MERCEDES-BENZ ML350 1997 Complete Repair Manual

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
me
Saturday, October 02, 2010 3:17:56 PMPage 25 © 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.

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
me
Saturday, October 02, 2010 3:17:56 PMPage 27 © 2006 Mitchell Repair Information Company, LLC.

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

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 29 © 2006 Mitchell Repair Information Company, LLC.

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

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 30 © 2006 Mitchell Repair Information Company, LLC.

Compression pressure
least 8 revolutions.
10Carry out test procedure
at the remaining cylinders
in the same way
11Compare measurements
obtained with the
specified pressures *BE01.00-P-1001-01D
*BE01.00
-P-1002-01D
*BE01.00
-P-1003-01D
If necessary, if the
pressure is below the
minimum compression
pressure or if permissible
difference between
individual cylinders is
exceeded:?
Inspect cylinders for
leaksAR01.00-P-1300HV
12Install in the reverse
order
NumberDesignationEngines 112.910/
911/912/920/921/923/940/941/
942/943/960, 113.940/942/
943/961/963 low compressionEngines 112.910/
911/920/921/
922/923/940/
941/942/943/
944/945/946/947,
113.940/941/942/
943/960/961/962/
963/965/968/969
normal
compressionEngine
113.944
Standard
compression
BE01.00-
P-1001-
01DCompression
installation
tolerance or
new valuebar10...1212 to 1411 to 13
BE01.00-
P-1002-
01DCompression
pressure wear
limit or limit
valuebar8.09.010.0
BE01.00-
P-1003-
01DCompression
pressure
permissible
difference
between
individual
cylindersbar1.51.51.5

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 31 © 2006 Mitchell Repair Information Company, LLC.

Compression pressure
Fig. 19: Identifying Compression Recorder (001 589 76 21 00)

TESTING COMPRESSION PR ESSURE - AR01.00-P-1200V
ENGINE 112
Air filter motor page arranged
ENGINE 113 (except 113.995) in MODEL 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230 Air filter
motor page arranged
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODEL 463.243
NumberDesignation
Engines 113.980/
981/982/984 Standard
compressionEngine
113.992/995Engine
113.992/995
990/991/993
BE01.00-P-
1001-01DCompression installation
tolerance or new valuebar11 to 1311 to 139 to 12
BE01.00-P-
1002-01DCompression pressure wear
limit or limit valuebar10.08.08.0
BE01.00-P-
1003-01DCompression pressure
permissible difference
between individual cylinders
bar1.51.51.5

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 32 © 2006 Mitchell Repair Information Company, LLC.

Fig. 20: 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
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
1Bring engine to
operating temperature
(approx. 80°C)Test compression pressure only
when engine is at normal
operating temperature.
2Remove air filter
housingAll except model 203.065/265,
170.466: ?
Detach the air filter housing
from the rubber retainers at the
cylinder head covers vertically
upward.
Models 211, 220, 230.475:
Unclip engine front end cover.
Installation: Rub the retaining
rubbers on the cylinder head

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 33 © 2006 Mitchell Repair Information Company, LLC.

covers and sealing ring of the hot
film air mass sensor in the air
filter housing with lubricant.
Models 230.474, 203.065/265,
170.466AR09.10-P-1150SVK
Lubricant
*BR00.45
-Z-1002-
06A
3Remove spark plugs Remove only one spark plug
per cylinder: ?
Models
463.209 /232 /233 /244 /245 /250
with engine 112.945.AP15.10-P-1580GA
Models
463.206 /240 /241 /247 /248 /
249 /254 with Engine 113.962.
Models 463.243 /246 with Engine
113.982
Models 211, 220, 230.474/475AP15.10-P-1580AB
Models 210, 208, 203, 202, 170,
129AP15.10-P-1580A
4.1Remove key from
electronic ignition switch
(EIS)Models 211,230.474/475
Vehicles with code (889)
Keyless Go: Press the start/stop
button repeatedly until the ignition
is switched off.

5Crank engine with
starter. Do not crank engine at steering
lock but use contact switch of the
compression recorder.
In order to remove the
combustion residue from the
cylinders, crank the engine for
about 5 seconds with the starter.
All except model 203AR01.10-P-0110V
Model 203AR01.10-P-0110PV
Checking
6Insert compression tester
into spark plug bore Compression recorderFig. 21
7Open throttle valveExcept models 211, 230.474/475
8Crank engine with
starter. Do not crank engine at steering
lock but use contact switch of the
compression recorder.
All except model 203AR01.10-P-0110V
Model 203AR01.10-P-0110PV

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 34 © 2006 Mitchell Repair Information Company, LLC.