1997 MERCEDES-BENZ ML430 ignition

Fig. 83: Identifying Valve Springs And / Or Valve Stem Seal Components -Shown On Engine 112 (2 Of
2)
Remove/install
1Remove engine cover or
air filterRemove engine trim
panel or air filter by
pulling it vertically up
and off the cylinder head
covers.
2Remove viscous fan (1) Right-hand thread!AR20.40-P-5660C
3Fan shroud (2) On model 163
unscrew bolts at bottom
of fan shroud.
Models 163.AR20.40-P-5000GH
Model 463.AR20.40-P-6800V
4Remove poly-V-belt (3) Installation: Lock
tensioning device with a
drift or pin (diameter 5
mm).AR13.22-P-1202B
5Remove cylinder head
covers (6)Air filter located at
vehicle side.AR01.20-P-5014B
Air filter located on
engine side.AR01.20-P-5014BV
6
Remove spark plugs (8)Only one spark plug at
each cylinder.
Models 163.AP15.10-P-1580GH
Models 129, 202, 208,
210.AP15.10-P-1580A
Model 463.AP15.10-P-1580GA
7Remove intake manifold
(7) The intake manifold
system must not be
disassembled.
Remove intake
manifold together with
fuel rail.
Models 129, 163, 202,
208, 210.AR09.20-P-1310A
Model 463.AR09.20-P-1310AG
8Position crankshaft to 40°
after ignition TDC of
cylinder 1 Engine must not be
cranked back!AR05.10-P-6858V
9Remove chain tensioner
(5) AR05.10-P-7800C
10Remove camshaft AR15.10-P-2000A

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 79 © 2006 Mitchell Repair Information Company, LLC.

position sensor (11)
11Remove camshaft
sprockets (10) Lock right and left
camshaft with locating
plates.
Locating plateFig. 11
Locating plateFig. 12
Open-end wrenchFig. 22
Insertion toolFig. 66
Torque wrench001589722100
*BA05.20-P-1001-01B
After installation: ?
Inspect timing of engine.AR05.10-P-6858V
? If necessary after
checking:
Set basic position of
camshafts.AR05.20-P-6020AU
12Remove camsha ft bearing
bridges (9)Engines 112, 113 except
code (479) Cylinder
shutoff.AR05.20-P-7103AU
Engine 113 with code
(479) cylinder shutoff.AR05.20-P-7103AV
13Position piston of cylinder
to be processed to TDC Crank engine at
crankshaft for this
purpose and hold up
timing chain (so that it
does not jam).
Installation: Before
installing the camshaft
sprockets, again turn
back the crankshaft in the
starting position to 40 °
as per ignition TDC at
the first cylinder.

14Install retaining lock (13)
for crankshaft After setting TDC of
cylinder to be processed,
in order to prevent
crankshaft turning
further.AR03.30-P-5000B
15Connect up cylinder leak
tester (12) Turn connection
hose of cylinder leak
tester into the relevant
spark plug hole.*WH58.30-Z-1015-05A
16Pressurize compression
chamberWith a pressure of about
5 bar.

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 80 © 2006 Mitchell Repair Information Company, LLC.

Fig. 17: Inspecting Cylinders With Light Probe
Shown on engine 112
Remove/install
Risk of death caused by
contact with parts
conducting high voltages.Do not touch parts which
conduct high voltages.
Persons who have
electronic implants (e.g.
pacemakers) must not
perform any work on the
ignition system.AS15.10-Z-0001-01A
Risk of injury to skin and
eyes caused by handling
hot or glowing objects.Wear safety gloves,
protective clothing and
safety glasses, if necessary.AS00.00-Z-0002-01A
Risk of death cased by
vehicle slipping or
toppling off of the lifting
platform.Align vehicle between the
columns of the hydraulic
hoist and position the four
support plates below the
hoist support points
specified by the vehicle
manufacturer.AS00.00-Z-0010-01A
1Remove a spark plug from
each cylinderType 208.474
Type 202.088
Model 210.062/262
Replace spark plugsModel 129 with engine
112.923/943, 113.961AP15.10-P-1580AC
Model 163 with engine
112, 113AP15.10-P-1580GH
Model 209, 210 except
210.062 /262, 208 except
208.474, 202 except
202.088 with engine 112,
113
Model 203, 170 with
engine 112AP15.10-P-1580A
Model 215, 220 with
engine 137
Model 215, 220, 230 with
engine 275
Model 215, 220 with
engine 285AP15.10-P-1580L
Model 211 with engine
112, 113
Model 215 with Engine
113 AP15.10-P-1580AB

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 26 © 2006 Mitchell Repair Information Company, LLC.

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.

Model 203, 170 with
Engine 112.
Model 163 with Engine
112, 113.AP15.10-P-1580GH
Model 215, 220 with
Engine 137.AP15.10-P-1580L
Model 230.474/475, 211,
220 with Engine 112, 113AP15.10-P-1580AB
Model 240 with Engine
285.AP15.10-P-1580H
Model 463 with Engine
112,113AP15.10-P-1580GA
4Position piston of
cylinder to be tested to
ignition TDC Crank the engine at the
center bolt of the crankshaft
in the direction of rotation
of engine.
5Connect cylinder leak
tester (04) Calibrate cylinder
leakage tester (04) and
screw the connection hose
into the spark plug bore
Cylinder leak tester
*WH58.30-Z-1015-05A
6Remove the oil filler cap
(3)
Inspection
7Apply compressed air to
the cylinder, read off
pressure loss on the
cylinder leakage tester
(04) and determine the
cause if there is an
increased pressure lossCylinder leaktightness
permissible loss total
indication*BE01.00-P-1001-02Z
Cylinder leaktightness
permissible losses at valves
and cylinder head gasket*BE01.00-P-1002-02Z
Cylinder leaktightness
permissible losses at pistons
and piston rings*BE01.00-P-1003-02Z
If the crankshaft rotates: ?
Engine 112, 113, 137.
Install retaining lock for
crankshaft
AR03.30-P-5000B
Engine 285.
Lock crankshaft with
counterholder.
Retainer
Fig. 31
8Conduct the test of the
other cylinders in the
firing order of the engine AR01.00-P-1300-03HA
9Install in the reverse

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 41 © 2006 Mitchell Repair Information Company, LLC.

ENGINE 275 in MODELS 215, 220, 230
Shows model 202
Fig. 39: Identifying Cranking Engine With Starter
- Shows Model 202
Remove/install

Danger!
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
1Switch off ignition
Vehicles with Keyless-Go Code
889: press Start/Stop button
repeatedly until ignition is switched
off.

Model 129AR01.10-P-
0010-01AV
Model 163.1AR01.10-P-
0010-01V
Model 170AR01.10-P-
0010-01CA
Model 210 with engine 112 up to
production date 1.3.1997AR01.10-P-
0010-01B
Model 210 with engine 112 from
production date 2.3.1997,AR01.10-P-
0010-01E
Models 202, 208 with engine 112,
Models 210, 202, 208 with engine

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 47 © 2006 Mitchell Repair Information Company, LLC.

Fig. 40: Identifying Electrical Connection Kit (220 589 00 99 00)
2Connect compression recorder (01)
113
Model 211AR01.10-P-
0010-01T
Model 215, model 220AR01.10-P-
0010-01L
Model 230AR01.10-P-
0010-01R
Model 240AR01.10-P-
0010-01H
Model 463.2AR01.10-P-
0010-01GV
Compression recorderFig. 21
Electrical connection setFig. 40
Adapter cableFig. 42
3Crank engine
Press contact switch (02) on
compression recorder (01) for this
step.
Do not crank engine via
ignition/starter switch (8), EIS [EZS]
control unit or Start-Stop button.

4Install in the reverse order
5Read out fault memory and erase if
necessary
If the ignition was switched on
during the process: ?
Stored faults which may be caused
by removal and installation or test
operations, must be erased from the
diagnostic trouble code memories
after completing the work.
STAR DIAGNOSIS di agnosis system
Handheld tester (HHT)
*WH58.30-
Z-1048-13A
*WH58.30-
Z-1036-13A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 48 © 2006 Mitchell Repair Information Company, LLC.

housing coolant line
--> (17) from
thermostat housing
15.1Remove radiator Only engine 113.942 /965 /981.AR20.20-P-
3865HC
16Remove brake
pressure regulator
vacuum line (5) from
brake pressure
regulator at rear of
intake manifold
17Extract power
steering pump (19)
oil Hand pumpFig. 50
18Detach return flow
line and pressure line
of power steering
pump (19) Seal connections!
Set of plugsFig. 51
*BA46.30-P-
1002-01A
*BA46.30-P-
1003-01A
19Remove regeneration
vacuum line (6) from
intake pipe
Risk of explosion
caused by ignition of
flammable products,
risk of poisoning
caused by inhaling
fuel vapors or
swallowing fuel as
well as risk of
injury to skin and
eyes exposed to fuel.No fire, sparks, ope n flames or smoking.AS47.00-Z-0001-
01A
Pour fuels only into suitable and appropriately
marked containers.
Wear protective clothing when handling fuel.
20Disconnect fuel line
(4) Release fuel pressure through service valve!
Collect fuel.
M112: ?
*BA07.52-P-
1001-01A
M113: ?
*BA07.52-P-
1001-01A
Pressure hoseFig. 52
21Detach coolant line
(14)

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 55 © 2006 Mitchell Repair Information Company, LLC.