1997 MERCEDES-BENZ ML350 check engine

9
Detach return line (30f) and high-pressure

expansion hose (30i)

Connection fittings or banjo bolts

depending on the version. Seal off line

connections with plugs.


Installation:
Replace sealing rings.


Connection fitting, return line

*BA46.20-P-1001-01D

Connection fitting, high-pressure

expansion hose

*BA46.20-P-1002-01D

Banjo bolt, return line

*BA46.20-P-1004-01D

Banjo bolt, high-pressure expansion hose

*BA46.20-P-1005-01D

Plug

*129589009100

10
Detach nut (25d) and bolt from steering

coupling (25) and pull lower steering shaft

(80a) upwards out of steering coupling (25)

Do not use force as the corrugated tube is

sensitive to lateral forces. Enlarge clamping

groove a little with a screwdriver if necessary.


Installation:
Replace nut (25d).


Installation:
Turn rack-and-pinion

steering to center position and fit steering

coupling.

AR46.20-P-0600-01GH


*BA46.10-P-1001-01D

11
Detach rack-and-pinion steering (23) from

front axle carrier (1) by unscrewing bolts (23a)

The installed position of the shims (23h,

23i) on the right-hand side, between the

rubber mount and the front axle carrier, must

be observed as the shims are of different

thicknesses.


Installation:
Attach rack-and-pinion

steering to front axle carrier.

AR46.20-P-0600-03GH


Assessing condition of steering gear when

repairing accident vehicles

AH46.20-P-9409-01A

12
Check rubber mount (21) of rack-and-pinion

steering mounting for damage
Replace rubber mount if necessary:
#

Removing rubber mounts on rack-and-pinion

steering mounting

AR46.20-P-0600-02GH

13
Install in the reverse order

14
Fill and bleed power steering pump
Engines 112, 113

AR46.30-P-0010B
Engines 111, 612, 628
AR46.30-P-0010P

15
Check steering for function and leaks

There is a grease cushion under the cover
cap. A small amount of escaping grease is to

be regarded as normal and must not be

confused with leakage.

16.1
Check toe on front axle and adjust if necessary
When installing a new rack-and-pinion

steering, see:

#

Performing chassis alignment check

AR40.20-P-0200A


Steering shaft

Number

Designation
Model 163

BA46.10-P-1001-01D
Self-locking nut, steering coupling to steering shaft

and rack-and-pinion steering
Nm
28


Steering gear

Number

Designation
Model 163

BA46.20-P-1001-01D
Screwed connection fitting from return line

to rack-and-pinion steering
Nm
15

BA46.20-P-1002-01D
Screwed connection fitting from high-

pressure expansion hose to rack-and-pinion

steering
Nm
15

BA46.20-P-1003-01D
Bolted connection, rack-and-pinion steering

to front axle carrierNm
50

BA46.20-P-1004-01D
Banjo bolt, return line to rack-and-pinion

steering
Nm
30

BA46.20-P-1005-01D
Banjo bolt, high-pressure expansion hose to

rack-and-pinion steering
Nm
30

Copyright DaimlerChrysler AG 06.07.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

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

Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
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

Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 3

SI47.10-P-0004A
Service Information: Procedure when tank is filled with incorrect fuel
19.12.00

MODEL
202 with ENGINE 611

MODEL
203 with ENGINE 611, 612, 646

MODEL
210 with ENGINE 611, 612, 613

MODEL
220 with ENGINE 613, 628, 648

MODEL
163 with ENGINE 612, 628

MODEL
168 with ENGINE 668

MODEL
209 with ENGINE 612

MODEL
211 with ENGINE 628, 646, 647, 648

MODEL
463 with ENGINE 612, 628

Modification notes

26.7.04

Engines have been added and procedure has been updated

Incorrect refueling of diesel-power vehicles with a common rail
injection system. Please be aware that if the customer fills the fuel
tank with the wrong type of fuel, this is the customer's fault and

cannot be submitted as a warranty claim.

If the diesel-powered vehicle with a common rail injection system has

been refueled with gasoline, follow the steps below:

1.
If the engine was not started after fuel tank is filled with the wrong

type of fuel, then emptying the fuel tank and cleaning the fuel low-

pressure lines should be enough to solve the problem.
2.

If the engine was started after fuel tank was filled with wrong type

of fuel:

On engines 611, 612, 613, 668:
-
On the rail, open the low pressure connection of the high
pressure pump return (plastic connection in area of pressure

regulator valve) and check connecting point in rail for chips.

On engine 646, 647, 648, 628:
-
Disconnect Y-distributor unit (return line HDP/Rail) at the output

and, with ignition ON, collect the fuel in a clean container. Check

fuel for metal shavings.

If the high pressure pump is not damaged and there are no metal

shavings in the injection system:

-
As in step 1, empty fuel as per the guidelines and clean the fuel

low-pressure lines. In addition to this, remove/install/replace the

high-pressure pump and fuel filter.

If metal shavings are found in the fuel

system or the high pressure pump drive is

damaged:

#
b

Engine runs rough, surges or does not start
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

AF07.00-P-9000B

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

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.

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

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

The opening angle of the throttle valve will only be determined by the accelerator pedal specification when no
limiting functions are active.
The accelerator pedal position is detected by the set value potentiometer (B37r1) or Hall sensor in the pedal
value sensor (B37) and information is released to the ME control unit (N3/10). In this way, the ME-SFI control
unit determines the position of the throttle valve and actuates the throttle valve motor (M16/1 m1).
The actual value potentiometer in the actuator (M16/1r1) signals the throttle valve position back to the ME-SFI
control unit.
The second potentiometer in the actuator (M16/1 r2) and the second signal from the pedal value sensor
(potentiometer or Hall sensor) supplies a reference value for the plausibility check. In addition, the system
switches over to the second potentiometer or the Hall sensor if the first potentiometer or Hall sensor fails
(emergency mode).
Adaptive accelerator pedal (model 203, 209, 211, 215, 220, 230):
The engine control unit recognizes how the accelerator pedal is being actuated and switches between
characteristic curves. Eighty percent of the engine load is released for a pedal travel of about 50 % for a sporty
driver and about 40 % for a quiet driver. There is no further difference felt above a pedal travel of about 90 %.

If, for example, the characteristic curve for a quiet driver is active after a long drive on the motorway then the
accelerator pedal must be pressed down unusually hard to obtain a higher acceleration level.
Kickdown switch (S16/6)
The kickdown switch was no longer used from 9/01. Recognition of full load is now achieved over the signal
from the pedal value sensor. The pressure point on the accelerator pedal before achieving the full load position
remains.
Motor electronics control unit, location/task/
design/functionexcept M111 EVOGF07.61-P-
5000F
M111 EVOGF07.61-P-
5000GS
Electronic accelerator/cruise control/idle speed
control actuator location/task/design/functionexcept M111 EVOGF30.22-P-
4010F
Throttle valve actuator, location/task/design/
functionM111 EVOGF30.22-P-
4101GS
Pedal value sensor, location/task/design/
function GF30.20-P-
4011L
ME-SFI idle speed control function
Except engine 120 and engine 111 EVOGF30.22-P-
0003E
M111 EVOGF30.22-P-
0003GS

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY CAB Throttle Control, Speed Control Systems - 163 Chassis
me
Saturday, October 02, 2010 3:36:27 PMPage 3 © 2006 Mitchell Repair Information Company, LLC.

ENGINE 113.940 /941 /942 /943 /948 /960 /961 /963 /965 /966 /967 /968 /969
ENGINE 119.980 /981 /982 /985
ENGINE 137.970
Task
To allow safe further driving depending on the fault which has arisen in the electronic accelerator pedal system.
Pedal value sensor emergency mode
If the sensor in the pedal value sensor (B37) fails, the system will switch over to the second sensor. The throttle
valve opening is limited to approx. 60%. There is also dynamic limitation of the throttle valve's opening speed
where the throttle valve opening is delayed (the indicator lamp EPC does not light up).
If the plausibility check delivers a negative result or both sensors are defect only the idling speed will be
regulated (the indicator lamp EPC lights up).
Actuator for the throttle valve - emergency running, electrical
If a potentiometer in the actuator for the throttle valve breaks down the system switches-over to the second
intact potentiometer. The air flow mass serves as a second parameter for comparative purposes. Following a
plausibility check, the throttle valve opening is limited to approx. 60% in line with engine speed and load (EPC
indicator lamp does not come on).
If the plausibility check is negative or if both potentiometers are faulty, the throttle valve adopts a mechanical
emergency running position which is fixed by the spring capsule in the actuator (EPC indicator lamp comes on).
Actuator for the throttle valve - emergency running, mechanical emergency running stop
If the actuator motor is defect or there are other faults present the power supply to the actuator will be shut off.
The throttle valve then lies on the mechanical stop (spring box) so the throttle valve opening remains at a
constant 10-12°. At no engine load (idling) engine speed is regulated to about 900 rpm by shutting off or
activating the cylinders at the fuel side.
When driving, engine speed is controlled, in line with the engine load, by switching the cylinders off and on at
the fuel side. The maximum engine speed is about 1800 rpm. which is limited by the mechanical stop (the
indicator lamp EPC lights up).
Safety fuel shutoff
If a mechanical fault exists in the actuator, the safety fuel shutoff is activated.
Here the fuel injection valves are shut off for engine speeds < 1400 rpm and actuated again at speeds < 1200
rpm (the indicator lamp EPC li
ghts up).

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY CAB Throttle Control, Speed Control Systems - 163 Chassis
me
Saturday, October 02, 2010 3:36:27 PMPage 14 © 2006 Mitchell Repair Information Company, LLC.

Fig. 13: Identifying Electronic Accelerator/Cruise Control/Idle Speed Control Actuator Components
Function
The actual value potentiometers for the throttle valve inform the ME control unit about the position of the
throttle valve (idling up to full load) in order to recognize the various loading conditions.
A.Ignition "Off"
In the de-energized state the throttle valve position is determined by the spring capsule (3).
B.Ignition "On"
When the ignition is switched on, the actuator motor in the EA/CC/ISC actuator is operated by the ME
control unit and the return spring is checked. The throttle valve adopts a position which then depends on
the coolant temperature.
C.Idle speed
The actuator motor controls the engine speed in the idle speed range by opening the throttle valve further,
depending on coolant temperature and engine load (increased mixture), or closing it further (reduced
mixture).
In this case, the throttle valve may be closed further by the actuator motor by overcoming the force of the
sprin
g capsule (mechanical end stop).

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY CAB Throttle Control, Speed Control Systems - 163 Chassis
me
Saturday, October 02, 2010 3:36:27 PMPage 21 © 2006 Mitchell Repair Information Company, LLC.