1997 MERCEDES-BENZ ML320 engine

Fig. 45: Identifying Harmonics - Positive Diode Defective
Fig. 46: Identifying Diode Harmonics OK

REPLACE SPARK PLUGS - AP15.10-P-1580GH
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

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 71 © 2006 Mitchell Repair Information Company, LLC.

Fig. 47: Identifying Spark Plugs And Cylinder 4 Ignition Coil

Remove/install and
replacing

Risk of death due to
contact with high-voltage
conductive partsDo not touch parts which
conduct high voltages.
Persons who are carriers
of electronic implants
(e.g. cardiac pacemaker)
may not carry out any
work on the ignition
systemAS15.10-Z-0001-01A
Notes on avoiding damage
to ignition systemEngine 104, 111, 112,
113, 119, 120,271AH15.10-P-0002-01D
1Remove/install air filter
upper section
2
Remove ignition coils
Remove/install ignition
coils
AR15.12-P-2003A
3Disconnect spark plug
connectors Prise over cylinder
head cover.
Double open-ended
wrenchFig. 24
Checking
4Check spark plug Replace, if necessary.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 72 © 2006 Mitchell Repair Information Company, LLC.

Spark plugs
Fig. 48: Identifying Spark Plug Wrench (112 589 01 09 00)

Fig. 49: Identifying Open
-End Wrench, Double (110 589 01 01 00)
connectors, ignition coil
connectors and ignition
lines for damage,
deformation and crack
formation
5Remove/install spark plugs
(R4) *BA15.10-P-1001-01A
Spark plug wrenchFig. 48
NumberDesignationEngine
104,110,111,
113.940/941/942/943/
944/948/960/961/962/
963/964/965/966/967/
968/969/971/980/981/
982/984/986/992/993/
995,115,117,119,
120Engines
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/
973/975/976
BA15.10-P-1001-
01ASpark plugsNm2828

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 73 © 2006 Mitchell Repair Information Company, LLC.

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

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AP18.00-P-0101AR
Engine - oil and filter change
20.1.99

ENGINE
612

Modification notes

12.9.02

Engine oil level modified
Step 9:

Only Model 203:

Up to engine end number: 134 163 oil level
MAX. 135
mm,
MIN 110
mm.

As of engine end number: 134 164 oil level

MAX. 124,5
mm,
MIN 99,5
mm.


Remove

Danger!

Risk of death
cased 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


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


Change the engine oil only when the engine

is at operating temperature

1
Remove trim panel of cylinder head cover

AR01.20-P-5014-02B

2
Replace oil filter element, drain oil filter

Model 203: Remove clamp attaching fuel

line in order to insert wrench socket.

AP18.00-P-0101-06EG

*BA18.20-P-1002-01G

Socket wrench bit

*103589020900

3.1
Suction off engine oil

AP18.00-P-0101-02Z
4.1
Remove rear left frame cross brace

Only necessary when draining engine oil

at oil drain plug.

MODEL 163

f

Model 203 except 203.018/218/718, 209
AR94.30-P-5300P

Model 210

AR94.30-P-5300AB

4.2
Detach lower engine compartment paneling

Only necessary when draining engine oil

at oil drain plug.

f

Only Model 203.018/218/718

AR61.20-P-1105P

5.1
Unscrew oil drain plug, drain engine oil


Install

6.1
Screw in oil drain plug

Replace sealing ring, in order to avoid

leakage.


*BA01.45-P-1003-01A

7
Pour in engine oil
Note specified and approved quality

grades and viscosity classes conforming to

SAE at enduring ambient temperatures.

*BE18.00-P-1001-02B


*BF18.00-P-1001-01A

g

Viscosity classes of engine oils (car engines)
Sheet 224.1

BB00.40-P-0224-01A

8
Run engine and inspect for leaks

9
Switch off engine

10.1
Fit on bottom part of noise encapsulation

Only necessary when draining engine oil

at oil drain plug.

f

Model 210

AR94.30-P-5300AB

MODEL 203, 209

AR94.30-P-5300P

MODEL 163

10.2
Install lower engine compartment paneling.

Only necessary when draining engine oil

at oil drain plug.

f

Only Model 203.018/218/718

AR61.20-P-1105P

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

11
Check oil level approx. 5 min. after switching

off warm engine

Insert oil dipstick up to the stop and keep

to a residence time of at least 3 seconds.

Model 163, 210 with Engine 612
*BE18.00-P-1001-02B
Model 203, Model 209 with Engine 612

On Model 203, Model 209 after oil level

check pay attention to correct seating of the
cap, otherwise it could result in engine

damage.

Only Model 203:

Up to engine end number: 134 163 oil level

MAX. 135
mm,
MIN 110
mm.

As of engine end number: 134 164 oil level

MAX. 124,5
mm,
MIN 99,5
mm.

Measuring rod


*120589072100

12
Install trim panel of cylinder head cover

AR01.20-P-5014-02B


*BA01.20-P-1002-01A


*BA01.20-P-1003-01A

Test values for engine lubrication - general

Number

Designation
Engine

612.961
Engine

612.963

BE18.00-P-1001-02B
Dipstick marking

Color red
t
1

Color black
t
2

Color green
t
3

Color gentian blue
t
4

Numbers on handle
Number
6020760206

Round handle
Color
--

Bottle opener-shaped

handle
Color
11

Designation
Engine

612.961/962/

963/965/966,

613.961
Engine

612.967
Engine

612.990

BA01.45-P-1003-01A
Oil drain plug at oil pan
M12
Nm
---

M14
Nm
303030


Engine lubrication, oil filter

Number

Designation
Engine

612.961/962/
963/967/990,

613.960/961

BA18.20-P-1002-01G
Screw cap at oil filter
Nm
25

Crankcase ventilation, cylinder head cover

Number

Designation
Engine

612.961/

962/967
Engine

612.963
Engine

612.990

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

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

to cylinder head cover
Nm
1010
8

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

distribution pipe
Nm
1010
-

Designation
Engine

612.961
Engine 612.962/

967
Engine

612.963/966

BF18.00-P-1001-01A
Engine oil
Filling capacity

(oil and filter change)
Liter
7,06.57.5

Specifications for Operating

Fluids
SheetBB00.40-P-0228-01ABB00.40-P-0228-01ABB00.40-P-0228-01A
SheetBB00.40-P-0228-03ABB00.40-P-0228-03ABB00.40-P-0228-03A
SheetBB00.40-P-0228-05ABB00.40-P-0228-05ABB00.40-P-0228-05A
SheetBB00.40-P-0229-01ABB00.40-P-0229-01ABB00.40-P-0229-01A
SheetBB00.40-P-0229-03ABB00.40-P-0229-03ABB00.40-P-0229-03A
SheetBB00.40-P-0229-05ABB00.40-P-0229-05ABB00.40-P-0229-05A


Engine lubrication system

Number

Designation
Engine 612.990

BF18.00-P-1001-01A
Engine oil
Filling capacity

(oil and filter change)
Liter
6.5

Specifications for Operating

Fluids
SheetBB00.40-P-0228-01A
SheetBB00.40-P-0228-03A
SheetBB00.40-P-0228-05A
SheetBB00.40-P-0229-01A
SheetBB00.40-P-0229-03A
SheetBB00.40-P-0229-05A

120 589 07 21 00

Measuring rod

Socket wrench bit

103 589 02 09 00

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e. g.)
Order number

WH58.30-Z-1007-16A
Engine oil extractor
Deutsche Tecalemit

Am Metallwerk 11

33659 Bielefeld

1.386950.2

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

AR61.20-P-1105GH
Remove/install bottom engine compartment paneling
22.6.00

MODEL
163.172 with ENGINE 113.942

MODEL
163.174 with ENGINE 113.981

MODEL
163.175 with ENGINE 113.965

P61.20-2017-12
1
Engine compartment paneling

2
Grub screw

3
Plastic clips


Remove/Install

1
Remove grub screws (2) of plastic clips (3)

6 grub screws pins.


Installation:
Check grub screws, replace

if necessary.

2
Pull out plastic clips (3)


Installation:
Check plastic clips, replace

if necessary.

3
Remove engine compartment panel (1)


Installation:
Ensure that engine

compartment panel is positioned correctly.

4
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