1997 MERCEDES-BENZ ML320 engine

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

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Fig., see
AR01.30-P-5800-03BAR01.30-P-5800-03B

Cylinder head

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

BA01.30-P-1001-01D
Bolt of cylinder head to

crankcase
1st stageNm
1010

2nd stage
Nm
3030

3rd stage
(°
9090

4th stage
(°
9090

Crankcase, timing case cover, end cover

Number

Designation
Engine

112

except

112.951
Engine

113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/

984/986/992

BA01.40-P-1002-01C
Bolt, cylinder head to timing case cover
Nm
2020


Camshaft

Number

Designation
Engine

112

except 112.951
Engine

113.940/941/
942/943/944/
948/961/962/
963/965/966/
967/968/969/
980/981/982/

984/986/992

BA05.20-P-1001-01B
Bolt of camshaft sprocket
M12 x 45
1st stageNm
5050

2nd stage
(°
9090


Fuel rail

Number

Designation
Engine

112 except

112.945/951/

960/961

BA07.52-P-1001-01A
Fuel feed line to fuel rail
Nm
38

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Fuel rail

Number

Designation
Engine

113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/988/

BA07.52-P-1001-01A
Fuel feed line to fuel distributor
Nm
38


Exhaust manifold

Number

Designation
Engine

112

except

112.951
Engine

113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/992/

993

BA14.10-P-1002-01B
Flange connection of exhaust manifold or front

exhaust pipes
Nm
2020

112 589 00 32 00 112 589 01 32 00
001 589 76 09 00 000 589 01 10 00

Locating plate

Torx bit set

External Torx set
Locating plate

112 589 01 03 00

Screwdriver insert

Insertion tool

Open-end wrench
Screwdriver insert

112 589 00 01 00000 589 03 10 00000 589 04 10 00

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AR01.20-P-5014-02B
Remove/install cylinder head cover trim
Crankcase ventilation, cylinder head cover

Number

Designation
Engine

612.961/

962/967
Engine

612.963
Engine

612.965/

966
Engine

612.990

BA01.20-P-1002-01A
Screw of trim panel of cylinder head cover

to cylinder head cover
NM
101010
8

BA01.20-P-1003-01A
Screw attaching cover panel to charge air

distribution pipe
NM
101010
-

P01.20-2018-11

1
Unscrew bolts (3, 4).


Installation:
Pay attention to tightening torques
.
2
Pull out trim panel (2) of charge air distribution pipe to the side.


Installation:
Insert shackles of trim panel (2) into the rubber

mounts (5), so that the trim panel (2) is not damaged.

3
Take off trim panel (1) of cylinder head cover.

Installation:
Ensure the trim panel is correctly installed; ensure
no lines are trapped.

4
Install in reverse sequence.

Illustrated on Engine 612.961

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Page 1

GF54.30-P-2002A
Display instruments, location / task / function
24.10.96

MODEL
129, 140 as of 1.6.96,

163, 168, 170,

202 as of 1.8.96,

208 up to 31.7.99,

210 as of 1.6.96 up to 30.6.99

Display
Type of data transmission

D
Outside temperature indicator (A1p4)

D
Fuel level gauge (A1p2)

D
Engine oil pressure gauge (A1p3), only

model 129 and model 140

D
Low windshield washer fluid level

indicator lamp (A1e13), model 163 as of

01.09.01

Direct lines

GF54.30-P-3004A

D
Total mileage odometer (A1h4)

D
Electronic speedometer (A1p8)

D
Tachometer (A1p5)

D
Coolant temperature gauge (A1p1)

D
Active service system (ASSYST)

D
Gear indicator (A1p12), only model 168

CAN data lines

GF54.30-P-3005A

D
Electronic clock
Internal

GF54.30-P-3011A

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GF54.30-P-3028GH
Displaying coolant level, function
28.6.99

MODEL
163 as of 1.3.99

Function prerequisite

Engine: ON

Function

If the coolant level drops below the minimum mark the low ECL

indicator lamp (A1p11) is illuminated.

To record the coolant level the instrument cluster (A1) is connected

direct to the
coolant level indicator electronic switch (S41)
via two

cables. The
coolant level indicator electronic switch (S41)

consists of two electrodes.

D
If the
level is correct
both electrodes are immersed in the

coolant. The coolant serves as a dielectric between the

electrodes.

D
If the coolant level is below the minimum mark the electrodes of

the sensor are no longer immersed in the coolant. There is only

air between the electrodes as a dielectric. Evaluation

The instrument cluster (A1) sends test pulses to the sensor for

a period of one millisecond. These pulses are deformed

differently depending on the dielectric (air or coolant).

The instrument cluster (A1) evaluates the pulse shape and, if

the coolant level is below the minimum (electrodes are

completely in air), actuates the low ECL indicator lamp (A1p11)

after a delay of
approx. 60 seconds
.

The delay serves to prevent the indicator lamp flickering due to

the coolant moving from side to side on corners or off-road.

Diagnosis

Diagnosis is carried out, as described in the Diagnosis Manual, via

the simulation of the
coolant level indicator electronic switch (S41)

by a resistance.

Coolant level switch,

location/task/design/function

GF54.30-P-4103GH

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AR47.10-P-4000GH
Empty fuel tank if fuel pump is faulty
28.10.97

MODEL
163.113 with ENGINE 612.963

MODEL
163.128 with ENGINE 628.963

MODEL
163.136 with ENGINE 111.977

MODEL
163.154 with ENGINE 112.942

MODEL
163.157 with ENGINE 112.970

MODEL
163.172 with ENGINE 113.942

MODEL
163.174 with ENGINE 113.981

MODEL
163.175 with ENGINE 113.965

P47.20-2076-06

1
Fondsitzkonsole

2
Cover of left C-pillar

3
Seat retaining cable

4
Wiring harness

P47.10-2077-09

84
Closing cover

90/10
Ground line (vacuum unit)

90/11
Fuel return line
90/12

Fuel feed line

90/13
Stationary heater connection

90/14
Extraction hose


Remove, Install


Danger!
Risk of explosion
from fuel igniting,
risk of

poisoning
from inhaling and swallowing fuel

as well as
risk of injury
to eyes and skin

from contact with fuel.
Fire, sparks, open flames or smoking

forbidden.

Pour fuels only into suitable and appropriately

marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

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GF54.21-P-4106-01GH
Extended Activity Module - Task

n

The primary tasks of the Extended Activity Module (EAM, N10/1) are

as follows:
D
To control the door sill lights

D
To suppress the auto-dimming mirror function

D
To control the headlight cleaning system (HCS)

D
To control the rear window defroster

D
To control seat heating

D
To control the power supply via control console to tilt/sliding or

louvered sunroof switch

D
To control the PTC heater booster (R22/3)

D
To control the auxiliary fan (M4)

D
To read the cruise control switch (S40) and relay data to control

module (DAS, N73/1)

D
To read the contacts for wiper speed settings 1 and 2 on

combination switch (S4) for diagnosis.

To perform these tasks the Extended Activity Module (EAM, N10/1)

reads various signals and switch settings directly.

The Extended Activity Module (EAM, N10/1) interfaces with other
control modules via the engine compartment CAN.

-----------------------------------------------------------------------------------------
Diagnosis

Diagnosis is performed using the Star diagnostic tool. To facilitate

this task, the Extended Activity Module (EAM, N10/1) is equipped

with its own diagnostics cable.
This cable is also used to diagnose the
All Activity Module (AAM,

N10)
and the
transfer case control module (N78)
.

The Extended Activity Module (EAM, N10/1) is linked to the All

Activity Module (AAM, N10) via the
engine compartment CAN
.

Data communication between the All Activity Module (AAM,

N10) and the Extended Activity Module (EAM, N10/1) is

assumed by the
CAN (N10 - N10/1)
when terminal 15 is off.

The CAN (N10 - N10/1)
is an independent CAN bus located

between the All Activity Module (AAM, N10) and the Extended

Activity Module (EAM, N10/1).
No other
control modules are

connected to the CAN (N10 - N10/1).

-----------------------------------------------------------------------------------------

Details:

Door sill lights

When the front interior light is on and one of the front doors is open,

or when the rear interior light is on and one of the back doors is open,

the door sill lights for the open door will illuminate.

Headlight cleaning system (HCS)

Activating a separate switch causes the EAM to send a turn-on signal

to the HCS pump relay.

EAM will send an additional turn-on signal to the HCS pump relay

only after the cleaning operation is completed and a "rest period" of

approximately 2.5 sec. has passed.

Auto-dimming mirror function

The auto-dimming mirror function is suppressed when the interior

light is on or reverse gear is engaged.

Auto-dimming suppression for the outside rearview mirror (slave) is

activated by the inside rearview mirror (master).

Heater booster/PTC air heater for diesel engines

EAM monitors system voltage and adjusts heater booster capacity to

minimize load on battery.
Rear window defroster

EAM sets maximum ON time for rear window defroster depending

on outdoor temperature and current vehicle speed.
D
Standard ON time:
10 min.

D
Outdoor temperature < 5
o
C:
Additional 5 min.

D
Speed >80 km/h:
Additional 3 min.

Seat heating

Sets maximum seat heating time.
D
Setting 1: max. 20 min.

D
Setting 2: max. 5 min.

Tilt/sliding or louvered sunroofs

Signal via AAM2 allows operation of tilt/sliding or louvered sunroofs

when ignition is on (standard mode) or off (keyless mode).

Ignition authorization via CAN

The EAM issues ignition authorization to AAM2 via the engine

compartment CAN depending on the requirements of the engine

control unit in connection with the FBM.

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