MERCEDES-BENZ ML350 1997 Complete Repair Manual

Fig. 92: Identifying Torque Wrench (001 589 72 21 00)
Commercially available tools
Repair materials
SCREW DIAGRAM FOR TIMING CASE COVER - AR01.40-P-8000-01B
Assignment of bolts for timing case cover
Apply sealant at the bolts marked (arrows).
NumberDesignation
WH58.30-Z-1001-06A6 mm socket hexagon on flexible shaft for hose clamps with worm drive
WH58.30-Z-1002-06A7 mm socket hexagon on flexible shaft for hose clamps with worm drive
NumberDesignationOrder number
BR00.45-Z-1013-01ASealantA 003 989 98 20

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 95 © 2006 Mitchell Repair Information Company, LLC.

Fig. 93: Identifying Timing Case C over Bolts & Bolts Needing Sealant
REMOVE/INSTALL TIMING CA SE COVER - AR01.40-P-8000B
ENGINE 112 in model 129, 163, 170, 202, 208, 210.061 /063 /065 /261 /263 /265 /663, 220
ENGINE 113 (except 113.991) in MODELS 129,163, 202, 208, 210, 215, 220, 230.475 /474 (except,
215.374,220.074/174)
Shown on engine 112 in model 210

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 96 © 2006 Mitchell Repair Information Company, LLC.

Fig. 94: Identifying Timing Case Cover Remove/Install Components - Shown On Engine 112 In Model
210
Modification notes
1.9.04
Value
changed from
10 Nm to 14
NmValue in row 1003 changed for engine
112.910/911/912/913/914/915/916/917/
920/921/922/923/940/941/942/943/944/
945/946/947/949/953/954/955/960/961 / 970/972/973/975
*BA20.10-P-
1003-01M
Value
changed from
10 Nm to 14
NmValue in series 1004 changed for engine
112.910/911/912/913/914/915/916/917/
920/921/922/923/940/941/942/943/944/
945/946/947/949/953/954/955/960/961 / 970/972/973/975
*BA20.10-P-
1004-01M
Remove/install
Risk of explosion
caused by
oxyhydrogen gas.
Risk of No fire, sparks, open fl ames or smoking. Wear acid-
resistant gloves, clothing and safety glasses. Only pour
battery acid into suitable and appropriately marked
containers.AS54.10-Z-
0001-01A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 97 © 2006 Mitchell Repair Information Company, LLC.

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
1Disconnect
battery ground
cableModels 129, 163, 170, 202, 208, 210AR54.10-P-
0003A
Model 215, 220AR54.10-P-
0003I
Model 230.474 /475AR54.10-P-
0003R
Notes on batteryAll modelsAH54.10-P-
0001-01A
2Remove engine
compartment
panelingModel 129,202,208,210AR61.20-P-
1105AB
Models 163.172/174/175AR61.20-P-
1105GH
Model 170AR61.20-P-
1105A
Model 215, 220AR61.20-P-
1105M
Model 230AR61.20-P-
1105R
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, protec tive clothing and safety
glasses.
AS20.00-Z-
0001-01A
3Drain coolant
from radiatorEngine 112, 113 in models 129, 163, 202, 208,
210,215,220AR20.00-P-
1142HA
Engine 113.963 in models 230.475
Engine 112.960 in model 170.466AR20.00-P-
1142RVK
Engine 113.992 in model 230.474

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 98 © 2006 Mitchell Repair Information Company, LLC.

Engine 113.963 in models 230.475
Engine 112.947 in model 170.465AR20.00-P-
1142SV
Engine 112.960 in model 170.466
4.1Remove engine
cover with
integrated air
filterModel 129
Type 170.465
Model 202.033/ 093
Model 208.370 /374 /470
Model 220
Type 230.475
Unclip covering on front si de of engine. Remove the
engine cover with integrated air filter from the cylinder
head covers vertically in the upward direction.
4.2Remove air filterEngine 112.960 in model 170.466
Engine 113.992 in model 230.474AR09.10-P-
1150SVK
5.1Remove viscous
fan clutch (1)Engine 112 in model 210, 202, 129
Engine 112 in model 163.154 /157
Engine 113 in model 210, 208, 202, 129
Engine 113 in model 163.172
Right-hand thread!AR20.40-P-
5660C
6.1Remove heater
unitModel 170.465 with retrofitted stationary heater Thermo
Top C.AR83.70-P-
5302NB
7.1Remove fan
shroud (3)Engine 113 in model 215
Engine 112 in model 220
Engine 113 in model 220
Engine 113.963 in models 230.475
Engine 113.992 in model 230.474AR20.40-P-
6800AB
7.2Remove electric
fan Model 163 unscrew bolts at bottom of fan shroud.
Engine 113.965 in model 163.175AR20.40-P-
5000GH
Engine 113.981 in model 163.174
Engine 112.947 in model 170.465AR20.40-P-
5000SV
Engine 112.960 in model 170.466
8Attach guard
plate for radiator /
condenser
Guard plate for
radiator /
condenserEngines 112, 113, 137, 271, 272, 275, 285, 602, 604, 605,
606, 611, 612, 613, 628, 648WF58.50-P-
0110-01A
9.1Remove poly-V-
belt for
superchargerEngine 113.992 in model 230.474AR13.21-P-
1202RVK
9.2Remove poly V-
belt (2)ENGINE 112 in models 129, 163AR13.22-P-
1202B

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 99 © 2006 Mitchell Repair Information Company, LLC.

Engine 113 in model 129, 202, 208, 210
Engine 113 (except 113.965 /981) in model 163
Engine 112 in model 202, 208, 210AR13.22-P-
1202BA
Engine 112 in model 220
Engine 113 in model 215.373 /375
Engine 113 in models
220.070 /073 /075 /083 /084 /170 /173 /175 /183 /184 /875
Engine 113.965 in model 163.175
Engine 113.981 in model 163.174
Engine 113.984 in model 208.374 /474
Engine 113.963 in models 230.475AR13.22-P-
1202R
Engine 113.992 in model 230.474
Engine 112.947 in model 170.465AR13.22-P-
1202SV
10Remove cylinder
head covers (6)Engine 112, 113 air filter located on vehicle sideAR01.20-P-
5014B
Engine 112, 113 air filter located on engine sideAR01.20-P-
5014BV
11Detach coolant
line (17, 18) from
coolant pump
(12).
12Detach coolant
line (16) at
thermostat
housing (13).
13Dismount
refrigerant
compressor (A9) Place to the side with lines connected.

*BA83.55-P-
1001-01A
14.1Remove
alternator (G2)Engine 113.963 in models 230.475
Engine 113.992 in model 230.474AR15.40-P-
5032R
15.1Remove ATF line
bracket (23).Model 230
15.2Detach ATF line
from front axle
carrierModel 163
16Remove oil pan
bottom section (9)Engine 112.942 in model 163.154AR01.45-P-
7555V
Engine 112.970 in model 163.157
Engine 113.942 in model 163.172
Engine 113.965 in model 163.175AR01.45-P-
7555VE

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 100 © 2006 Mitchell Repair Information Company, LLC.

Engine 113.981 in model 163.174
Engine 112 in models 210, 208, 202, 170, 129, engine 113
in model 210, 208, 202, 129AR01.45-P-
7555VA
Engine 112 (except 112.975) in model 220
Engine 113 (except 113.948 /966) in model 220
Engine 112.975 in model 220AR01.45-P-
7555IW
Engines 113.948/ 966 in model 220
Engine 113.963 in models 230.475AR01.45-P-
7555R
Engine 113.992 in model 230.474
17.1Remove oil pumpEngine 112, 113 in model 163AR18.10-P-
6020B
18.1Remove oil pan
(22)Engine 112, 113 in model 129AR01.45-P-
7500FD
Engine 112.942 in model 163.154AR01.45-P-
7500FB
Engine 112.970 in model 163.157
Engine 113.942 in model 163.172
Engine 113.965 in model 163.175
Engine 113.981 in model 163.174
Engine 112.947 in model 170.465 with transmission 722.6AR01.45-P-
7500SV
Engine 112.960 in model 170.466 with transmission 722.6
Engine 112 in model 202, 208AR01.45-P-
7500FC
Engine 113 in model 208
Engine 113.944 in model 202.033 /093
Engine 112 in models 210.06 /26 /66AR01.45-P-
7500F
Engine 113 in model 210
Engine 112 (except 112.975) in model 220AR01.45-P-
7500I
Engine 113 (except 113.948 /966) in model 220
Engine 112.975 in model 220AR01.45-P-
7500IW
Engines 113.948/ 966 in model 220
Engine 113.963 in models 230.475AR01.45-P-
7500R
Engine 113.992 in model 230.474
19.1Remove
tensioning device
for compressor
poly-V-beltEngine 113.992 in model 230.474AR13.25-P-
3217RVK

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 101 © 2006 Mitchell Repair Information Company, LLC.

20Remove poly-V-
belt tensioning
device (5)Engine 112 in models 129, 163AR13.25-P-
3200B
Engine 113 in model 129, 202, 208, 210
Engine 113 (except 113.965 /981) in model 163
Models 129, 202, 210 with manual transmission.
Unscrew damper of belt te nsioning device at coolant
pump.
Engine 113.963 in models 230.475AR13.25-P-
3200R
Engine 113.992 in model 230.474
21Remove vibration
damper (4)Engine 112 in models 129, 163AR03.30-P-
1600C
Engine 113 in models 129, 202.033 /093
Engine 113 (except 113.981) in model 163
Engine 113 (except 113.980) in model 210
Engine 113 (except 113.984) in model 208
Engine 112.947 in model 170AR03.30-P-
1600CA
Engine 112 in model 202, 208, 210, 220
Engine 113.981 in model 163.174
Engine 113 (except 113.991) in models 215, 220.
Engine 113.963 in models 230.475
Engine 113.992 in model 230.474AR03.30-P-
1600RVK
22Remove chain
tensioner (14)ENGINE 112 in models 129, 163
Engine 113 (except 113.965 /981) in model 163
Engine 113 in model 129, 202, 208, 210AR05.10-P-
7800C
Engine 112 in model 170, 202, 208, 210
Engine 113 in model 163.174 /175AR05.10-P-
7800CA
Engine 112 in model 220
Engine 113 in model 215.373 /375
Engine 113 in models
220.070 /073 /075 /083 /084 /170 /173 /175 /183 /184 /875
Engine 113 in model 230.474 /475AR05.10-P-
7800AM
23.1Remove oil filter
housingEngine 113.992 in model 230.474AR18.20-P-
3471RKV
23.2Remove oil filter
housing with
oil/water heat
exchanger (7)Engine 112 in models 170, 202, 208, 210, 220AR18.20-P-
3471BA
Engine 113 in model 220
Engine 113.963 in models 230.475
Engine 113.965 in model 163.175
Engine 113.981 in model 163.174
Engine 112 in models 129, 163AR18.20-P-
3471B

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 102 © 2006 Mitchell Repair Information Company, LLC.

Engine 113 in model 129, 202, 208, 210
Engine 113 (except 113.965/981) in model 163
24.1Remove oil
reservoir on
power steering
pump (11)Model 163
Removal: Extract oil from rese rvoir. Remove circlip.
Installation: Replace sealing ring. Ch eck that circlip is
correctly seated.
Power steering -
checking and
correcting oil
level AP46.00-P-
4611BB
Hand pumpFig. 95
24.2Detach power
steering pump
(11) with oil
reservoir. Do not disconnect lines.
*BA46.30-P-
1005-01A
*BA46.30-P-
1010-01A
*BA46.30-P-
1010-01C
25.1Detach guide
pulley at timing
case coverModel 230.474
*BA13.25-P-
1008-01D
25.2Take off guide
pulley (15) at
coolant pump Except model 230.474
Take plastic cover off guide pulley.
*BA20.10-P-
1001-01C
*BA20.10-P-
1001-01M
26.1Remove
compressorEngine 112.960 in model 170.466
Engine 113.992 in model 230.474AR09.50-P-
4705SVK
27Remove air pump
(20)Engine 112 (except 112.960) in model 170
Engine 112 in 163, 202, 208, 210
Engines 113 in 163, 202, 208, 210AR14.30-P-
7251A
Engine 112.922 in model 220.063AR14.30-P-
7251AA
Engine 112.923 in model 129.059
Engine 112.943 in model 129.064
Engine 112.944 in model 220.065 /165
Engine 112.972 in model 220.067 /167
Engine 112.975 in model 220.087 /187
Engine 113.941 in models 220.070/170
Engine 113.948 in model 220.083 /183
Engine 113.960 in model 220.075/175
Engine 113.960 in model 215.375
Engine 113.961 in model 129.068
Engine 113.963 in models 230.475
Engine 113.966 in model 220.084 /184

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 103 © 2006 Mitchell Repair Information Company, LLC.

Engine 113.992 in model 230.474AR14.30-P-
7251RVK
28Separate electrical
line from coolant
temperature
sensor
29Unscrew bolts
(21) of cylinder
head to timing
case cover on
right and left *BA01.40-P-
1002-01C
30Remove screws
of the timing case
cover Installation: Apply sealant to marked bolts, observing
the bolt diagram for th e timing case cover: ?*BR00.45-Z-
1015-01A
Bolt diagram for timing case cover engine 112, 113AR01.40-P-
8000-01B
Bolt diagram for timing case cover engine 113.992,AR01.40-P-
8000-01RVK
*BA01.40-P-
1001-01C
*BA01.40-P-
1002-01C
31Take off timing
case cover Installation: The bolt threads for the coolant pump,
the belt tensioning device, and the power steering pump
are not cut into a new timing case cover. For this reason,
use new self-tapping bolts in combination with a new
timing case cover for attaching the coolant pump, the belt
tensioning device and th e power steering pump. Pay
attention to tightening torque with non-pre-tapped threads.
*BA13.25-P-
1001-01D
*BA13.25-P-
1001-01M
*BA13.25-P-
1005-01D
*BA13.25-P-
1006-01D
*BA13.25-P-
1007-01D
*BA20.10-P-
1001-01C
*BA20.10-P-
1001-01M
*BA20.10-P-
1002-01C
*BA20.10-P-

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 104 © 2006 Mitchell Repair Information Company, LLC.