1997 MERCEDES-BENZ ML320 engine

BE03.10-P-1003-05B
Dimension
Plain compression ring
mm
89.9 X 1.5 X 3.1

Taper-faced hook

scraper ring
mm
89.9 X 1.75 X 3.5

Test values for piston rings

Number

Designation
Engine 113.944/

980/981/982/984
Engine 113.960/

961/ 962/ 963/

965/ 968/
Engine

113.992 AMG

BE03.10-P-1003-05B
Dimension
Plain compression ring
mm
97.0 X 1.2 X 3.597.0 X 1.5 X 3.197.0 X 1.2 X 3.5

Taper-faced hook

scraper ring
mm
97.0 X 1.5 X 4.097.0 X 3.5 X 3.5
97.0 X 1.75 X 3.5

000 589 51 37 00

Pliers

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

AR03.10-P-7021AV
Removing/installing pistons
2.7.97

ENGINE
112

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 in MODEL 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230

P03.10-2029-09

Shown on engine 112

1
Circlip

2
Piston pin

3
Pistons

4
Conrod
5

Conrod bearing cap

6
Conrod bolts

7
Conrod bearing shell

8
Anti-twist lock

9
Groove

10


Clamping strap


Remove

Danger!

Risk of death
caused by vehicle slipping or

toppling off of the lifting platform.
Align vehicle between the columns of the

lifting platform and position the four support

plates
at the lifting platform support points

specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

1
Remove engineModels 463.206/ 209/ 232/ 233/ 240/ 241

AR01.10-P-2400CC

Models 463.244/ 245/ 247/ 248/ 249/ 250/ 254

AR01.10-P-2401GT

Models 463.243/ 246

AR01.10-P-2401MG

Model 230.475

AR01.10-P-2400R

Model 230.474

AR01.10-P-2400RVK

Model 220 without 4MATIC

AR01.10-P-2400AB

Model 220 with 4MATIC

AR01.10-P-2400IW

Model 210 with 4MATIC

AR01.10-P-2400C

Models 129, 202, 208, 210 without 4MATIC

AR01.10-P-2400CB

Model 203 without 4MATIC, 209 with Engine

112

AR01.10-P-2400PV

Model 203 with 4MATIC

AR01.10-P-2400PW

Model 209 with Engine 113

AR01.10-P-2400Q

Models 211.061/065/070

AR01.10-P-2400TC

Model 170

AR01.10-P-2400SV

Model 163

AR01.10-P-2400CA

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

2.1
Detach automatic transmission from engine
Models 463.206/ 209/ 232/ 233/ 240/ 241

AR27.10-P-0500BD

Models 463.243/ 244/ 245/ 246/ 247/ 248/

249/ 250/ 254

AR27.10-P-0500GA

Model 230.475

AR27.10-P-0500R

Model 230.474

Model 220 without 4MATIC

AR27.10-P-0500I

Model 220 with 4MATIC

AR27.10-P-0500IW

Models 129, 170, 202, 208, 210

AR27.10-P-0500B

Model 203 without 4MATIC, 209 with Engine

112,113

AR27.10-P-0500P

Model 203 with 4MATIC

AR27.10-P-0500PW

Model 211.061/065/070

AR27.10-P-0500T

Model 163

AR27.10-P-0500GH
2.2
Detach manual transmission from engine
Models 129, 202, 210

AR26.10-P-0020A
Models 203, 209 with Engine 112
AR26.10-P-0020P

Model 211.061

AR26.10-P-0020T

Model 208 with transmission 716.662/622

AR26.10-P-0020E

Model 170,

Model 208 with transmission 716.663

AR26.10-P-0020D

3
Detach top part of oil pan
Models 463.206/ 209/ 232/ 233/ 240/ 241/

243/ 244/ 245/ 246/ 247/ 248/ 249/ 250/ 254

AR01.45-P-7500FG

Model 230.474/
AR01.45-P-7500R

Model 220 without 4MATIC

AR01.45-P-7500I

Model 220 with 4MATIC

AR01.45-P-7500IW

Model 210 with 4MATIC

AR01.45-P-7500FA

Model 210 without 4MATIC

AR01.45-P-7500F

Models 202, 208

AR01.45-P-7500FC

Model 203 without 4MATIC, 209 with Engine

112,113

AR01.45-P-7500PV

Model 203 with 4MATIC

AR01.45-P-7500PW

Models 211.061/065/070

AR01.45-P-7500TV

Model 170

AR01.45-P-7500SV

Model 163

AR01.45-P-7500FB

Model 129

AR01.45-P-7500FD

4
Take off cylinder head

Remove intake manifold with complete

wiring loom during this step.

Models 463.206/ 209/ 232/ 233/ 240/ 241/

243/ 244/ 245/ 246/ 247/ 248/ 249/ 250/ 254

AR01.30-P-5800GV

Engine 112 in model 129 and engine 113 in

models 129, 202, 208, 210

AR01.30-P-5800B

Engine 112 in models 170, 202, 208, 210,

220 and engine 113 in models 220,

230.474 /475

AR01.30-P-5800BA

Model 163

AR01.30-P-5800MV

Models 203, 209 with engine 112, 113

Models 211.061/065/070

AR01.30-P-5800PV

5
Remove oil pump

Push back chain tensioner for this step

and take off chain.

All except models 203, 209, 211.061/065/070,

220 without 4MATIC, 230.474 /475

AR18.10-P-6020B

Model 203 without 4MATIC, 209,

211.061/065/070

AR18.10-P-6020PV

Model 203 with 4MATIC, model 220 with

4MATIC

AR18.10-P-6020PW

Model 230.474/475

AR18.10-P-6020R

6
Remove conrod bearing cap (5)

For this step, mark conrod (4) and

connecting rod bearing cap (5) on one side

relative to each other.

7
Remove conrod (4) together with pistons (3)

by lifting up and out

If pistons have been used (3), the arrows

indicating the direction of the travel and the

markings on the pistons may no longer be

visible due to carbon deposits. For this

reason, remove the carbon deposits from the

pistons. If the arrows indicating direction of
travel on the pistons are no longer

recognizable, these must be re-marked.

8
Remove circlip (1) of piston pin (2)

Do not damage piston (3). Place a clean

cloth underneath.

9
Press out piston pin (2)


Installing

10
Assign piston (3) to cylinder bore

AR03.10-P-7021-02BV

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

11
Oil piston pin (2) and conrod bush

12
Assemble piston (3) and conrod (4)

Install piston (3) with arrow in direction of

travel.

13
Push in piston pin (2) by hand

14
Insert circlip (1) of piston pin (2) in the groove

on piston (3)

Do not damage piston (3). Place a clean

cloth underneath.

15
Oil cleaned parts (cylinder bore, conrod

bearing journal, conrod bearing shells and

pistons)

16
Fit on tensioning strap (10) and tension

Piston ring gaps must be offset 120°.

Tensioning strap

*000589041400

17
Install piston (3) with arrow pointing in

direction of travel

Rotate crankshaft far enough so that the

connecting rod when inserting piston into

cylinder bore does not line up at the

connecting rod journal!

18
Inspect conrod bolts (6)

AR03.10-P-6111-01BV

Thread and shank length

*BE03.10-P-1001-03A

19
Install conrod bearings and fit on conrod

bearing cap (5)


The connecting rod bearing shell (7) with

oil drilling (arrow) must be mounted in the

connecting rod, otherwise the piston pin (2) is

not lubricated.

The anti-twist locks (8) of the connecting rod

bearing shells (7) must be seated in the

grooves (9) in the conrods (4) and connecting

rod bearing caps (5).
AR03.10-P-6111-06AV

The connecting rod and connecting rod

bearing cap are cracked (broken) (arrow).

They must not be installed the wrong side

round!

20
Tighten conrod bolts (6)

AR03.10-P-6111-02BV


*BA03.10-P-1001-01E

21
Rotate crankshaft

To inspect ease of operation.

22
Install oil pump
-
Ensure oil return flow check valve is

correctly located.

-
Clean strainer of oil pump.

-
Fill oil pump with engine oil before

installing so that it pumps oil when first

started.

All except models 203, 209, 211.061/065/070,

220 without 4MATIC, 230.474 /475

AR18.10-P-6020B

Model 203 without 4MATIC, 209,

211.061/065/070

AR18.10-P-6020PV

Model 203 with 4MATIC, model 220 with

4MATIC

AR18.10-P-6020PW

Model 230.474/475

AR18.10-P-6020R

23
Fit on cylinder head
Models 463.206/ 209/ 232/ 233/ 240/ 241/

243/ 244/ 245/ 246/ 247/ 248/ 249/ 250/ 254

AR01.30-P-5800GV

Engine 112 in model 129 and engine 113 in

models 129, 202, 208, 210

AR01.30-P-5800B

Engine 112 in models 170, 202, 208, 210,

220 and engine 113 in models 220,

230.474 /475

AR01.30-P-5800BA

Model 163

AR01.30-P-5800MV

Models 203, 209 with engines 112, 113

Models 211.061/065/070

AR01.30-P-5800PV

24
Fit on top part of oil pan
Model 463

AR01.45-P-7500FG

Model 230.474/475

AR01.45-P-7500R

Model 220 without 4MATIC

AR01.45-P-7500I

Model 220 with 4MATIC

AR01.45-P-7500IW

Model 210 with 4MATIC

AR01.45-P-7500FA

Model 210 without 4MATIC

AR01.45-P-7500F

Models 202, 208

AR01.45-P-7500FC

Model 203 without 4MATIC, 209 with engines

112,113

AR01.45-P-7500PV

Model 203 with 4MATIC

AR01.45-P-7500PW

Model 211.061/065/070

AR01.45-P-7500TV

Model 170

AR01.45-P-7500SV

Model 163

AR01.45-P-7500FB

Model 129

AR01.45-P-7500FD

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 3

25.1
Fit on automatic transmission
Models 463.206/ 209/ 232/ 233/ 240/ 241

AR27.10-P-0500BD

Models 463.243/ 244/ 245/ 246/ 247/ 248/

249/ 250/ 254

AR27.10-P-0500GA

Model 230.475

AR27.10-P-0500R

Model 230.474

Model 220 without 4MATIC

AR27.10-P-0500I

Model 220 with 4MATIC

AR27.10-P-0500IW

Models 210, 208, 202,170. 129

AR27.10-P-0500B

Model 203 without 4MATIC, 209 with engines

112,113

AR27.10-P-0500P

Model 203 with 4MATIC

AR27.10-P-0500PW

Models 211.061/065/070

AR27.10-P-0500T

Model 163

AR27.10-P-0500GH

25.2
Fit on manual transmission
Models 210, 202, 129

AR26.10-P-0020A

Models 203, 209 with engine 112

AR26.10-P-0020P

Model 211.061

AR26.10-P-0020T

Model 208 with transmissions 716.662/622

AR26.10-P-0020E

Model 170,

Model 208 with transmission 716.663

AR26.10-P-0020D

26
Install engine
Models 463.243/ 244/ 245/ 246/ 247/ 248/

249/ 250/ 254

AR01.10-P-2400CC

Model 230.475

AR01.10-P-2400R

Model 230.474

AR01.10-P-2400RVK

Model 220 without 4MATIC

AR01.10-P-2400AB

Model 220 with 4MATIC

AR01.10-P-2400IW

Model 210 with 4MATIC

AR01.10-P-2400C

Model 210 without 4MATIC, 208, 202, 129

AR01.10-P-2400CB

Model 203 without 4MATIC, 209 with engine

112

AR01.10-P-2400PV

Model 203 with 4MATIC

AR01.10-P-2400PW

Model 209 with engine 113

AR01.10-P-2400Q

Models 211.061/065/070

AR01.10-P-2400TC

Model 170

AR01.10-P-2400SV

Model 163

AR01.10-P-2400CA

Inspection data of conrod bolts

Number

Designation
Engine

112 except

112.951,

113.94/96/980/

981/982/984/986
Engine

113.992

BE03.10-P-1001-03A
Conrod bolts
Thread
4M8B18B1

Shank length
when new
mm
4742

max.
mm
47.642.6

Part no.
--

Designation
Engines

112 except

112.951,

113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/980/
981/982/984/
986/987/988/
990/991/992/

993

BA03.10-P-1001-01E
Connecting rod bolt
Stage 1
Nm
5

2nd stage
Nm
25

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

AR46.20-P-0600GH
Removing and installing rack-and-pinion steering
1.3.97

MODEL
163.113 /128 /136 /154 /157 /172 /174 /175

P46.20-2126-09

Shown on model 163.154 (vehicles

without speed-sensitive power steering)

1
Front axle carrier

10a
Tie rod joint

21
Rubber mount
25d

Nut

25f
Steering coupling shield

30f
Return line

30i
High-pressure expansion hose

80a
Lower steering shaft

23

Rack-and-pinion steering

23a
Bolts

23h
Shim

23i
Shim

25
Steering coupling

Modification notes
10.9.03

Reference to adjusting toe on front axle replaced by

reference to chassis alignment check
Step 16.1

Removing, installing

Danger!

Risk of fatal injury
if the vehicle slips or

topples off the lifting platform
Align vehicle between the columns of the

lifting platform and position the four support

plates
at the lifting platform support points

specified by the vehicle manufacturer.

AS00.00-Z-0010-01A


Danger!

Risk of injury
with
trapped or crushed

fingers when removing and installing or

aligning hoods, doors, trunk lid/tailgate and

sliding roof.
When moving components ensure that no

body parts or limbs are in the area of

movement.

AS00.00-Z-0011-01A

1
Open engine hood

AR88.40-P-1000GI

2
Extract oil from power steering pump supply

reservoir

Hand pump

*210589007100

3
Raise vehicle

4
Remove front axle gear

AR33.30-P-0525GH

5
Press tie rod joints (10a) off steering knuckles


Installation:
Replace self-locking nuts.

AR46.40-P-0200-02C


*BA46.40-P-1001-01C

Thrust piece

*140589006300

Puller

*202589023300

6
Turn steering wheel to horizontal position

(front wheels in straight-ahead position)

7
Remove key and engage steering lock

8.1
Unplug speed-sensitive power steering

connector from timing case
On vehicles with speed-sensitive power

steering code 213a

Copyright DaimlerChrysler AG 06.07.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

9
Detach return line (30f) and high-pressure

expansion hose (30i)

Connection fittings or banjo bolts

depending on the version. Seal off line

connections with plugs.


Installation:
Replace sealing rings.


Connection fitting, return line

*BA46.20-P-1001-01D

Connection fitting, high-pressure

expansion hose

*BA46.20-P-1002-01D

Banjo bolt, return line

*BA46.20-P-1004-01D

Banjo bolt, high-pressure expansion hose

*BA46.20-P-1005-01D

Plug

*129589009100

10
Detach nut (25d) and bolt from steering

coupling (25) and pull lower steering shaft

(80a) upwards out of steering coupling (25)

Do not use force as the corrugated tube is

sensitive to lateral forces. Enlarge clamping

groove a little with a screwdriver if necessary.


Installation:
Replace nut (25d).


Installation:
Turn rack-and-pinion

steering to center position and fit steering

coupling.

AR46.20-P-0600-01GH


*BA46.10-P-1001-01D

11
Detach rack-and-pinion steering (23) from

front axle carrier (1) by unscrewing bolts (23a)

The installed position of the shims (23h,

23i) on the right-hand side, between the

rubber mount and the front axle carrier, must

be observed as the shims are of different

thicknesses.


Installation:
Attach rack-and-pinion

steering to front axle carrier.

AR46.20-P-0600-03GH


Assessing condition of steering gear when

repairing accident vehicles

AH46.20-P-9409-01A

12
Check rubber mount (21) of rack-and-pinion

steering mounting for damage
Replace rubber mount if necessary:
#

Removing rubber mounts on rack-and-pinion

steering mounting

AR46.20-P-0600-02GH

13
Install in the reverse order

14
Fill and bleed power steering pump
Engines 112, 113

AR46.30-P-0010B
Engines 111, 612, 628
AR46.30-P-0010P

15
Check steering for function and leaks

There is a grease cushion under the cover
cap. A small amount of escaping grease is to

be regarded as normal and must not be

confused with leakage.

16.1
Check toe on front axle and adjust if necessary
When installing a new rack-and-pinion

steering, see:

#

Performing chassis alignment check

AR40.20-P-0200A


Steering shaft

Number

Designation
Model 163

BA46.10-P-1001-01D
Self-locking nut, steering coupling to steering shaft

and rack-and-pinion steering
Nm
28


Steering gear

Number

Designation
Model 163

BA46.20-P-1001-01D
Screwed connection fitting from return line

to rack-and-pinion steering
Nm
15

BA46.20-P-1002-01D
Screwed connection fitting from high-

pressure expansion hose to rack-and-pinion

steering
Nm
15

BA46.20-P-1003-01D
Bolted connection, rack-and-pinion steering

to front axle carrierNm
50

BA46.20-P-1004-01D
Banjo bolt, return line to rack-and-pinion

steering
Nm
30

BA46.20-P-1005-01D
Banjo bolt, high-pressure expansion hose to

rack-and-pinion steering
Nm
30

Copyright DaimlerChrysler AG 06.07.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

AR20.40-P-5000GH
Remove/install electric fan
22.6.00

ENGINE
113.965 in MODEL 163.175

ENGINE
113.981 in MODEL 163.174

P20.40-2025-06

1
Connector

2
Electrical connections

3
Tie strap

4
Electric fan

5
Screws

6
Sheet metal nuts

7
Sheet metal clamps

8
Retainer tabs

9
Protective caps

10
Bracket


Remove/Install

1
Disconnect electrical plug (1).

2
Unbolt electrical connections (2)

For this step detach protective caps (9).

Insulate wire ends, in order to avoid a

short circuit due to an unintended ground

contact.

3
Unclip cable straps (3)

4
Press coolant hose out of bracket (10)

5
Remove engine compartment paneling
AR61.20-P-1105GH

6
Unbolt electric fan (4) at the bottom

For this step unscrew bolts (5) and

remove sheet metal nuts (6).

7
Take off plate clamps (7)

8
Remove electric fan (4)


Installation:
Ensure, that the retainer tabs

(8) of the electric fan are seated in the

mounts of the radiator on right and left

9
Install in the reverse order

Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1