MERCEDES-BENZ ML350 1997 Complete Repair Manual

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.

Engine 112 in model 208,
Engine 112, 113, 612.963, 628.963 in model
163,
Engines 112.923/943, 113.961 in model 129,
Engines 137, 275 in models 215, 220,
Engines 613.960, 628.960 in model 220,
Engine 113.992 in model 230.474,
Engine 271 in MODELS 209, 203,
Engine 285.950 in models 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
9Remove air filter
housing (5).
10Remove air intake
pipe (6) with
resonance body (7) For this step separate connector of hot film
mass air flow sensor (HFM) and unscrew air
intake pipe at cylinder head cover.
The air intake pipe is attached to the rear of
the intake manifold with a plastic strap.
Do not damage the plastic strap.
Engines 112.942/970AR07.07-P-
1454A
Engines 113.942/965/981AR07.07-P-
1454MV
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
11Disconnect fuel line
at fuel rail Release fuel pressure at service valve.
Collect fuel!
Engine 112: ?
*BA07.52-P-
1001-01A
Engine 113: ?

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Saturday, October 02, 2010 3:17:57 PMPage 86 © 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
me
Saturday, October 02, 2010 3:17:57 PMPage 87 © 2006 Mitchell Repair Information Company, LLC.

TDC on first cylinder Rotate engine at cra nkshaft in direction of
rotation until 40° marking on belt pulley/
vibration damper is al igned with marking on
timing case cover.
The grooves on the camshafts must be pointing
toward the inner V.
23Lock camshafts with
locating plate Locating plateFig. 85
Locating plateFig. 86
24Remove 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
25.1Remove oil filter
housing (18) with
oil/water heat
exchangerEngine 113.942.AR18.20-P-
3471B
Engines 113.965/981.AR18.20-P-
3471BA
26Remove camshaft
sprockets (19) If the camshaft sprockets are removed, the
engine must no longer be cranked otherwise the
timing chain might jam.
Engines 113.942 /965/981: ?
Tie timing chain tight on both camshaft
sprockets with cable straps.
Engine 112.942 /970: ?
Right-hand camshaft sprocket:
Tie timing chain tight on camshaft sprocket
with cable 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 positi on of camshafts.
If necessary after checking: ?AR05.10-P-
6858V
Set the basic position of camshafts.AR05.20-P-
6020AU
Open-end wrenchFig. 87
Insertion toolFig. 88
Torque wrenchFig. 92
*BA05.20-P-
1001-01B
27Remove camshaft
bearing bridges (28) Observe slackening and tightening pattern!AR05.20-P-
7103AU

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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28Unscrew bolts,
cylinder head -->
timing case cover
(20) *BA01.40-P-
1002-01C
29Slacken cylinder
head bolts (21) in
stages, unscrew Slacken cylinder head bolts according to
loosening pattern only once the engine has
cooled down, in order to avoid that the cylinder
head warps.AR01.30-P-5800-
09B
Installation: Observe tightening pattern and
tightening instructions of cylinder head bolts.
Oil thread and head cont act surface of cylinder
head bolts.AR01.30-P-5800-
07B
Screwdriver insertFig. 72
Screwdriver insertFig. 73
*BA01.30-P-
1001-01D
30Remove cylinder
head Installation: On Engine 112/113 observe
porous points in the le ft 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, 113AH01.30-P-1000-
04VA
The sealant must be applied within 10
minutes.
Loctite 5900 sealant.*BR00.45-Z-
1013-01A
31
Inspect version of
cylinder head gasket
Information for
assigning the
cylinder head gasketsAssignment of cylinder head gasket
Engine 112, 113AH01.30-P-1000-
06V
32Check cylinder head
bolts (21) AR01.30-P-5800-
03B
*BE01.30
-P-
1001-04B
33Clean sealing
surfaces, check for
cracks, shrink holes
and flatness, clean
bolt 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 se ries production. Silicone
sealant is applied in the gasket area when
carrying out repairs only if shrink holes are
present.
The sealant must be applied within 10
minutes.
*BR00.45-Z-

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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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.

Cylinder head
Crankcase, timing case cover, end cover
Camshaft
Camshaft
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
Engines
113.940/941/
942/943/944/
948/960/961/
962/963/965/
966/967/968/
969/971/980/
981/982/984/
986
BA01.30-P-
1001-01DBolt, cylinder
head to
crankcaseStage 1Nm1010
Stage 2Nm3030
Stage 3Angle °9090
Stage 4Angle °9090
NumberDesignation
Engine 112
except 112.951/
976
Engine 112.951/
976
Engines
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/992/995
BA01.40-P-
1002-01CBolt, cylinder
head to timing
case coverNm202020
NumberDesignation
Engine 112
except
112.951/976
Engine
112.951/ 976
BA05.20-P-
1001-01BBolt, camshaft
sprocketM12 x 45Stage 1Nm5050
Stage 2Angle °9090
Engines
113.940/941/
942/943/944/
948/961/962/

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 91 © 2006 Mitchell Repair Information Company, LLC.

Fuel rail
Fuel rail
Exhaust manifold
NumberDesignation
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/992/995
BA05.20-P-
1001-01BBolt, camshaft
sprocketM12 x 45Stage 1Nm50
Stage 2Angle °90
NumberDesignation
Engine 112 except
112.945/951/ 960/961
BA07.52-P-1001-01ADisconnect fuel feed line
at fuel railNm38
NumberDesignation
Engines
113.940/941/942/943/944/945/946/948/960/961/ 962/963/964/965/966/967/968/969/9
7
BA07.52-
P-1001-
01ADisconnect
fuel feed
line at fuel
railNm38
NumberDesignation
Engine
112
except
112.951/
976
Engines 113.940/941/ 942/ 943/944/ 945/946/948/
960/961/962/963/964/965/966/967/968/ 969/971/980/981/982/984/986/992/
9
BA14.10-
P-1002-
01BFlange
connection,
exhaust
manifold
and front
exhaust
pipesNm2020

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Fig. 83: Identifying External Torx Set (001 589 76 09 00)
Fig. 84: Identifying Torx Bit Set (000 589 01 10 00)
Fig. 85: Identifying Locating Plate (112 589 00 32 00)

Fig. 86: Identifying Locating Plate (112 589 01 32 00)

Fig. 87: Identifying Open End Wrench (112 589 00 01 00)

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Fig. 88: Identifying Insertion Tool (112 589 01 03 00)
Fig. 89: Identifying Screwdr iver Insert (000 589 03 10 00)

Fig. 90: Identifying Screwdr iver Insert (000 589 04 10 00)

Fig. 91: Identifying Pressure Hose (119 589 04 63 00)

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 94 © 2006 Mitchell Repair Information Company, LLC.