engine 113) of
transmission bell Ensure that engine does not hit at front
against radiator or condenser damaging them
40Pull engine out
toward front and lift
out
41Install in the reverse
order
42Inspect cooling
system for leaks If fitting new cylinder head gaskets, bring
engine to operating temperature beforehand.AR20.00-P-
1010HA

43Risk of accident
caused by vehicle
starting off by itself Secure vehicle to prev ent it from moving by
itself.
Wear closed and snug-fitting work clothes. AS00.00-Z-0005-
01A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 57 © 2006 Mitchell Repair Information Company, LLC.

Crankcase ventilation, cylinder head cover
Fuel rail
railvehicles with a non-
flexible fuel line.
Release fuel pressure
through service valve!
Pressure hoseFig. 52
*BA07.52-P-1001-01A
*BA07.52-P-1001-01A
11Remove cylinder head
covers (4, 5) *BA01.20-P-1001-01E
Installation:
Ensure cylinder head
cover gasket is correctly
installed.AR01.20-P-5014-01B
12Install in the reverse order

13Risk 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
engine
Run engine and inspect for
leaksSecure 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
NumberDesignation
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/ 973/975/976Engines 113.940/
941/942/943/ 944/948/960/
961/962/963/ 964/965/966/
967/968/969/ 971/980/981/
982/984/986/ 992/995
Engine
113.987/988/
990/991/993
BA01.20-
P-1001-
01EScrew of
cylinder
head cover
Nm8108
BA01.20-
P-1002-
01E
Bolt of
ignition
coils to
cylinder
head cover
Nm888
NumberDesignationEngine 112 except
112.945/951/ 960/961Engine
112.945Engine
112.960/ 976Engine
112.960/ 961
AMG

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 64 © 2006 Mitchell Repair Information Company, LLC.

Double open-ended wrenchFig. 57
5Pull off vent hoses on
right connector (6) and on
left connector (7) of the
right cylinder head cover
(2) and left cylinder head
cover (3)
6Pull off engine vent hose
on left connector (8) of
left cylinder head cover
(3)
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, date service.AS47.00-Z-0001-01A
7.1Disconnect fuel line at
fuel rail Only in case of vehicles with
a non-flexible fuel line and.
Models 211.061/065/
070/076/276,
Model 215.374
Model 220.074
Model 230.474/475
Release fuel pr essure through
service valve!
Engine 112*BA07.52-P-1001-01A
Engine 113*BA07.52-P-1001-01A
Pressure hoseFig. 52
8Remove right cylinder
head cover (2) and left
cylinder head cover (3) Installation: Check cylinder
head covers for leaks, see: ?
Ensure cylinder head cover
gasket is correctly installed.AR01.20-P-5014-01B
*BA01.20-P-1001-01E
9Install in the reverse order

10Risk 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 Secure 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

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 68 © 2006 Mitchell Repair Information Company, LLC.

Cylinder head/cyl inder head bolts
Loctite 5900 sealant.1013-01A
34Install in the reverse
order

35Risk 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 engine
Run engine and
inspect for leaksSecure vehicle to prev ent it from moving by
itself.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.AS00.00-Z-0005-
01A
36Inspect cooling
system for leaks Warm up engine to operating temperature
and then inspect cooling system or leaks.AR20.00-P-
1010HA
37Read fault memory,
erase. 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.
NumberDesignation
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/
973/975/976Engines
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/987/988/
990/991/992/
993/995
BE01.30-P-
1001-04BCylinder head
boltThread diameterM1111
Length (L) when
newmm141.5141.5
Length (L)mm< or = 144.5< or = 144.5
See pictureAR01.30-P-
5800-03B
AR01.30-P-
5800-03B

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 90 © 2006 Mitchell Repair Information Company, LLC.

1002-01M
*BA20.10-P-
1003-01C
*BA20.10-P-
1003-01M
*BA20.10-P-
1004-01C
*BA20.10-P-
1004-01M
*BA46.30-P-
1010-01A
*BA46.30-P-
1010-01C
Clean sealing surfaces, appl y sealant only to specified
surfaces in form of bead with height and width of 2.0 mm
± 0.5 mm. The sealant must be applied within 10 minutes!
The silicone bead must not be spread!*BR00.45-Z-
1013-01A
Notes on
application of
sealant to timing
case cover AH01.40-P-
1000-01B
Installation: If sealing compound enters the oil ducts,
this is carried by the oil flow and will clog the oil supply
bores.
Do not damage cylinder head gasket.
Replace seals on ti ming case (19).
Replace front crankshaft radial sealing ring: ?

Engine 112 in model 129
Engine 113 in model 129
Engine 113 in model 163, 202, 208, 210AR03.20-P-
3000B
Engine 112 in models 170, 202, 208, 210, 220
Engine 113 in model 215, 220
Engine 113.981 in model 163.174
Engine 113.963 in models 230.475
Engine 113.992 in model 230.474AR03.20-P-
3000BA
32Install in the
reverse order

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
Secure 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

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 105 © 2006 Mitchell Repair Information Company, LLC.

Crankcase, timing case cover, end cover
Crankcase, timing case cover, end cover
crankshaft must be free of
oil and grease, in order to
guarantee a proper
function.
Install crankshaft radial
seal (3)AR03.20-P-3063-01B
Fig. 97
Installation: Pay
attention to fitted sleeves
(2) when pressing on end
cover!
Notes on application of
sealant to end cover with
radial shaft seal AH01.40-P-1000-06A
Sealant*BR00.45-Z-1013-01A
4Install in the reverse order

Risk of accident caused by
vehicle starting off by itsel
f
when engine is running.
Risk of injury caused by
contusions and burns
during starting procedure
or when working near the
engine as it is running

Secure vehicle to prevent
it from moving by itself.
Wear closed and snug-
fitting work clothes.
Do not touch hot or
rotating parts.
AS00.00-Z-0005-01A
5Carry out engine test run Before installing
transmission, inspect for
oil leaks
NumberDesignation
Engine 112 except
112.951/ 976
BA01.40-P-1004-
01CEnd cover screwThread not pre-
tappedNm14
Thread pre-tapped10
Engine
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
Engine 113.987/
988/990/

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 114 © 2006 Mitchell Repair Information Company, LLC.

Crankcase ventilation, cylinder head cover
Notes on application of
sealant to oil panEngine
113.941/942/960/962/965/981.AH01.45-P-0001-01E
*BA01.45-P-1001-01B
*BR00.45-Z-1013-
01A
5Install in the reverse
order
6Read out fault memory
and eraseStored 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.

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
engine
Secure 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
7Run engine and inspect
for leaks
NumberDesignation
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/
973/975/976
Engine 113.940/
941/942/943/
944/948/960/
961/962/963/
964/965/966/
967/968/969/
971/980/981/
982/984/986/
992/995
Engine
113.987/988/
990/991/993
BA01.20-P-
1001-01EScrew of
cylinder head
coverNm8108

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 132 © 2006 Mitchell Repair Information Company, LLC.

AR54.21-P-1200GH
Remove/install Extended-Activity-Module (EAM)
11.7.00

MODEL
163.136 /154 /172 #A as of 145273,

163.136 /154 /172 #X as of 708319,

163.113 /128 /157 /174 /175

P54.21-2098-06

1
Lock

2
Extended-Activity-Module (EAM)


Remove/install

1.1
Read out coding of Extended-Activity-Module

(EAM)

Only

when replacing the EAM and if it can

still be read out using STAR DIAGNOSIS.

2
Remove cover under the instrument panel (left)

AR68.10-P-1500GH

3
Loosen the lock (1) which secures the EAM in

the bracket

4
Remove the Extended-Activity-Module (EAM)

(2) downwards out of the bracket

5
Disconnect connectors

6
Remove drive authorization module

AR54.21-P-1300GH

7
Install in the reverse order

8.1
Code the EAM

Only

when installing a new EAM.

AR54.21-P-1200-01GH

9
Turn ignition key into position 1 and wait for

40 seconds before first starting the engine.

Copyright DaimlerChrysler AG 05.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
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