1997 MERCEDES-BENZ ML350 check engine

covers and sealing ring of the hot
film air mass sensor in the air
filter housing with lubricant.
Models 230.474, 203.065/265,
170.466AR09.10-P-1150SVK
Lubricant
*BR00.45
-Z-1002-
06A
3Remove spark plugs Remove only one spark plug
per cylinder: ?
Models
463.209 /232 /233 /244 /245 /250
with engine 112.945.AP15.10-P-1580GA
Models
463.206 /240 /241 /247 /248 /
249 /254 with Engine 113.962.
Models 463.243 /246 with Engine
113.982
Models 211, 220, 230.474/475AP15.10-P-1580AB
Models 210, 208, 203, 202, 170,
129AP15.10-P-1580A
4.1Remove key from
electronic ignition switch
(EIS)Models 211,230.474/475
Vehicles with code (889)
Keyless Go: Press the start/stop
button repeatedly until the ignition
is switched off.

5Crank engine with
starter. Do not crank engine at steering
lock but use contact switch of the
compression recorder.
In order to remove the
combustion residue from the
cylinders, crank the engine for
about 5 seconds with the starter.
All except model 203AR01.10-P-0110V
Model 203AR01.10-P-0110PV
Checking
6Insert compression tester
into spark plug bore Compression recorderFig. 21
7Open throttle valveExcept models 211, 230.474/475
8Crank engine with
starter. Do not crank engine at steering
lock but use contact switch of the
compression recorder.
All except model 203AR01.10-P-0110V
Model 203AR01.10-P-0110PV

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 34 © 2006 Mitchell Repair Information Company, LLC.

Fig. 30: Identifying Components For Inspecting Cylinders For Leaks
Shown on Engine 112
Remove, Install

1Risk of accident from
vehicle starting off by
itself when engine
running. Risk of injury
suffered in the form of
bruises or burns to the
hands when reaching in
while the engine cranks
or runs
Bring engine to operating
temperature (approx. 80 °
C)Secure vehicle to prevent it
from moving off by itself.
Wear closed and close-
fitting work clothes.
Do not grasp hot or rotating
parts.
Check the cylinder for
leaks only when the engine
is at normal operating
temperature.AS00.00-Z-0005-01A

Risk of injury to skin
and eyes suffering
scalding from contact
with hot coolant spray.
Risk of poisoning from
swallowing coolant.
Do not open cooling system
unless coolant temperature
is below 90 °C. Open cap
slowly and release the
pressure. Do not pour
coolant into beverage
bottles.
Wear protective gloves,
protective clothing and eye
protection.
AS20.00-Z-0001-01A
2Open cap (2) of
expansion reservoirIn Model 463 with Engine
112, 113, a cap (2) with a
detent is built-in
Turn cap carefully up to the
first pre-detent, relieve the
pressure and then unscrew
the cap (2).
A 1-stage cap is fitted to
Model 163 with Engine
112, 113.
Turn the 1-stage and 2-
stage cap half a revolution
counterclockwise, relieve
the pressure, then unscrew
the 1-stage or 2-stage cover.
3Remove a spark plug
(19) from each cylinder
Model 202, 208, 209, 210
with Engine 112, 113.AP15.10-P-1580A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 40 © 2006 Mitchell Repair Information Company, LLC.

22Disconnect engine
wiring harness AR01.00-P-
2410V
23Remove poly V-belt
(3) Installation: Lock tensioning device with a
drift or pin (diameter 5 mm).
Model 163.154/157/172.AR13.22-P-
1202B
Model 163.174/175.AR13.22-P-
1202BA
24Disconnect
connector from A/C
compressor (10)
25Unbolt AC
compressor (10)
from timing case
cover Attach AC compressor at side in bottom of
engine compartment with lines connected.

*BA83.55-P-
1001-01A
26.1Remove left inner
fender (24) Only engine 113.942 /965 /981.AR88.10-P-
1300GH
27.1Remove shield (25) Only engine 113.942 /965 /981.
28Detach exhaust
system (11) at
exhaust manifold Installation: On vehicles with engine
damage check exhaust sy stem for chips before
assembly and remove any chips present to
prevent later damage

*BA14.10-P-
1002-01B
29Detach exhaust
bracket (12)Support exhaust system for this step.
Installation: Install new nuts.
30Unbolt torque
converter (20) from
starter ring gear(21) Installation: The mounting points (arrows,
black) of the torque converter (20) must be
flush with the three recesses (arrows, white) in
the starting ring gear (21).

*BA27.20-P-
1002-01C
31Disconnect left O2
sensor connector
before TWC
(G3/3x1) and right
O2 sensor connector
before TWC
(G3/4x1) from
transmission Remove cable ties!
32Unscrew starter Do not disconnect electric cables.
*BA15.30-P-
1003-01A
33Unscrew bolts at
transmission bell Engine 112.942/ 970.
Do not unscrew two top bolts at transmission
bell.
Engine 113.942 /965/ 981. Do not unscrew

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

Oil pan
Fuel distributor
Fuel distributor
Exhaust manifold
when engine is
running. Risk of
injury caused by
contusions and burns
during starting
procedure or when
working near the
engine as it is
running
Check for leaks with
engine runningDo not touch hot or rotating parts.
44Read out fault
memory and eraseStored 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.
NumberDesignation
Engine 112.910/911/ 912/913/914/
915/917/920/ 921/922/923/
940/941/942/ 943/944/945/
946/947/949/ 951/954/955/
960/961/970/ 972/973/976Engine 113.940/941/
942/943/944/ 945/946/960/
961/962/963/ 965/967/968/
969/980/981/ 982/984/986/
992/995
BA01.45-P-
1003-01BOil drain
screw to
oil pan
M14Nm3030
NumberDesignationEngine 112 except 112.945/951/ 960/961
BA07.52-P-1001-01AFuel feed line to fuel distributorNm38
NumberDesignationEngine 113.940/941/ 942/943/944/ 945/946/948/ 960/961/962/
963/964/965/ 966/967/968/ 969/971/ 980/ 981/982/984/ 986/988
BA07.52-P-
1001-01AFuel feed line to
fuel distributorNm38
NumberDesignation
Engine 112
except
112.951 / 976Engine 113.940/941/ 942/943/944/
945/946/948/ 960/961/962/ 963/964/965/
966/967/968/ 969/971/980/ 981/982/984/
986/992/993/ 995
Flange connection,

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 58 © 2006 Mitchell Repair Information Company, LLC.

Double open-ended wrenchFig. 57
5Pull off vent hoses on
right connector (6) and on
left connector (7) of the
right cylinder head cover
(2) and left cylinder head
cover (3)
6Pull off engine vent hose
on left connector (8) of
left cylinder head cover
(3)
Risk of explosion caused
by fuel igniting, risk of
poisoning caused by
inhaling and swallowing
fuel as well as risk of
injury to eyes and skin
caused by contact with
fuel.No fire, sparks, open flames or
smoking.
Pour fuels only into suitable and
appropriately marked containers.
Wear protective clothing when
handling fuel, date service.AS47.00-Z-0001-01A
7.1Disconnect fuel line at
fuel rail Only in case of vehicles with
a non-flexible fuel line and.
Models 211.061/065/
070/076/276,
Model 215.374
Model 220.074
Model 230.474/475
Release fuel pr essure through
service valve!
Engine 112*BA07.52-P-1001-01A
Engine 113*BA07.52-P-1001-01A
Pressure hoseFig. 52
8Remove right cylinder
head cover (2) and left
cylinder head cover (3) Installation: Check cylinder
head covers for leaks, see: ?
Ensure cylinder head cover
gasket is correctly installed.AR01.20-P-5014-01B
*BA01.20-P-1001-01E
9Install in the reverse order

10Risk 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 Secure 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

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 68 © 2006 Mitchell Repair Information Company, LLC.

Fig. 70: Identifying Heli-Coil Repair Set (102 589 00 99 00)
CHECKING CYLINDER HEAD BOLTS - AR01.30-P-5800-03B
Cylinder head/Cylinder head bolts
Cylinder head/cyl inder head bolts
1. Measure length (L) of cylinder head bolts.
If the length (L) exceeds the maximu m permissible dimension then the cyli nder head bolts must be replaced.
NumberDesignation
Engines
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/
973/975/976Engines
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/987/988/
990/991/992/
993/995
BE01.30-P-
1001-04BCylinder head
boltThread diameterM1111
Length (L) when
newmm141.5141.5
Length (L)mm< or = 144.5< or = 144.5
See pictureAR01.30-P-
5800-03B
AR01.30-P-
5800-03B
NumberDesignationEngine 113.989
BE01.30-P-1001-
04BCylinder head boltThread diameterM11
Length (L) when
newmm141.5
Length (L)mm< or = 144.5
See pictureAR01.30-P-5800-
03B

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 77 © 2006 Mitchell Repair Information Company, LLC.

*BA07.52-P-
1001-01A
Pressure hoseFig. 52
12Remove right and
left ignition coils
(12) AR15.12-P-
2003A
13Remove right and
left cylinder head
covers (13) AR01.20-P-
5014B
14Remove intake
manifold (14) Installation: On vehicles with engine
damage, the intake manifold must be examined
for swarfs before assembling and any swarfs
present must be removed, in order to avoid
consequential damage.
The intake manifold system must not be
disassembled.
Remove intake manifold together with fuel
distributor.AR09.20-P-
1310A
15.1Remove camshaft
angle position sensor
(15) Only necessary if right cylinder head is
removed.AR15.10-P-
2000A
16Remove poly-V-belt
(8) Installation: Lock tensioning device with a
drift or pin (diameter 5 mm).
Models 163.154/157/172.AR13.22-P-
1202B
Models 163.174/175.AR13.22-P-
1202BA
17Detach coolant line
(16) at left cylinder
head 6 mm socket hexagon*WH58.30-Z-
1001-06A
7 mm socket hexagon*WH58.30-Z-
1002-06A
18.1Remove inner fender
(9) Only for engine 113.942 /965 /981.AR88.10-P-
1300GH
19.1Remove shield (10) Only for engine 113.942 /965 /981.
20.1Remove exhaust
bracket (11) Only for engine 113.942 /965 /981.
Support exhaust system.
21Detach exhaust
system at exhaust
manifold Installation: On vehicles with engine
damage check exhaust sy stem for chips before
assembly and remove any chips present to
prevent later damage
*BA14.10-P-
1002-01B
22Position crankshaft
to 40° after ignition The engine must not be turned back;
otherwise the timing chain can get jammed. AR05.10-P-
6858V

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 87 © 2006 Mitchell Repair Information Company, LLC.

TDC on first cylinder Rotate engine at cra nkshaft in direction of
rotation until 40° marking on belt pulley/
vibration damper is al igned with marking on
timing case cover.
The grooves on the camshafts must be pointing
toward the inner V.
23Lock camshafts with
locating plate Locating plateFig. 85
Locating plateFig. 86
24Remove chain
tensioner (17)Model 163.154 /157 with Engine 112.942 /970,
model 163.172 with Engine 113.942.AR05.10-P-
7800C
Model 163.174/175 with Engine 113.981 /965.AR05.10-P-
7800CA
25.1Remove oil filter
housing (18) with
oil/water heat
exchangerEngine 113.942.AR18.20-P-
3471B
Engines 113.965/981.AR18.20-P-
3471BA
26Remove camshaft
sprockets (19) If the camshaft sprockets are removed, the
engine must no longer be cranked otherwise the
timing chain might jam.
Engines 113.942 /965/981: ?
Tie timing chain tight on both camshaft
sprockets with cable straps.
Engine 112.942 /970: ?
Right-hand camshaft sprocket:
Tie timing chain tight on camshaft sprocket
with cable strap.
Left-hand camshaft sprocket:
Mark camshaft sprocket to timing chain and
remove camshaft sprocket.
It is not possible for the timing chain to
jump across at the crankshaft and balancing
shaft.
After installation: ?

Inspect basic positi on of camshafts.
If necessary after checking: ?AR05.10-P-
6858V
Set the basic position of camshafts.AR05.20-P-
6020AU
Open-end wrenchFig. 87
Insertion toolFig. 88
Torque wrenchFig. 92
*BA05.20-P-
1001-01B
27Remove camshaft
bearing bridges (28) Observe slackening and tightening pattern!AR05.20-P-
7103AU

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 88 © 2006 Mitchell Repair Information Company, LLC.