1997 MERCEDES-BENZ ML350 check oil

AR03.10-P-7311-02V
Measure gap clearance of piston rings

Test values for piston rings
Number

Designation
Engine 112.910/

911/912
Engine 112.920/

921/922/923/940/
941/942/943/944/
945/946/947/948/

960,

113.940/941/942/

943
Engine 113.944/

980/981/982/984

BE03.10-P-1002-05B
Piston ring gap clearance
Groove 1
mm
0,200...0,3500,200...0,3500,200...0,350

Groove 2
mm
0,200...0,4000,200...0,4000,200...0,400

Test values for piston rings

Number

Designation
Engine 113.960/

961/ 962/ 963/

965/ 968/
Engine

113.967

BE03.10-P-1002-05B
Piston ring gap clearance
Groove 1
mm
0,200...0,3500,200...0,350

groove 2
mm
0,200...0,4000,200...0,400

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e.g.)
Order number

WH58.30-Z-1008-12A
Feeler gage
Stiefelmayer

D-73734 Esslingen
59

P03.10-2035-01

1
Clean cylinder contact surface.

2
Insert the two compression rings one after the other into the unworn area of the cylinder

wall and measure end clearance with

feeler gauge; replace piston rings, if necessary.

The gap clearance of the oil scraper ring cannot be checked because of its three-part

design. If the compression rings are replaced, the oil scraper ring must also be replaced.

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Page 1

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

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Page 3

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-sensitive power steering)

1
Front axle carrier

10a
Tie rod joint

21
Rubber mount
25d

Nut

25f
Steering coupling shield

30f
Return line

30i
High-pressure expansion hose

80a
Lower steering shaft

23

Rack-and-pinion steering

23a
Bolts

23h
Shim

23i
Shim

25
Steering coupling

Modification notes
10.9.03

Reference to adjusting toe on front axle replaced by

reference to chassis alignment check
Step 16.1

Removing, installing

Danger!

Risk of fatal injury
if the vehicle slips or

topples off the lifting platform
Align vehicle between the columns of the

lifting platform and position the four support

plates
at the lifting platform support points

specified by the vehicle manufacturer.

AS00.00-Z-0010-01A


Danger!

Risk of injury
with
trapped or crushed

fingers when removing and installing or

aligning hoods, doors, trunk lid/tailgate and

sliding roof.
When moving components ensure that no

body parts or limbs are in the area of

movement.

AS00.00-Z-0011-01A

1
Open engine hood

AR88.40-P-1000GI

2
Extract oil from power steering pump supply

reservoir

Hand pump

*210589007100

3
Raise vehicle

4
Remove front axle gear

AR33.30-P-0525GH

5
Press tie rod joints (10a) off steering knuckles


Installation:
Replace self-locking nuts.

AR46.40-P-0200-02C


*BA46.40-P-1001-01C

Thrust piece

*140589006300

Puller

*202589023300

6
Turn steering wheel to horizontal position

(front wheels in straight-ahead position)

7
Remove key and engage steering lock

8.1
Unplug speed-sensitive power steering

connector from timing case
On vehicles with speed-sensitive power

steering code 213a

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Page 1

3.1
Remove viscous fan (1)

Engine 112.942 /970 and 113.942.

Right-hand thread!

AR20.40-P-5660C

3.2
Remove electric fan

Only Engine 113.965 /981.

AR20.40-P-5000GH
4.1
Pull off plate clamps of fan shroud (2)

Only for Engine 112.942, from 5/98.

5.1
Remove fan shroud (3)

Only for Engine 112.942 /970 und

113.942. Unscrew the bolts at bottom of fan

shroud for this step


Installation:
If installing a new radiator

with integral power steering pump oil cooler, a

new fan shroud is required if a radiator

without integral oil cooler was previously
installed.

6
Remove headlamp (7).

AR82.10-P-4730GH

7
Remove radiator crossmember (8)

AR62.30-P-2300GH

8
Detach coolant line (4, 6) and expansion

reservoir coolant line (5) at the radiator


Installation:
Replace the hose clamps on

the radiator fitting for the coolant hose, as

they could cause damage to the screw/thread.

Hose clamp

*BA20.20-P-1004-01A

9
Remove the rubber seal on radiator (9)

10.1
Remove oil line (return line of radiator
!

power steering pump expansion reservoir)

(18) and oil line (feed line of steering gear

!

radiator) (19)

From 5/98 only, seal off the connections.

Set of plugs

*129589009100

11
Unscrew ATF lines (10) at the radiator

Seal off the connections.


*BA20.20-P-1001-01A


*BA20.20-P-1003-01A

Set of plugs

*129589009100

12.1
Detach the connector from the fan and
remove the fan grille (11)

Only for Engine 112.942 /970 and 113.942.

13
Unscrew the condenser from the radiator
Do not disconnect the lines.

14
Remove fasteners (20) and damper rubber

(21)

The damper rubber (21) is designed to

prevent possible vibrations between the

condenser and radiator (15) during off-road

driving.

15
Remove air conditioning system fluid

reservoir (14) from the radiator

Place aside with the lines connected.

Detach the condenser from the radiator.

16
Remove radiator (15)

When installing, the spigots on the

radiator must be inserted in the rubber

grommets in the bottom crossmember.

Installation:
On Model 163.154 with

Engine 112.942 before VIN end number

043553, when installing a new radiator with

integral power steering pump oil cooler,

additional operations are required, if they

have not already been carried out:

#
v

Retrofit the bracket for the oil cooler line of

the power steering pump

SM46.30-P-0002A

k

Radiator with integral oil cooler for the power

steering pump

BT20.20-P-0001-01A

17
Detach air guides (12)

Replace the clamps on air guides (13).

18
Install in the reverse order

19
Pour in coolant

AR20.00-P-1142HA

20
Check the headlamp setting and correct if

necessary

e

Check and adjust the headlamp setting

AP82.10-P-8260GH

Danger!

Risk of accident
caused by vehicle starting

off when engine is running.
Risk of injury


caused by contusions and burns when

working in engine during starting procedure
Secure the 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

21
Check the oil level in the automatic

transmission and correct if necessary

AR27.00-P-0101A

22
Check the cooling system for leaks

AR20.00-P-1010HA


Radiator, coolant hoses

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Page 2

13
Disconnect coolant hose to coolant pump (8),

coolant hose from thermostat housing (9) and

coolant hose from coolant expansion tank

(10) at radiator

Hexagon socket wrench

*WH58.30-Z-1001-06A

Hexagon socket wrench

*WH58.30-Z-1002-06A

14
Detach air guides (12)


Installation:
Replace fastening clamps

(13)

15
Unscrew bolts (16) at condenser (17) to

radiator

Avoid deformation of condenser lines.

Do not disconnect lines.

16
Remove attachment parts (20) and rubber

shock absorber (21)


Installation:
Ensure, that the rubber

shock absorbers do not drop when installing

the radiator.

Replace fastening clamps.

17
Take off fluid reservoir of AC (14) at radiator

Place to the side with lines connected.

External torx set

*001589760900

18
Remove bracket of charge air pipe at left

radiator

Installation:
Insert bracket of charge air

pipe into the bracket at the radiator.

19
Remove radiator (15)

Installation:
When installing, the mounting

studs of the radiator must be inserted into the

rubber grommets of the lower crossmember.

20
Install in the reverse order

21
Check headlamp adjustment, correct if

necessary

e

Check and correct headlamp adjustment

AP82.10-P-8260A

22
Inspect cooling system for leaks

AR20.00-P-1010HA

23
Fill power steering pump and bleed


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

24
Run engine and inspect for leaks
Crankcase ventilation, cylinder head cover

Number

Designation
Engine

612.963

BA01.20-P-1002-01A
Bolt, cylinder head cover trim panel to

cylinder head cover
Nm
10

BA01.20-P-1003-01A
Bolt, cover panel to charge air distribution

pipe
Nm
10

Power steering pump

Number

Designation
Model

163.113

BA46.30-P-1012-01A
Banjo bolt, power steering oil line to radiator
Nm
30


Cooling system

Number

Designation
Engine

612.963

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

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Page 3

2
Withdraw ignition key

3
Unclip cap (1) from outer paneling (3)

4
Unscrew bolt (2) from belt end fitting (4)

*BA91.40-P-1001-01D

Torx bit set

*000589011000

5
Pull belt end fitting (4) out of front seat

6
Remove paneling on B-pillar

AR68.30-P-4700GH

7
Unscrew bolt (5) of belt height adjuster from

B-pillar


*BA91.40-P-1004-01D

8
Disconnect connector from passenger ETR

[GUS] ignition squib (R12/2)

9
Unscrew bolt (6) from automatic belt retractor

(7)


*BA91.40-P-1008-01D

Torx bit set

*000589011000

10
Detach automatic belt retractor (7)

The automatic belt retractor must not be

disassembled.

Never use oil or grease to eliminate noises.

Automatic belt retractors that have been

opened are no longer under warranty!

11
Check seat belt for signs of damage

e

Check seat belts for damage

AP91.40-P-9150GH

12
Install in the reverse order


Installation:
Pay attention to different

version (left/ right) of emergency tensioning
retractors and satisfactory seating in the

locking device.

13
Read fault memory and erase

14Carry out diagnosis
see Diagnosis Manual.


Seat belts/emergency tensioning retractors

Number

Designation
Model 163 up to

08/99
Model 163 as of

09/99

BA91.40-P-1001-01D
Screw on belt end fitting
Nm
3535

BA91.40-P-1004-01D
Bolt to belt height adjuster
Nm
2525

BA91.40-P-1008-01DScrew on front automatic belt reel
Nm
30 (+10/-0.15)30 (+10/-0.15)

Torx bit set

000 589 01 10 00

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Page 2

3
Unscrew bolt (1) from seat belt guide bracket

(2)
If necessary, remove belt height adjuster
(5).


*BA91.40-P-1002-01D

4
Disconnect connector from right rear ETR

[GUS] ignition squib (R12/7)

5
Unscrew bolt (3) from automatic belt retractor

(4)


*BA91.40-P-1003-01D

6
Detach automatic belt retractor (4)

The automatic belt retractor must not be

disassembled.

Never use oil or grease to eliminate noises.

7
Check seat belts for damage

e

Check seat belts for damage

AP91.40-P-9150GH

8
Install in the reverse order


Installation:
Pay attention to different

version (left/ right) of emergency tensioning
retractors and satisfactory seating in the

locking device.

9
Read fault memory and erase

10Carry out diagnosis
see Diagnosis Manual.


Seat belts/emergency tensioning retractors

Number

Designation
Model 163 up to

08/99
Model 163 as of

09/99

BA91.40-P-1002-01D
Screw in rear upper belt guide fitting
Nm
3030

BA91.40-P-1003-01D
Bolt to rear inertia reel
Nm
3030

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Page 2

SI18.00-P-0010A
Service Information: oil sludge
26.3.01

ENGINE
111 in MODELS 124, 163, 170, 202, 203, 208, 210

ENGINE
112 in MODELS 129, 163, 170, 202, 203, 208, 210, 220

ENGINE
112, 113 in MODEL 463

ENGINE
113 in MODELS 129, 163, 202, 208, 210, 215, 220

ENGINE
137 in MODEL 215, 220

ENGINE
166 in MODEL 168

Oil sludging in gasoline engines with ASSYST maintenance

system

Recently we have determined that time and time again oil

sludging occurs in gasoline engines with an ASSYST maintenance

system.

Oil sludging can lead to the following complaints:
D
engine oil consumption

D
engine smoke (white/blue)

D
influencing of oil level indicator

D
clogged oil filter, engine oil thickened like jelly

D
Check engine lamp illuminated

D
oil sludge visible during assembly job, e.g. in oil filter, in cylinder

head covers, condensation sludging
(engine 166) etc.

-----------------------------------------------------------------------------------------
The following list of causes may lead individually or as a combination
to engine oil sludging:

D
Crankcase ventilation inoperable, function orifices, bores,

passages in cylinder head cover, cylinder head, crankcase etc.

are mechanically sealed. A nonfunctioning crankcase

ventilation boosts loads on the engine oil through organic

nitrates. The risk of oil sludging increases.

The mechanical condition of the engine is always to be

checked, i.e. all engine oil drain orifices on the cylinder head

and crankcase and all crankcase ventilation ducts must be free

of obstacles. Crankcase breather lines may not be kinked.
Check the ventilation bores in the cylinder head covers.

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

D
The engine oil used does not comply with the specifications in

Sheet 229.1 or 229.3 of the Specifications for Service Products.

The additive process, e.g. dirt-carrying capability, neutralization

capability and oxidation resistance as well as the quality of the

base stock influence sludging time.

Use of engine oils with best possible resistance to formation of

sludge, i.e. use only tested and approved engine oils (from

Sheet 229.1 or 229.3). The best protection is afforded by the

engine oils on Sheet 229.3, which fulfill more stringent

specifications with regard to preventing sludge and deposits
(see Sheet 221.0, page 11). These oils have a distinctly better

anti-sludge characteristic than other engine oils.

D
Sludging after adding a fuel or engine oil special additive.

Do not use fuel or engine oil special additives. More information

hereto is available on Sheet 219.0 of the Specifications for

Service products. Reference to customer not to use special

additives.

D
Engine oil change not performed according to ASSYST

specifications. At driven distances

exceeding > approx. 3000 km, engine oil sludging may occur.

-----------------------------------------------------------------------------------------
Comply with engine oil and filter change as under ASSYST

specifications. Observe remaining distance.

D
Fuel grade lies outside standard (regionally contingent). If

contaminated, deficient fuel is used, then engine oil sludging

may occur even where approved engine oil is used.

Operation with fuel, e.g. as under DIN EN 228. Clarify refueling

behavior of customer. If engine operation regional, is

temporarily possible with deficient oil only, then the startup

distance has to be individually reduced, i.e. the oil change

temporarily performed at an interval of, e.g. 10,000 km.

D
Radiator antifreeze penetration into engine oil, e.g. through an

internal engine leak (cylinder head gasket, casting porosity).

The engine oil sludges within a short period. The crankcase

ventilation clogs up and stops functioning. Condensation

sludging clogs up the oil separator cells

(engine 166).
Rectify coolant leakage. Clean all sludged engine parts, in

particular the crankcase ventilation parts. If the occurrence

repeats, and casting porosity is suspected, e.g. replace

crankcase.

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

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Page 1