1997 MERCEDES-BENZ ML350 check engine

1998-2005 ENGINE
Complete engine - 163 Chassis
GENERAL INFORMATION
DETERMINE LOSS OF PR ESSURE AT CYLINDER - AH01.00-N-1300-02A
All engine
If an increased pressure loss was found with the cylinde r leak tightness tester, inspect engine by listening at
cylinder head gasket, air intake area, exhaust, oil fi ller opening and prechamber or spark plug bores of the
adjacent cylinder or cylinders.
Check the coolant in the coolant expansion reservoir for the formation of air bubbles.
Possible causes for the pressure loss are: 1. Outlet of air through prechamber or spark plug bo re of adjacent cylinder or cylinders, air bubbles
in coolant expansion reservoir:
pressure loss at cylinder head gasket
2. Outlet of air through air intake area:
For inspecting by listening, open throttle valve pressure loss at inlet valve(s)
3. Outlet of air through exhaust:
pressure loss at exhaust valve(s)
4. Outlet of air through oil filler opening:
pressure loss through pistons and piston rings
It is possible to pinpoint the pressure loss of the rele vant cylinder by spraying with engine oil. Engine oil
seals off the gap between piston and cylinder briefly.
If a reduced pressure loss now occurs for a short time, th e cause is very likely to be at the pistons, piston rings
or cylinder contact surface of the relevant cylinder.
Determining the cause can be falsified by the position of th e piston ring joints. If suspicion exists that the loss o
f
pressure is caused by the piston ring joints being positioned directly one above the other, fit parts to engine and
repeat test after running engine for a short time.
GENERAL INFORMATION ON INSPECTING CYLINDER WALLS - AH01.00-P-0300-01A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:55 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.
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Saturday, October 02, 2010 3:18:01 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.

USE OF ENGINE NO. WHEN INSTALLING RECONDITIONED ENGINES AND FACTORY-NEW REPLACEMENT
ENGINES OR CRANKCAS ES - AH01.10-P-0001-01A
All engines
The engine number has a different le gal significance in individual countries. In the Federal Republic of
Germany, for example, it has been cl assified by the legislative authorities since mid-1972 as "insignificant in
terms of traffic legi slation". It is therefore no longer included in the vehicl e title document and vehicle
registration document.
Practically all other countries continue to require the indication of the engine number on motor vehicles which
are registered in such countries. In dealing with internat ional traffic, the authorities proceed on the basis of the
provisions of the country in which the vehicle is registered.
In order to avoid any problems on the occasion of vehicl e checks or when crossing international frontiers as a
result of the lack of or in correct engine number, the fo llowing directives have to be observed when carrying out
repairs.
1. Directives for vehicles wh ich are registered in the Fe deral Republic of Germany
a. In the case of vehicles for which no engine number is indicated in the vehicle registration
document (first registration after a pprox. mid-1972), it is not necessa ry to stamp or revise an
engine number if a replacement engine or crankcase of the same type is fitted.
b. If an engine number is indicated in th e vehicle registration document , it is possible, if an
engine of the same type is fitted, to transfer the number of the removed component to the new
engine, or the appropriate authority (vehicle in spection authority, vehicle registration authority)
should be requested to delete the engine numbe r in the vehicle title document or registration
document. The German Federal Mini ster of Transport has issued appropriate ministerial orders in
Transport Gazette 1973, p. 66.
2. Vehicles which are registered outside of the Federal Republic of Germany
If a reconditioned engine or factory-new replacement engine or crankcase is fitted and this is of the
identical type, it is then necessary to adopt the engine number of the engine removed and to transfer it to
the new engine or crankcase.
For this reason, pay attention to th e particular directives stated in Para 3 for the installation of
reconditioned en
gines, crankcases and shortblocks.

Notes on application of
sealant to the timing case
cover
ENGINE 611, 612, 613, 646, 647, 648 ...AH01.40-P-
1000-01E

Information on applying
sealant to a cylinder head
gasketENGINE 112 ENGINE 113 ENGINE 112.951 ENGINE
112.976AH01.30-P-
1000-04VA
NOTE: It is possible in the case of vari ous engines only to stamp the engine
number in place when the engine is removed.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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3. Special directives
3.1 Installation of factory-new repl acement engine of identical type
a. If a factory-new engine is installed and an engine num ber is required (e.g. vehicle registered
outside of the Federal Republic of Germany), the number of the factory-new engine must be
ground off and the number of the originally instal led engine of identical type stamped in its
place.
b. If the factory-new engine is fitted with an e ngine type plate (older car engines) and it is
necessary to indicate an engine number in the ve hicle documents, in this case take the engine
type plate off the engine remove d and affix it at the same point on the engine of identical
type to be installed.
3.2 Installation of recondition ed engine of identical type
a. The reconditioned engine plate must not be re moved either from the reconditioned engine to
be installed, nor from the engine removed, if the latter was a reconditioned engine.
b. If the engine removed is fitt ed with an engine type plate (older car engines) and it is
necessary to indicate an engine number in the vehicle documents, the engine type plate then
has to be taken off the engine removed and a ffixed at the same point to the reconditioned
engine to be installed. This plate should be affixed in addition to the reconditioned engine
plate.
In the event that a vehicle owner has problems on the occasion of vehicle checks or when crossing
international frontiers be cause of the lack of an engine num ber, the workshop in question may in
certain circumstances be held liable.
After replacing an engine , the engine number has to be altere d in the vehicle maintenance booklet
and on the vehicle data cards as well as in the re pair customer file. These documents should clearly
show which engine is installed in the vehicl e in order to ensure smooth parts service.
In addition, the copy of the vehicle data card which is held at the Parts Department of the relevant
Branch or Importer shoul d also be altered.
3.3 Model designation id entification of crankcases and shortblocks
Crankcases and shortblocks available in the parts sector are not provided with an engine model designation
identification and also not with an engine number.
To make it possible to identify the engine on the occas ion of vehicle inspections (e.g. by an inspection authority
when a vehicle is taken out of service or at the Customs on the occasion of importation of vehicle), the
workshop carrying out the repairs has to stamp the engine model designation in the crankcase or the shortblock
in the space provided fo r the engine number.
Example:
Type Engine model designation
201.024 102.962

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Extract from Transpor t Gazette 1973 p. 66
(applies only to the Federal Republic of Germany)
Official Gazette of the Fede ral Minister of Transport
Directive in respect of vehicl e title document (VkBl 1972 p. 354)
Bonn, 28 December 1972
StV 2/36.15.17
Pursuant to the directive relating to the vehicle ti tle document dated 20 June 1972, Part C. No. 9.1, a dash
should be inserted at the relevant poi nt in the place of data which are no longer required in future (e.g. in the
case of the "factory number of engine") in those instances where the olde r type of title documents are used for
the preparation of the vehicle title document.
The question which is now posed is what procedure shoul d be adopted in respect of the vehicle title document
or the vehicle registration document in the event that th e factory number of the engine from the past is still
entered in the older type of title documents and a repl acement engine with a new number is now installed in the
vehicle in question. Following consul tation with the competent authorities in the regions, I now provide the
following instructions:
I. In view of the fact that the fact ory number of the engine is regarded as insignificant in respect of traffic
legislation, no change requires to be made to the vehicle documents. This also does not conflict with 27
Para 1 StVZO pursuant to which the data in the vehi cle title and registration documents constantly have
to reflect actual circumstances. This requirement namely covers only those particulars relating to actual
circumstances which are of significance in terms of traffic legislation. This is no longer the case,
however, in respect of the fa ctory number of the engine.
II. In order to spare the relevant vehicle owner any misunderstandings or indeed possible disadvantages (e.g.
on the occasion of checks when abroad), I recommend proceeding as follows:
In the event that the replacement engine installed has a different number than that entered in the title and
registration document, the figures in the column "e ngine factory number" shall be deleted and the following
endorsement made at a suitable point both in th e title as well as in the registration document:
"Entry of engine factory number no longer necessary".
If the endorsement is made close to th e deletion, it is sufficient to state:
"Entry no longer required".
The Federal Minister of Transport Ip. p.
Wagner
NOTES ON APPLICATION OF SEALANT TO CYLINDER HEAD GASKET - AH01.30-P-1000-04V

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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The sealing compound must only be applied to the speci fied surfaces in the form of a bead of 2.0 mm ± 0.5
mm in diameter.
The sealing compound must be processe d within 10 min. The sealing compound bead must not be spread. Only
the sealing compound listed in the s ection Repair products may be used.
TROUBLE DIAGNOSIS
GURGLING NOISE IN HEA TER HOUSING - AF01.30-P-1000AG
ENGINE 113.##### up to 286599 in MODEL 129, 163, 202, 208, 210, 215, 220
ENGINE 113.### ## up to 286599 in MODEL 463
Modification notes
17.1.01Replaces STIP 20.10-004 dated 17.01.2001
Damage
codeCauseRemedy
01 243 B2
Heater return duct in cylinder
head clogged with casting
crust
Before working on the cooling system,
coolant pump, heater housing, etc.:?
1 Remove left cylinder head
ENGINE 113 in MODEL 210, 208, 202, 129AR01.30-P-
5800B
ENGINE 113 in MODEL 220AR01.30-P-
5800BA
ENGINE 112.945, 113.962 in MODEL 463AR01.30-P-
5800GV
ENGINE 113.942 in MODEL 163.172
ENGINE 113.981 in MODEL 163.174AR01.30-P-
5800MV

2 Check coolant duct, if necessary, remove
possible casting crust
As of engine end number 285600 (as of
beginning of 01/2001) there is no casting crust
at this point.


2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Fig. 15: Locating Casting Crust In Cooling Duct
COOLANT TEMPERATURE HIGHER THAN NORMAL - AF01.30-P-8000A
ENGINE 113.##### up to 286599 in MODEL 129, 163, 202, 208, 210, 215, 220
ENGINE 113.### ## up to 286599 in MODEL 463
Modification notes
17.1.01Supersedes STIP 20.10-004 dated 17.01.2001
Damage
codeCauseRemedy
01 243 B2
Cylinder head with
casting crust in
coolant duct
Before performing work on cooling system, coolant
pump, heater housing, etc.: ?
1. Remove left cylinder head

ENGINE 113 in MODEL 210, 208, 202, 129AR01.30-P-
5800B
ENGINE 113 in MODEL 220AR01.30-P-
5800BA
ENGINE 112.945, 113.962 in MODEL 463AR01.30-P-
5800GV
ENGINE 113.942 in MODEL 163.172AR01.30-P-
5800MV
ENGINE 113.981 in MODEL 163.174

2 Check coolant duct, if necessary, remove possible casting
crust As of engine end number (as of beginning of
01/2001) there is no casting crust at this point.


2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Saturday, October 02, 2010 3:17:56 PMPage 24 © 2006 Mitchell Repair Information Company, LLC.

Model 220 with engine
112, 113
Model 230 with engine
112, 113
Model 240 with engine
285AP15.10-P-1580H
Model 463 with Engine
112, 113AP15.10-P-1580GA
2.1Remove bottom engine
compartment panelingModel 240AR61.20-P-1105H
3Position piston of cylinder
to be inspected to BDCTo do this, crank the
engine at the central bolt of
the crankshaft in the
direction of rotation of the
engine: ?
Firing orderAR01.00-P-1300-03HA
4Connect cylinder
inspection lamp (05) and
insert the flexible test
probe for the inspection
lamp via the spark plug
bore into the respective
cylinder Cylinder inspection
equipment*WH58.30-Z-1014-05A
Flexible inspection light*WH58.30-Z-1006-05A
Flexible inspection light*WH58.30-Z-1007-05A
Check
5Inspect cylinder walls Normal condition:
Mat-grey surface, no
honing pattern.
If the condition of the
cylinder wall is not clearly
recognizable: ?
Model 129, 163, 170, 202,
203, 208, 209, 210,
215,220,230,463
Remove cylinder head
Model 129 with engine
112, 113AR01.30-P-5800B
Model 202, 208, 210 with
engine 113
Model 163 with engine
112, 113AR01.30-P-5800MV
Model 170, 202, 208, 210
with engine 112AR01.30-P-5800BA
Model 220 with engine
112, 113
Model 230 with engine

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 27 © 2006 Mitchell Repair Information Company, LLC.

connection for hot
film mass air flow
sensor (HFM-SFI)
for this step and
unbolt resonance
pipe at cylinder
head cover.

The resonance pipe is
attached to the rear of the
intake manifold with a
plastic bracket.

Do not damage plastic
plate.
5Remove spark plugsRemove only one spark
plug at each cylinder: ?
Models 210, 208, 202
with engine 112
Model 210 with engine
113AP15.10-P-1580A
Model 163 with engines
112, 113AP15.10-P-1580GH
6Crank engine with starter.Do not crank engine at
steering lock but use
contact switch of the
compression recorder.
Crank engine several
times with the starter in
order to eliminate
combustion residues in
the cylinder.AR01.10-P-0110V
Checking
7Insert compression tester
into spark plug bore Fig. 21
8Open throttle valve
9Crank engine with starterDo not crank engine at
steering lock but use
contact switch of the
compression recorder.
To check the
compression pressure,
crank the engine by at AR01.10-P-0110V

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 30 © 2006 Mitchell Repair Information Company, LLC.