1997 MERCEDES-BENZ ML350 check engine

connection diagram011.00
Risk of accident caused
by vehicle starting off by
itself when engine is
running. Risk of injury
caused by contusions and
burns during starting
procedure or when
working near the running
engineSecure vehicle to prevent it
from moving by itself.
Wear closed and snug-
fitting work clothes.
Do not grasp hot or rotating
parts.AS00.00-Z-0005-01A
3Start engine
4Load battery (G1) with
volt ampere tester (079)
and check charging
current of alternator (G2)
with increased engine
speed Vary load resistance
long enough until the
maximum load current is
achieved; when this is
done, the regulating voltage
must not drop below 12.7
V.
Engines 111, 612*BE15.40-P-1001-01A
Engines 112, 113*BE15.40-P-1001-01K
Engine 628*BE15.40-P-1001-01J
Volt ampere tester with
load resistance*WH58.30-Z-1002-09A
Volt ampere tester ETT
011.00*WH58.30-Z-1003-09A
Charging current below
desired value: ?
Check diodes for
alternator (G2).
AR15.40-P-9301-02EA
Engine tester with
oscilloscope
If diodes are faulty: ?
Replace alternator
(G2)
*WH58.30-Z-1046-13A
Engines 111, 112, 113AR15.40-P-5032GH
Engine 612AR15.40-P-5032GI
Engine 628 with water-
cooled alternator (G2)AR15.40-P-5032IA
Engine 628 with air-cooled
alternator (G2)AR15.40-P-5032GD
5Turn off engine
6Disconnect volt ampere
tester (079) with current Volt ampere tester with
load resistance*WH58.30-Z-1002-09A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 58 © 2006 Mitchell Repair Information Company, LLC.

Check values for alternator
Check values for alternator
Check values for alternator
Commercially available tools
clamp (065) Volt ampere tester ETT
011.00*WH58.30-Z-1003-09A
NumberDesignationEngine 111 in
models 163, 203
Engine 111 in
models 202, 208
with code 910
Bosch/ ValeoEngine 612 in
models 163,203,
209, 210, 463
Delphi
BE15.40-P-1001-
01ACharging current
of alternatormax.A120190
min.A90150
Engine speedrpm25002500
RatioI=2.932.53
NumberDesignationEngine 628.963
in model 163
NF 14V 150AEngine 628.963
in model 163
E10 14V 90-
200A
BE15.40-P-1001-
01JCharging current
of alternatormax.A150200
min.A120160
Engine speedrpm25002500
RatioI=2.82.93
NumberDesignationEngine 112 in
models 163, 170,
202, 203, 208,
209, in model 210
without code 978,
in model 211
without code 910,
Bosch/ValeoEngine 113 in
models
163,171,203,208,
209,210,211,215,
219, 220, 230 except
models 211.076/276,
215.374, 219.376,
220.074/174,
230.472/474 Bosch
BE15.40-P-
1001-01KCharging
current of
alternatormax.A120150
minA90120
Engine speedrpm25002500
RatioI=2.932.93
NumberDesignation
WH58.30-Z-1002-09AVolt-amp(s) tester with load resistance (no longer
available)

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 59 © 2006 Mitchell Repair Information Company, LLC.

Alternator
Repair materials
REMOVE/INSTALL GENERATOR BELT PULLEY - AR15.40-P-5710GF
ENGINE 111.977, 112.942/970, 113.942/965/981 in MODEL 163
ENGINE 166.940 /960 in MODEL 168
ENGINE 112.923 /943, 113.961 in MODEL 129
sequence
10Perform basic programming AR00.19-P-0200GH
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 procedureSecure 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
11Carry out engine test run Visual inspection of the poly-
V-belt.
12Perform operational check
NumberDesignationEngine 111Engine
112.91/92/94/953/954/955/96/97,113.94/96/98
BA15.40-P-
1001-01ANut of circuit
B+ to generatorNm1518
BA15.40-P-
1002-01ANut of circuit
D+ to
generatorNm45
BA15.40-P-
1003-01AScrew,
alternatorNm4242
NumberDesignationOrder number
BR00.45-Z-1002-06ALubricantA 000 989 01 60

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:55 PMPage 62 © 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.

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

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

AF07.00-P-9000B
Engine runs rough, surges or does not turn over
29.4.02

ENGINE
611 in MODEL 203, 202, 210

ENGINE
612 in MODEL 163, 203, 210, 209

ENGINE
613 in MODEL 210, 220

ENGINE
628 in MODEL 163, 220, 211

ENGINE
646 in MODEL 203, 211

ENGINE
647 in MODEL 211

ENGINE
648 in MODEL 220, 211

ENGINE
668 in MODEL 168

ENGINE
612, 628 in MODEL 463

Modification notes

23.3.01

Supersedes STIP 07.16-014 dated 11.12.00

Damage code
Cause
Remedy

07 206 D5
High-pressure pump

To verify whether high pressure pump is

damaged.

#

High pressure pump of common rail

injection system is damaged mechanically.

1
Remove/install/replace high pressure

pump.

When the high pressure pump of the common

rail injection system is damaged metal chips

and/or damage to the pump drive (timing

drive) can occur due to contamination of the

injection system components.
2
Turn high pressure pump by hand with

driver.

If mechanical resistance can be felt,

perform the following tests. Clarify additional

work with ESKULAB by specifying repair work:

#
3
Check driver of high pressure pump or

mount in sprocket for damage (visual

check).

If high pressure pump is locked:
#
4
Check timing

5
Check timing drive for damage.

In each case:
#
6
Remove/install/replace timing chain.

If timing deviates by a crankshaft angle of

more than 20 degrees (corresponding to one

tooth skipped):

#
7
Check pressure loss.

8
Open low pressure connection on high

pressure pump return (plastic line in

area of pressure regulator valve) and

check connection point in rail for chips.

If chips are present when checking

injection system:

#
9
Thoroughly clean all fuel low pressure

lines as well as feed and return lines.

Flush and blow out with compressed air.

10
Remove fuel preheater and fuel filter

with filter housing, replace.

Fuel preheater is only installed in models

202, 203 and 163.

11
Remove/install/replace fuel cooler at

vehicle and engine end.

Not installed in model 210 up to 6/99 and

model 168.

12
Remove fuel tank, replace.

On engine 628:
#

13
Remove/install/replace electric supply

pump.

14
Remove/install/replace injectors, rail

(including pressure regulation valve and

rail pressure sensor), high pressure

lines and injector leak oil rail.*

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

Fuel pump (gear pump) and electric

shutoff valve can remain on engine.

15
Check injection system for leakage.

16
Check with HHT/DAS for proper

function (check actual value).

17
Read DTC memory and erase after
checking.

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