MERCEDES-BENZ ML350 1997 Complete Repair Manual

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
or when working
near the running
engine

33Run engine and
inspect for leaks
34Inspect cooling
system for leaksFirst warm up engine to operating temperature.
Engine 112 (except 112.947 /960)
Engine 113 (except 113.992 /963)AR20.00-P-
1010HA
Engine 112 in Model 170AR20.00-P-
1010P
35Perform basic
programmingModel 215, 220
All except model 215, 220: Code radio and normalize
power window.
Vehicles with stationary he ater: adjust time display on
stationary heater.AR00.19-P-
0200M
36.1Read out fault
memory and eraseAll except models 215, 220, 230
Stored faults which can result from cables being
disconnected or from simu lation 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.
36.2Read out fault
memory with
STAR
DIAGNOSIS and
erase if necessary.Model 220, 230
Connect STAR
DIAGNOSIS and
read out fault
memory AD00.00-P-
2000-04A
STAR DIAGNOSIS diagnosis system
Stored faults which can result from removal and
installation or test work, have to be processed and erased
in the fault memories after completing the work.*WH58.30-Z-
1048-13A
NumberDesignation
Engine 112
except 112.951/
976
Engine 112.951/
976
Engine 113.987/
988/990/
991/993
BA01.40-P-
1001-01CTiming case
cover to
crankcaseNm202020
BA01.40-P- Bolt, cylinder Nm202020

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 106 © 2006 Mitchell Repair Information Company, LLC.

Crankcase, timing case cover, end cover
Belt tensioning device
Belt tensioning device
1002-01Chead to timing
case cover
NumberDesignation
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
Engine 113.987/
988/990/ 991/993
BA01.40-P-1001-
01CTiming case cover
to crankcaseNm2020
BA01.40-P-1002-
01CBolt, cylinder head
to timing case coverNm2020
NumberDesignation
Engine
112.910/911/91
2/913/914/915/
916/917/920/
921/922/923/
940/941/942/
943/944/945/
946/947/949/
953/954/955/
960/961/970/
972/973/975
BA13.25-P-1001-
01MSelf-tapping bolt of
belt tensioner to
timing case coverThread not pre-
tappedNm35
Thread pre-tappedNm25
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 113.990/
991/992/

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 107 © 2006 Mitchell Repair Information Company, LLC.

Coolant pump, coolant thermostat
NumberDesignation986/987/988993/995
BA13.25-P-
1001-01DSelf-tapping bolt
of belt tensioner
to timing case
coverThread not pre-
tappedNm3535
Thread pre-
tappedNm2525
BA13.25-P-
1005-01DBolt of belt
tensioner to
timing case
coverM7 x 25Nm3535
BA13.25-P-
1006-01DSelf-tapping bolt
of compressor
belt tensioner to
timing case
coverThread not pre-
tappedNm-35
Thread pre-
tappedNm-25
BA13.25-P-
1007-01DBracket for charge air cooler water
pipesNm714
BA13.25-P-
1008-01DBolt of guide
pulley for
compressor and
major assembly
belts to timing
case coverM8x78Nm-68
NumberDesignation
Engine
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/992
993/995
BA20.10-P-
1001-01CSelf-tapping
screw for
coolant pump to
timing caseThread not pre-
tappedM6Nm14
Thread not pre-
tappedM8Nm35
Thread pre-
tappedM6Nm10
Thread pre-
tappedM8Nm25
BA20.10-P-
1002-01CBelt pulley to coolant pumpNm10
BA20.10-P- Bolt, coolant thermostat housing M6 Nm
10

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 108 © 2006 Mitchell Repair Information Company, LLC.

Coolant pump, coolant thermostat
Power steering pump
Power steering pump
1003-01C
BA20.10-P-
1004-01CCoolant pump at the timing caseM7Nm10
NumberDesignation
Engine
112.910/911/91
2/913/914/915/
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-
1001-01MSelf-tapping
screw for
coolant pump to
timing caseThread not pre-
tappedM6Nm14
Thread not pre-
tappedM8Nm35
Thread pre-
tappedM6Nm10
Thread pre-
tappedM8Nm25
BA20.10-P-
1002-01MBelt pulley to coolant pumpNm9
BA20.10-P-
1003-01MBolt, coolant thermostat housingM6Nm14
BA20.10-P-
1004-01MCoolant pump at the timing caseM7Nm14
NumberDesignationModel 170
BA46.30-P-1005-01AScrew, power steering
pump to cylinder liner
collar seat or crankcaseNm25
Model
208.365/370/
Models
210.061/063/
065/070/074/08
1/082/083/261/
263/265/270/27
4/281/282/283/

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 109 © 2006 Mitchell Repair Information Company, LLC.

Power steering pump
Power steering pump
Power steering pump
Refrigerant compressor
NumberDesignation374/465/470663
BA46.30-P-
1010-01ASelf-tapping
bolt, power
steering pump to
timing caseThread not pre-
tappedNm3535
Thread pre-
tappedNm2020
NumberDesignation
Model
202.026/029/
033/086/089/093
Model 129.059/
064/068
BA46.30-P-
1010-01ASelf-tapping
bolt, power
steering pump to
timing caseThread not pre-
tappedNm3535
Thread pre-
tappedNm2020
NumberDesignation
Model 215.374/
375/378/ 379
Model
220.083/084/08
7/183/184/187
BA46.30-P-
1010-01CSelf-tapping
bolt, power
steering pump to
timing caseThread not pre-
tappedNm3535
Thread pre-
tappedNm2020
NumberDesignation
Models
220.063/065/
070/073/075/
165/170/173/
175 without
code 487a
Model 230
without code
487
Model 230
with code 487
BA46.30-P-
1010-01CSelf-tapping
bolt, power
steering pump
to timing caseThread not
pre-tappedNm353535
Thread pre-
tappedNm202020
NumberDesignation
Engine 112.910/911/
920/921/940/941,
113.940/943/944/980 /984
in model 202, 208, 210Engine
112.923/943,
113.961 in model
129
BA83.55-P-1001-
01ABolt, refrigerant
compressor to
bracketNm2020

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 110 © 2006 Mitchell Repair Information Company, LLC.

Refrigerant compressor
Refrigerant compressor
Refrigerant compressor
Fig. 95: Identifying Hand Pump (210 589 00 71 00)

Commercially available tools
Repair materials
NumberDesignation
Engine
111.977,112.942,
112.970,113.942 /
965/981 in model
163
Engine 112.947/960
in model 170
BA83.55-P-1001-
01ABolt, refrigerant
compressor to
bracketNm2020
NumberDesignation
Engines
112.922/944 in
model 220
Engine 113.960 in
model 215
BA83.55-P-1001-
01ABolt, refrigerant
compressor to
bracketNm2020
NumberDesignation
Engine 113.941/960
in model 220
Engine
113.963/992/995 in
model 230
BA83.55-P-1001-
01ABolt, refrigerant
compressor to
bracketNm2020
NumberDesignation
WH58.30-Z-1048-13ASTAR DIAGNOSIS diagnosis
system, Compact Passenger Car6511 1801 00
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 111 © 2006 Mitchell Repair Information Company, LLC.

REMOVE/INSTALL THE END COVER - AR01.40-P-8913B
ENGINE 1123.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 112 in MODEL 129, 163, 170, 202, 203, 208, 209, 210, 220
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113 in MODEL 129, 163, 202, 208, 209, 210, 220, 230.474 /475
ENGINE 112.913 in MODEL 211.061/261
ENGINE 112.949 in MODEL 211.065 /265
ENGINE 113.967 in MODEL 211.070 /270
ENGINE 113.982 in MODEL 463.243 /246
ENGINE 112.917 in MODEL 211.080 /280
ENGINE 112.954 in MODEL 211.082 /282
ENGINE 113.969 in MODEL 211.083 /283
Shown on engine 112
BR00.45-Z-1015-01ASealantA 002 989 71 20

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 112 © 2006 Mitchell Repair Information Company, LLC.

Fig. 96: Identifying End Cover Remove/Install Components - Shown On Engine 112
Remove/install
1Remove flywheel/drive
plate AR03.30-P-8001C
2Remove the end cover (1). Pry off end cover (1)
carefully at both marked
points with a slanted
screwdriver (see magnified
section).
The crankshaft radial
sealing ring (3) must
always be replaced when
end cover (1) is removed.
*BA01.40-P-1004-01C
3Install a new rear
crankshaft radial seal (3) The rear crankshaft
radial sealing ring (3) must
only be removed once end
cover (1) has been
removed.
Installation:
Circumference and lip of
the crankshaft radial
sealing ring (3) as well as
the counter tread on the

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 113 © 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.