1997 MERCEDES-BENZ ML320 Complete Repair Manual

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Page 3745 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
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

AR

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

Page 3746 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
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 pi

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

Page 3747 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
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-050

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

Page 3748 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
Stage 3
(°
90

Retaining strap

000 589 04 14 00

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 3749 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
BT27.50-P-0002-02A
Plain bearing of input shaft changed to an anti-

friction bearing

TRANSMISSION
722.60# /61# /660 /662 /664 /665 /69# ## as of 1317917 as of 7.1.99,
722.62# /63# /661 /663 /6

Page 3750 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
BT27.35-P-0003-01A
Primary pump non-return valve dispensed with
722.5

k

TRANSMISSION
722.5## ## as of 3652931

Serieneinsatzdaten/Änderungen/Neuerungen

Getriebe/

Lenk-

getriebe
Füll-

Nr.

Page 3751 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
GF54.30-P-3017A
Quartz, location/task/function
8.7.99

MODEL
129, 140 as of 1.6.96,

163, 168, 170,

202 as of 1.8.96,

208,

210 as of 1.6.96,

215, 220

P54.30-0519-01

Piezo-electric effect

Page 3752 of 4133

MERCEDES-BENZ ML320 1997 Complete Repair Manual
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-sensitiv

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