bolt pattern MERCEDES-BENZ ML350 1997 Complete Repair Manual
[x] Cancel search | Manufacturer: MERCEDES-BENZ, Model Year: 1997, Model line: ML350, Model: MERCEDES-BENZ ML350 1997Pages: 4133, PDF Size: 88.89 MB
Page 1142 of 4133
338 IndexTele Aid* 171
Emergency calls 173
Information 177
Initiating an emergency call
manually 175
Remote door unlock 179
Roadside assistance 175
Stolen vehicle tracking services 180
System self-check 172
Upgrade signals 178
Telematics* 315
Telephone* 170
Temperature
Grades of tires 309
Tires 228
Third row seats* 102
Folding down single seat 102
Installing single seat 104
Removing single seat 104
Storing single seat 103
Tie-down rings (Cargo
compartment) 158Tightening torque 315
Tightening torque (Wheel bolts) 277
Tilt
Head restraint 37, 39
Time
Setting hours 118
Setting minutes 118
Tire inflation pressure
Checking 216, 227
Tire speed rating 198, 315
Tire traction 197
Tires 295, 308
Direction of rotation 227
Driving instructions 196
Retreads 226
Rims and tires 295
Rotating 228
Service life 227
Temperature 228
Temperature grades 309
Tread depth 230
Wear pattern 228
Winter 230Tools 257
Vehicle jack 258
Vehicles with CD-changer* 258
Wheel bolt wrench 258
Tow-away alarm 29, 84
Arming 84
Disarming 84
Disarming for transport 84
Towing
Trailer 206
Towing a trailer 209
Automatic transmission 124
Towing eyes
Front 285
Rear 285
Towing the vehicle 283
Stranded vehicle 286
Tracking services
For stolen vehicle 180
Page 1145 of 4133
341 Index
Wear pattern (tires) 228
Weights 299
Wheel bolt wrench 258
Wheel change
Tightening torque 277
Wheels
Rotating 228
Window curtain airbags 64
Windows see Side windows
Windshield
Defogging 138
Refilling washer fluid 224
Replacing wiper blades 273
Washer fluid 224, 307
Washer system 307
Windshield washer fluid 307
Filler neck 224
Mixing ratio 307
Refilling 224
Wiping with 50Windshield washer system 307
Windshield wipers 49, 129
Intermittent 49
Interval wiping 130
Normal wiper speed 49
Rain sensor* 130
Rear window wiper/washer 51
Replacing wiper blades 273
Simultaneous wiping and washing 51
Single wipe 50
Switching on 49
Wiping with windshield washer
fluid 50
Winter driving
Snow chains 231
Tires 230
Winter driving instructions 198
Winter tires 230Wiper blades
Cleaning 237
Installing 273
Removing 273
Replacing 273
Wiper switch 49
Wiper/washer
Rear window 51
Wiping
And washing simultaneously 50
Intermittent 49, 130
With windshield washer fluid 50
Wiping and washing simultaneously 51
X
Xenon headlamps*
Bi-Xenon* 311
Page 2088 of 4133
16
Remove poly V-belt (8)
Installation:
Lock tensioning device with
a drift or pin (diameter 5 mm).
Model 163.154 /157 /172.
AR13.22-P-1202B
Model 163.174 /175.
AR13.22-P-1202BA
17
Detach the coolant line (16) at the cylinder
head on the left
6 mm socket hexagon
*WH58.30-Z-1001-06A
7 mm socket hexagon
*WH58.30-Z-1002-06A
18.1
Remove fender liner (9)
Only with engine 113.113.942 /965 / 981.
AR88.10-P-1300GH
19.1
Remove shield (10)
Only with engine 113.942 /965 /981.
20.1
Remove exhaust bracket (11)
Only with engine 113.942 /965 /981.
Support exhaust system.
21
Detach exhaust system at exhaust manifold
Installation:
On vehicles with engine
damage, the exhaust system must be
examined for swarfs before assembling and
any swarfs present must be removed, in order
to avoid consequential damage.
*BA14.10-P-1002-01B
22
Position crankshaft to 40° after ignition TDC
on cylinder 1
The engine must not be turned back;
otherwise the timing chain can get jammed.
AR05.10-P-6858V
Rotate engine at the crankshaft in running
direction until scribe mark 40° on pulley/
vibration damper corresponds with scribe
mark on timing case.
The grooves on the camshafts must be
pointing toward the inner V.
23
Lock camshafts with locating plates
Locating plate
*112589003200
Locating plate
*112589013200
24
Remove 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
25.1
Remove oil filter housing (18) together with oil-
water heat exchanger
Engine 113.942.
AR18.20-P-3471B
Engine 112.942/970.
AR18.20-P-3471BA
26
Unscrew camshaft sprockets (19)
If camshaft sprockets are removed,
engine must no longer be cranked, otherwise
timing chain might jam.
Engine 113.942 /965 /981:
#
Tie timing chain tight on both camshaft
sprockets with tie straps.
Engine 112.942 /970:
#
Right-hand camshaft sprocket:
Tie timing chain tight on camshaft sprocket
with tie 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 position of camshafts.
AR05.10-P-6858V
If necessary after checking:
#
Set the basic position of camshafts
AR05.20-P-6020AU
Open-end wrench
*112589000100
Insertion tool
*112589010300
Torque wrench
*001589722100
*BA05.20-P-1001-01B
27
Remove camshaft bearing bridges (28)
Pay attention to slackening and tightening
pattern!
AR05.20-P-7103AU
28
Unscrew bolts, cylinder head
!
timing case
cover (20)
*BA01.40-P-1002-01C
Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 4
Page 2089 of 4133
29
Slacken cylinder head bolts (21) in stages,
unscrew
Loosen cylinder head bolts according to
loosening schematic only after engine has
cooled down to prevent cylinder head from
distorting.
AR01.30-P-5800-09B
Installation:
Observe tightening pattern
and tightening instructions of cylinder head
bolts.
Oil thread and head contact surface of
cylinder head bolts.
AR01.30-P-5800-07B
Screwdriver insert
*000589031000
Screwdriver insert
*000589041000
*BA01.30-P-1001-01D
30
Remove cylinder head
Installation:
On Engine 112/113 observe
porous points in the left 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, 113
AH01.30-P-1000-04VA
The sealant must be applied within
10 minutes.
Loctite 5900 sealant.
*BR00.45-Z-1015-01A
31
Inspect version of cylinder head gasket
Assignment of cylinder head gasket
Information for assigning the cylinder head
gaskets
Engine 112, 113
AH01.30-P-1000-06V
32
Check cylinder head bolts (21)
AR01.30-P-5800-03B
*BE01.30-P-1001-04B
33
Clean sealing surfaces, inspect for cracks,
shrink holes and flatness, clean threaded
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 series production.
At the time of repair installation, silicone
sealant is applied to the sealing area only in
case of any shrink holes.
The sealant must be applied within
10 minutes.
Loctite 5900 sealant.
*BR00.45-Z-1015-01A
34
Install in the reverse order
Danger!
Risk of accident
caused by vehicle starting
off by itself when engine is running.
Risk of
injury
caused by contusions and burns when
working in engine during starting procedure
Secure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.
AS00.00-Z-0005-01A
35
Run engine and inspect for leaks
36
Inspect cooling system for leaks
Warm up engine to operating temperature
and then inspect cooling system or leaks.
AR20.00-P-1010HA
37
Read out and erase fault memory
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.
Cylinder head/cylinder head bolts
Number
Designation
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
Engine
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/987/
988/990/991/
992/993
BE01.30-P-1001-04B
Cylinder head bolt
Thread diameter
M
1111
Length (L) when new
mm
141.5141.5
Length (L)
mm
T
144.5
T
144.5
Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 5
Page 2096 of 4133
16
Remove poly V-belt (8)
Installation:
Lock tensioning device with
a drift or pin (diameter 5 mm).
Model 163.154 /157 /172.
AR13.22-P-1202B
Model 163.174 /175.
AR13.22-P-1202BA
17
Detach the coolant line (16) at the cylinder
head on the left
6 mm socket hexagon
*WH58.30-Z-1001-06A
7 mm socket hexagon
*WH58.30-Z-1002-06A
18.1
Remove fender liner (9)
Only with engine 113.113.942 /965 / 981.
AR88.10-P-1300GH
19.1
Remove shield (10)
Only with engine 113.942 /965 /981.
20.1
Remove exhaust bracket (11)
Only with engine 113.942 /965 /981.
Support exhaust system.
21
Detach exhaust system at exhaust manifold
Installation:
On vehicles with engine
damage, the exhaust system must be
examined for swarfs before assembling and
any swarfs present must be removed, in order
to avoid consequential damage.
*BA14.10-P-1002-01B
22
Position crankshaft to 40° after ignition TDC
on cylinder 1
The engine must not be turned back;
otherwise the timing chain can get jammed.
AR05.10-P-6858V
Rotate engine at the crankshaft in running
direction until scribe mark 40° on pulley/
vibration damper corresponds with scribe
mark on timing case.
The grooves on the camshafts must be
pointing toward the inner V.
23
Lock camshafts with locating plates
Locating plate
*112589003200
Locating plate
*112589013200
24
Remove 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
25.1
Remove oil filter housing (18) together with oil-
water heat exchanger
Engine 113.942.
AR18.20-P-3471B
Engine 112.942/970.
AR18.20-P-3471BA
26
Unscrew camshaft sprockets (19)
If camshaft sprockets are removed,
engine must no longer be cranked, otherwise
timing chain might jam.
Engine 113.942 /965 /981:
#
Tie timing chain tight on both camshaft
sprockets with tie straps.
Engine 112.942 /970:
#
Right-hand camshaft sprocket:
Tie timing chain tight on camshaft sprocket
with tie 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 position of camshafts.
AR05.10-P-6858V
If necessary after checking:
#
Set the basic position of camshafts
AR05.20-P-6020AU
Open-end wrench
*112589000100
Insertion tool
*112589010300
Torque wrench
*001589722100
*BA05.20-P-1001-01B
27
Remove camshaft bearing bridges (28)
Pay attention to slackening and tightening
pattern!
AR05.20-P-7103AU
28
Unscrew bolts, cylinder head
!
timing case
cover (20)
*BA01.40-P-1002-01C
Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 4
Page 2097 of 4133
29
Slacken cylinder head bolts (21) in stages,
unscrew
Loosen cylinder head bolts according to
loosening schematic only after engine has
cooled down to prevent cylinder head from
distorting.
AR01.30-P-5800-09B
Installation:
Observe tightening pattern
and tightening instructions of cylinder head
bolts.
Oil thread and head contact surface of
cylinder head bolts.
AR01.30-P-5800-07B
Screwdriver insert
*000589031000
Screwdriver insert
*000589041000
*BA01.30-P-1001-01D
30
Remove cylinder head
Installation:
On Engine 112/113 observe
porous points in the left 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, 113
AH01.30-P-1000-04VA
The sealant must be applied within
10 minutes.
Loctite 5900 sealant.
*BR00.45-Z-1015-01A
31
Inspect version of cylinder head gasket
Assignment of cylinder head gasket
Information for assigning the cylinder head
gaskets
Engine 112, 113
AH01.30-P-1000-06V
32
Check cylinder head bolts (21)
AR01.30-P-5800-03B
*BE01.30-P-1001-04B
33
Clean sealing surfaces, inspect for cracks,
shrink holes and flatness, clean threaded
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 series production.
At the time of repair installation, silicone
sealant is applied to the sealing area only in
case of any shrink holes.
The sealant must be applied within
10 minutes.
Loctite 5900 sealant.
*BR00.45-Z-1015-01A
34
Install in the reverse order
Danger!
Risk of accident
caused by vehicle starting
off by itself when engine is running.
Risk of
injury
caused by contusions and burns when
working in engine during starting procedure
Secure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.
AS00.00-Z-0005-01A
35
Run engine and inspect for leaks
36
Inspect cooling system for leaks
Warm up engine to operating temperature
and then inspect cooling system or leaks.
AR20.00-P-1010HA
37
Read out and erase fault memory
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.
Cylinder head/cylinder head bolts
Number
Designation
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
Engine
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/987/
988/990/991/
992/993
BE01.30-P-1001-04B
Cylinder head bolt
Thread diameter
M
1111
Length (L) when new
mm
141.5141.5
Length (L)
mm
T
144.5
T
144.5
Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 5
Page 2292 of 4133
Camshaft
Camshaft
6Install the rocker arm spindles
(3)
guide shaft with the rocker arm spindle (3).2350AU
Ensure that the rocker arms (2) do not get
jammed.
Recirculated ai r warming cabinet*WH58.30-Z-
1001-28A
Heating oven*WH58.30-Z-
1003-28A
7Install camshaft bearing bridge
Observe tightening pattern.
All models except 171.473, 164.175, 251.075/175,
219.375/376AR05.20-P-
7103AU
Model 164.175AR05.20-P-
7103GZ
Models 251.075/175AR05.20-P-
7103RT
Models 219.375/376AR05.20-P-
7103TY
Model 171.473AR05.20-P-
7103VT
*BA05.20-P-
1002-01B
*BA05.20-P-
1004-01B
NumberDesignationEngine 112 except
112.951/976Engine
112.951/ 976
BA05.20-P-
1002-01BBolt,
camshaft
bearing
bridge to
cylinder headM7x45Stage 1Nm1515
Stage 2Angle°--
BA05.20-P-
1004-01BBolt,
camshaft
bearing
bridge to
cylinder headM7x84Stage 1Nm1010
Stage 2Angle°9090
NumberDesignationEngines
113.940/941/
942/943/944/
948/961/962/
963/964/965/
966/967/968/
969/971/980/ Engine
113.960
without
code
479
2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 51 © 2006 Mitchell Repair Information Company, LLC.
Page 2313 of 4133
Camshaft
Remove/install
1Remove
cylinder head
coverAir filter located at vehicle side.AR01.20-
P-5014B
Air filter located on engine side.AR01.20-
P-5014BV
2Position piston
of cylinder 1 at
40° after TDC Engine must not be cranked backwards.
Rotate engine at crankshaft in direct ion of rotation until 40° marking on belt
pulley/ vibration damper is aligned with marking on timing case cover.
Grooves in the camshafts must point towards the "inner V".AR05.10-
P-6858V
3Remove chain
tensioner (A)
Engine 112 in models 211.080/082/261/265 /280/282,
Engine 113 in model 211.083/270/283
Engine 112.945 in model 463.209/232/233 /244/245/250,
Engine 112 in models 163, 129,
Engine 113.962 in model 463.206/240/241 /247/248/249/254,
Engine 113 (except 113.965/981) in models 210, 208, 202, 163, 129,
Engine 113.982 in model 463.243/246AR05.10-
P-7800C
Engine 112 in models 170, 202, 203, 208, 209, 210,
Engine 113 in models 163.174/175, 209AR05.10-
P-7800CA
Engine 112 in models 211.061 /065, 220, 230.467,
Engine 113 in models 211.070/076/276,
215.373/374/375,220.070/073/074/075 /083/ 084/170/173/174/175/183/184/875,
230.474/475AR05.10-
P-
7800AM
4Remove
camshaft
bearing bridge Tie camshaft sprocket and timing ch ain together with a cable strap to
prevent the timing chain from skipping.
Slacken bolts in stages in the opposite sequence to the torquing pattern. (See
diagram)
Information on
installing
camshaft
bearing bridgeEngine 112/113 except cylinder shutoff code 479
Installation: Bolt, camshaft bearing bridge to cylinder head, engine 112,
113 except 113.969AH05.20-
P-2000-
01AV
*BA05.20-
P-1002-
01B
*BA05.20-
P-1004-
01B
5Install in the
reverse order
NumberDesignationEngine 112
except
112.951/976Engines
112.951/ 976
BA05.20-P- Bolt, camshaft M7x45Stage 1Nm158
2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 72 © 2006 Mitchell Repair Information Company, LLC.
Page 2383 of 4133
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.
Page 2435 of 4133
Fig. 72: Identifying Screwdr iver Insert (000 589 03 10 00)
Fig. 73: Identifying Screwdr iver Insert (000 589 04 10 00)
Tightening pattern/bolt assignment
Left and right cylinder head M 112
1-8 Collar bolt M11 a. a Combination bolts M850( to timing case cover)
b. b Combination bolts M830(to timing case cover)
2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 79 © 2006 Mitchell Repair Information Company, LLC.