1997 MERCEDES-BENZ ML320 engine

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

8
Pour in coolant

Warm up engine by running at moderate

revs. Top up coolant constantly at coolant

expansion reservoir. Close coolant expansion

tank once

coolant temperature is 60-70 °C.

*BF20.00-P-1001-02E


Note on coolant level
Model 124, 129, 140, 163.113, 168, 170, 202,

208, 210, 220, 463

AH20.00-P-1142-01A

9
Inspect cooling system for leaks

AR20.00-P-1010HA


Cooling system

Number

Designation
Engine

612.963

BF20.00-P-1001-02E
Cooling system
Total capacity
Liter
Y
11.0

Filling capacity of anticorrosion/

antifreeze agent down to

-37 °C
Liter
Y
5.5

Filling capacity of anticorrosion/

antifreeze up to -45 °C
Liter
Y
6.25

Specifications for Operating

Fluids
SheetBB00.40-P-0310-01A
SheetBB00.40-P-0325-00A

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

Crankshaft Position Sensor DIY


hopefully this will help others with what appears to be a common stalling issue in the ML series.


Location:


--------


It's on the rear of the engine where the engine mates with the tranny on the driver's side. There are 2

types. Be sure to get the correct one


Here it is:


1) Get
CPS
at dealer, its a VIN specific part. $125 from my local stealer.


2) Tools needed: Socket screwdriver, Good lighting (portable) shop lights, size 8 outside torx socket,
maybe a ratche
t and extentions depending on your flexibility, magnetic part retrieval tool (skip this at

your peril), bath towel, and long sleeve shirt, step stool, blue thread locker (optional)


3) Open hood and remove engine cover, it just pulls off and on


4) Set wor
k light(s) toward back of engine, lighting behind drivers cylinder head


5) Set bath towel on front of ML to kneel on of your knees will die, wearing long sleeve shirt or your

wrists will be cut.


6) Climb up on towel and look behind engine from above and
right (see .jpg), finding torx attachment
holding your
CPS
.

7) Remove torx screw and pull out
CPS
, disconnect one way connector (wiring)


8) Replace with new (leaving wire detached for now)


9) This is the hardest step by far, and requires patience and fl exibility. Apply some thread locker and

insert screw and start the threads. Tighten with torx on socket screwdriver. This step took about 1/2

hour and numerous dropped screws and retrievals with mag tool.


10) Attach wiring to
CPS


11) Reinstall engine cov
er


12) Clean up tools, towel and lights and everything


13) Drink beer and toast yourself for saving yourself at least $100 and a day of your time dropping off

and picking up cars at shop


Hope this helps someone in the community.


Dickie


00 ML 32
0

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

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Page 1

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 vertically up

and away from the cylinder head covers.


Installation:
With sliding compound,

slightly moisten the rubber retainers on the

cylinder head covers and the sealing ring of

the hot film mass air flow sensor in the air

cleaner housing.

1.2
Remove air cleaner housing
Engine 112.960 in Model 170.466

Engine 112.961 in Model 203.065/265

AR09.10-P-1150SVK

2
Remove crankshaft position sensor (L5)


*BA15.10-P-1001-03A

3
Install in the reverse order

4.1
Reinitialize crankshaft position sensor (L5)

using STAR DIAGNOSIS

If the crankshaft position sensor (L5) was

replaced, a re-initialization must be carried

out with STAR DIAGNOSIS in the "Control

unit adaptations" menu item.

Diagnosis system STAR DIAGNOSIS

*WE58.40-Z-1013-06A


Position sensor

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/
948/960/961/
962/963/965/
966/967/968/
969/980/981/
982/984/986/

992/993

BA15.10-P-1001-03A
Crankshaft position sensor to engine block
Nm
88

Workshop equipment/MB testers
(see Workshop Equipment Manual)

WE58.40-Z-1013-06A
Compact STAR DIAGNOSIS system for passenger cars, order number 6511 1801 00

Copyright DaimlerChrysler AG 29.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 2

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 Left headlamp unit
E2
Right headlamp unit

Operation no. of operation texts or of standard texts and flat rates
Division
Operation

no.
Operation text

P
621300
REPAIRING FRONT REINFORCEMENT BETWEEN WHEELHOUSES

P
621304
REPLACING FRONT LEFT AND CENTER REINFORCEMENT BETWEEN WHEELHOUSES

P
621305
REPLACING FRONT LEFT AND CENTER REINFORCEMENT BETWEEN WHEELHOUSES (WHEN REPLACING

WHEELHOUSE TOGETHER WITH LONGITUDINAL MEMBER)

P
621311
REPLACING FRONT RIGHT AND CENTER REINFORCEMENT BETWEEN WHEELHOUSES

P
621312
REPLACING FRONT RIGHT AND CENTER REINFORCEMENT BETWEEN WHEELHOUSES (WHEN REPLACING

WHEELHOUSE TOGETHER WITH LONGITUDINAL MEMBER)

P
621315
REPLACING FRONT CENTER REINFORCEMENT BETWEEN WHEELHOUSES

P
621320
COMPLETELY REPLACING FRONT REINFORCEMENT BETWEEN WHEELHOUSES

P
621321
COMPLETELY REPLACING FRONT REINFORCEMENT BETWEEN WHEELHOUSES (WHEN REPLACING

WHEELHOUSE TOGETHER WITH LONGITUDINAL MEMBER)

P
882302
REMOVING AND INSTALLING FRONT END CENTER SECTION


Removal, installation

1
Remove headlamp unit on left (E1) and right

(E2)

AR82.10-P-4730GH

2
Remove upper frame cross member (1)

Unscrew screws (2).

3
Remove engine hood control cable (3) from

engine hood lock (4)

For this purpose turn upper frame cross

member over.

Unhook engine hood control cable and pry

catch out of upper frame cross member.

4
Remove upper frame cross member (1)

5
Install in opposite order

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1

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

ENGINE
113.965 in MODEL 163.175

P01.30-2032-06

Shown on model 163.154 with engine 112

1
Air baffle

2
Viscous fan

3
Fan shroud

4
Bolts

5
Air cleaner housing

6
Air intake manifold

7
Resonance unit

8
Poly-V-belt

9
Fender liner

10
Shield

11
Exhaust bracket

P01.30-2033-06

12
Right and left ignition coils

13
Left and right cylinder head covers

14
Intake manifold

15
Camshaft position sensor

16
Coolant line

17
Chain tensioner

18
Oil filter housing

19
Camshaft sprockets

28
Camshaft bearing bridges

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

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

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Page 2

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

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Page 3