MERCEDES-BENZ ML350 1997 Complete Repair Manual

Compression pressure
9Carry out test procedure
at the remaining
cylinders in the same
way
10Compare measurements
obtained with the
specified pressuresCompression installation tolerance
or new value*BE01.00-P-1001-
01D
Compression pressure wear limit
or limit value*BE01.00-P-1002-
01D
Compression pressure permissible
difference betw een individual
cylinders*BE01.00-P-1003-
01D
If the pressure is below the
minimum compression pressure or
if the permissible difference
between individual cylinders is
exceeded: ?
Inspect cylinders for leaksAR01.00-P-1300HV
11Install in the reverse
order
NumberDesignation
Engines 112.910/
911/912/920/921/923/940/941/
942/943/960, 113.940/942/
943/961/963 low compression
Engines 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 compression
Engine
113.944
Standard
compression
BE01.00-
P-1001-
01DCompression
installation
tolerance or
new value
bar10...1212 to 1411 to 13
BE01.00-
P-1002-
01DCompression
pressure wear
limit or limit
value
bar8.09.010.0
BE01.00-
P-1003-
01D
Compression
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 35 © 2006 Mitchell Repair Information Company, LLC.

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

Repair materials
FIRING ORDER - AR01.00-P-1300-03HA
Fig. 22: Identifying Firing Order (Engines 111, 601, 604, 611, 271)
NumberDesignation
Engines 113.980/
981/982/984 standard
compressionEngine
113.987/988/
990/991/993Engine
113.992/995
BE01.00-P-
1001-01DCompression installation
tolerance or new valuebar11 to 139 to 1211 to 13
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
NumberDesignationOrder number
BR00.45-Z-1002-06ALubricantA 000 989 01 60

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 36 © 2006 Mitchell Repair Information Company, LLC.

Fig. 23: Identifying Firing Order (Engines 602, 605)
Fig. 24: Identifying Firing Order (Engines 603, 606)

Fig. 25: Identifying Firing Order (Engine 112)

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 37 © 2006 Mitchell Repair Information Company, LLC.

Fig. 26: Identifying Firing Order (Engine 113)
Fig. 27: Identifying Firing Order (Engine 273)

Fig. 28: Identifying Firing Order (Engine 272)

ENGINES 137,275,285

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 38 © 2006 Mitchell Repair Information Company, LLC.

Fig. 29: Identifying Firing Order (Engines 137,275,285)
INSPECT CYLINDERS FO R LEAKS - AR01.00-P-1300HV
ENGINE 112,137,285
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 463.243/246
ENGINE 113 (except 113.995) 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 39 © 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

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.

Model 203, 170 with
Engine 112.
Model 163 with Engine
112, 113.AP15.10-P-1580GH
Model 215, 220 with
Engine 137.AP15.10-P-1580L
Model 230.474/475, 211,
220 with Engine 112, 113AP15.10-P-1580AB
Model 240 with Engine
285.AP15.10-P-1580H
Model 463 with Engine
112,113AP15.10-P-1580GA
4Position piston of
cylinder to be tested to
ignition TDC Crank the engine at the
center bolt of the crankshaft
in the direction of rotation
of engine.
5Connect cylinder leak
tester (04) Calibrate cylinder
leakage tester (04) and
screw the connection hose
into the spark plug bore
Cylinder leak tester
*WH58.30-Z-1015-05A
6Remove the oil filler cap
(3)
Inspection
7Apply compressed air to
the cylinder, read off
pressure loss on the
cylinder leakage tester
(04) and determine the
cause if there is an
increased pressure lossCylinder leaktightness
permissible loss total
indication*BE01.00-P-1001-02Z
Cylinder leaktightness
permissible losses at valves
and cylinder head gasket*BE01.00-P-1002-02Z
Cylinder leaktightness
permissible losses at pistons
and piston rings*BE01.00-P-1003-02Z
If the crankshaft rotates: ?
Engine 112, 113, 137.
Install retaining lock for
crankshaft
AR03.30-P-5000B
Engine 285.
Lock crankshaft with
counterholder.
Retainer
Fig. 31
8Conduct the test of the
other cylinders in the
firing order of the engine AR01.00-P-1300-03HA
9Install in the reverse

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 41 © 2006 Mitchell Repair Information Company, LLC.

Cylinder leakage
Fig. 31: Identifying Counterholder (112 589 00 40 00)

Commercially available tools
DISCONNECTING AND CONN ECTING ENGINE WIRING HARNESS - AR01.00-P-2410V
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
Shown on Model 163.154
order
NumberDesignationAll Engines
BE01.00-P-1001-02ZCylinder leakage
permissible loss total
indication%< or = 25
BE01.00-P-1002-02ZCylinder leakage
permissible losses at valves
and cylinder head gasket%< or = 10
BE01.00-P-1003-02ZCylinder leakage
permissible losses at
pistons and piston rings%< or = 20
NumberDesignation
WH58.30-Z-1015-05ACylinder leakage testing unit

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 42 © 2006 Mitchell Repair Information Company, LLC.

Fig. 32: Identifying Engine Wiring Harness - Shown On Model 163.154
Fig. 33: Identifying Ground Strap Of Engine/Body
- Shown On Model 163.154
Shown on Model 163.154

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 43 © 2006 Mitchell Repair Information Company, LLC.

Fig. 34: Identifying Motor Electronics Control Module - Shown On Model 163.154
Shown on Model 163.154
Fig. 35: Identifying Connector Of Engine Compartment And Engine
- Shown On Model 163.154
Shown on Model 163.154

Remove/Install
1Disconnect ground of battery
(W10)
Installation: After connecting, read out fault memory,
encode radio and normalize power windows.
Vehicles with stationary he ater: adjust time display on
stationary heater.
AR54.10-
P-0003A
2Remove cover of fuse module
(1)
3Remove cover of relay module
(2)
Remove electronics ground of

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 44 © 2006 Mitchell Repair Information Company, LLC.