1997 MERCEDES-BENZ ML320 Complete Repair Manual

seats navigation system cooling clock reset lane assist coolant reservoir

Page 2081 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
AR15.12-P-2133A
Remove/install crankshaft position sensor
5.7.96

ENGINE
112.910 in MODEL 202.026 /086

ENGINE
112.920 in MODEL 202.029 /089

ENGINE
112.921 in MODEL 210.063 /081 /263 /281

ENG

AR15.12-P-2133A
Remove/install crankshaft position sensor
5.7.96

ENGINE
112.910 in MODEL 202.026 /086

ENGINE
112.920 in MODEL 202.029 /089

ENGINE
112.921 in MODEL 210.063 /081 /263 /281

ENGINE
112.922 in MODEL 220.063

ENGINE
112.923 in MODEL 129.059

ENGINE
112.940 in MODEL 208.365 /465

ENGINE
112.941 in MODEL 210.065 /082 /265 /282

ENGINE
112.942 in MODEL 163.154

ENGINE
112.943 in MODEL 129.064

ENGINE
112.944 in MODEL 220.065 /165

ENGINE
113.940 in MODEL 210.070 /270

ENGINE
113.941 in MODEL 220.070 /170

ENGINE
113.960 in MODEL 215.375, 220.075 /175

ENGINE
113.961 in MODEL 129.068

ENGINE
112.945 in MODEL 463.209 /232 /233 /244 /245 /250

ENGINE
113.944 in MODEL 202.033 /093

ENGINE
113.980 in MODEL 210.074 /274

ENGINE
113.943 in MODEL 208.370 /470

ENGINE
113.984 in MODEL 208.374

ENGINE
113.981 in MODEL 163.174

ENGINE
112.912 in MODEL 203.061 /261, 209.361 /461

ENGINE
112.946 in MODEL 203.064 /264

ENGINE
112.947 in MODEL 170.465

ENGINE
112.960 in MODEL 170.466

ENGINE
113.942 in MODEL 163.172

ENGINE
112.961 in MODEL 203.065 /265

ENGINE
113.965 in MODEL 163.175

ENGINE
113.963 in MODEL 230.475

ENGINE
112.913 in MODEL 211.061

ENGINE
112.949 in MODEL 211.065

ENGINE
113.967 in MODEL 211.070

ENGINE
113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254

ENGINE
113.982 in MODEL 463.243 /246

ENGINE
112.955 in MODEL 209.365 /465

ENGINE
112.916 in MODEL 203.081 /281

ENGINE
112.953 in MODEL 203.084 /284

ENGINE
112.973 in MODEL 230.467

ENGINE
112.972 in MODEL 220.067 /167

ENGINE
112.970 in MODEL 163.157

ENGINE
112.975 in MODEL 220.087 /187

ENGINE
113.948 in MODEL 220.083 /183

ENGINE
113.966 in MODEL 220.084 /184

ENGINE
112.917 in MODEL 211.080 /280

ENGINE
112.954 in MODEL 211.082 /282

ENGINE
113.969 in MODEL 211.083 /283

P15.12-0275-11

Shown on Engine 113 in Model 220

L5
Crankshaft position sensor

Copyright DaimlerChrysler AG 29.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

Page 2082 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
Remove/Install

1.1
Remove engine compartment cover with

integrated air cleaner
All except Engine 112.960 in Model 170.466,

Engine 112.961 in Model 203.065/ 265

Remove air cleaner by lifting

Page 2083 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual

Page 2084 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
AR62.30-P-2300GH
Removing and installing front end cross member
15.4.97

MODEL
163

P62.30-0350-06

1
Upper frame cross member

2
Screws

3
Engine hood control cable

4
Engine hood lock

E1 Le

Page 2085 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
AR01.30-P-5800MV
Remove/install cylinder head
22.7.98

ENGINE
112.942 in MODEL 163.154

ENGINE
112.970 in MODEL 163.157

ENGINE
113.942 in MODEL 163.172

ENGINE
113.981 in MODEL 163.174

ENGI

Page 2086 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
P01.30-0299-06

20
Bolts cylinder head
!
timing case cover

21
Cylinder head bolts

22
Cylinder head left

23
Cylinder head right

24
Left cylinder head gasket

25
Right cylinder head gasket

P01.30-0299-06

20
Bolts cylinder head
!
timing case cover

21
Cylinder head bolts

22
Cylinder head left

23
Cylinder head right

24
Left cylinder head gasket

25
Right cylinder head gasket

26
Dowel sleeves

Remove/Install

Notes on self-locking nuts and bolts
All models

AH00.00-N-0001-01A

External torx set

*001589760900

Torx bit set

*000589011000

Danger!

Risk of explosion
caused by oxyhydrogen

gas.
Risk of 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
No fire, sparks, open flames or smoking.

Wear acid-resistant gloves, clothing and

safety glasses. Pour battery acid only into

suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1
Disconnect battery ground cable

Installation:
After connecting, read out

fault memory, encode radio and normalize

power windows.

Vehicles with stationary heater: Set time on

timer for stationary heater
AR54.10-P-0003A

Notes on battery
All models

AH54.10-P-0001-01A

Danger!

Risk of death

caused by vehicle slipping or

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

hydraulic hoist and position the four support

plates below the hoist support points specified

by the vehicle manufacturer.

AS00.00-Z-0010-01A

2
Place the vehicle on lifting platform

AR00.60-P-1000GH
3.1
Remove air guide (1)

Only with engine 113.942

Danger!

Risk of injury
to skin and eyes suffering

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 bottles.

Wear protective gloves, protective clothing

and eye protection.
AS20.00-Z-0001-01A

4
Drain coolant

Remove coolant hose at bottom on

radiator.

AR20.00-P-1142HA

5
Remove engine cover

6.1
Remove viscous fan (2)

All except model 163.174 /175 with

engine 113.981 /965.

Right-hand thread!

AR20.40-P-5660C

7.1
Remove the fan shroud (3).

Only model 163.154 /157 /172. Unscrew

bolts (4) from bottom of fan shroud

7.2
Remove electric fan

Only model 163.174/ 175.

AR20.40-P-5000GH

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

Page 2087 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual 8
Attach guard plate for radiator/condenser

y

Guard plate for radiator/condenser
Engine 606 in model 124,
Engine 606.961 in model 140,

Engine 112, 113, 604, 605, 611.960 in model

202,

Engine

8
Attach guard plate for radiator/condenser

y

Guard plate for radiator/condenser
Engine 606 in model 124,
Engine 606.961 in model 140,

Engine 112, 113, 604, 605, 611.960 in model

202,

Engine 602.983, 612.966 in model 461,

Engine 628.962, 612.965, 606.964, 112.945,

113.962/ 982 in model 463,

Engine 111, 112, 611.962, 612.962 in model

203,

Engine 112, 113, 611.961, 612.961, 613.961

in model 210,

Engine 112 in model 170,
Engine 112 in model 220,

Engine 113 in model 211, 215, 220,

Engine 112 in model 208,

Engine 112, 113, 612.963, 628.963 in model

163,

Engine 112.923 /943, 113.961 in model 129,

Engine 137, 275 in model 215, 220,

Engine 613.960, 628.960 in model 220,

Engine 113.992 in model 230.474,

Engine 271 in model 209, 203,

Engine 285.950 in model 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 639.601/

603 /605 /701 /703 /705 /801 /803 /805

Engine 646.982 in model 639.601/ 603/ 605/
701 /703 /705

WF58.50-P-0110-01A

9
Remove air cleaner housing (5)

10
Remove air intake pipe (6) with resonance
tube (7)

Separate connector of hot film mass air

flow sensor (HFM) for this step and unbolt air

intake pipe at cylinder head cover

The air intake pipe is attached at the rear

at the intake manifold with a plastic plate.

Do not damage the plastic strap.

Engine 112.942/ 970

AR07.07-P-1454A

Engine 113.942/ 965/ 981

AR07.07-P-1454MV

Danger!

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

11
Disconnect fuel line at fuel rail

Release fuel pressure at service valve!

Collect fuel!

Engine 112:
#

*BA07.52-P-1001-01A

Engine 113:
#

*BA07.52-P-1001-01A

Pressure hose

*119589046300

12
Remove right and left ignition coils (12)

AR15.12-P-2003A

13
Remove right and left cylinder head covers (13)

AR01.20-P-5014B

14
Remove the 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.

AR09.20-P-1310A

The intake manifold system must not be

disassembled.

Remove intake manifold with fuel distributor

15.1
Remove camshaft position sensor (15)

Only necessary if the right cylinder head is

removed.

AR15.10-P-2000A

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

Page 2088 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
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

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.
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