Page 2239 of 4133
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
Page 2249 of 4133
RISK OF EXPLOSION AND PO ISONING - AS05.30-Z-0001-01A
Do not open sodium-filled valves. Wear protectiv e gloves and safety glasses when handling damaged
valves.
Exhaust valves fill ed with sodium
Potential risks
Risk of explosion
Explosion may occur when melting down sodium-filled va lves. Sodium has a very low self-ignition temperature
(121 °C) and may spontaneously ignite in moist air.
Improper disposal may lead to fires due to moisture in scrap containers.
Risk of poisoning
The inhalation of toxic vapors causes severe irritation, shortness of breath, headaches, nausea and vomiting.
Risk of injury
Leaked sodium that comes into contact with moist body tissue (perspiration on hands, tears) may undergo a
severe, explosive reaction and generate heat. This may lead to skin ir ritation and burns, and to corneal damage
with possible blinding.
Safety instructions/precautions
Keep water and sources of heat and ignition away from sodium.
When handling damaged, sodium-filled valves, wear su itable protective gloves and safety glasses, if
necessary.
Never machine sodium-filled valves.
Do not open sodium-filled valves.
Observe all additional safety requireme nts and regulations in your country.
First aid measures
Skin and eye contact
Remove sodium, treat the injured area with an oily solution, e.g. Biseptol and consult a physician.
Risk of explosion and poisoning caused by the melting down
or improper handling of sodium-f illed valves. Risk of injury
caused by skin contact with s odium resulting in heat or
chemical burns.ENGINE 111, 112, 113,
137, 155, 156, 166, 266,
646, 647, 648 ...AS05.30-Z-
0001-01A
2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 8 © 2006 Mitchell Repair Information Company, LLC.
Page 2251 of 4133
Fig. 8: Identifying Hydraulic Valve Clea rance Compensation Element Components - Shown On Engine
112 In Model 210
Shown on engine 112 in model 210
Remove/Install
1
Remove cylinder
head covers with
ignition coils (6)Air cleaner mounted on vehicle.AR01.20-
P-5014B
Air cleaner positione d at engine side.
AR01.20-
P-
5014BV
2
Position
crankshaft to 0°
after ignition
TDC of cylinder
1
The engine must not be turned back; otherwise the chain can get
jammed.
AR05.10-
P-6858V
Model 129,
463.206/209/232/233/240/241/243/2 44/245/246/247/248/249/250/254,
Model 163 except 163.174/175, Model 202, 208, 210 with engine 113AR05.10-
P-7800C
Model 163.174/175, Model 209 with engine 113.987 up to 23.4.04, AR05.10-
2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:37 PMPage 10 © 2006 Mitchell Repair Information Company, LLC.
Page 2286 of 4133
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249
ENGINE 113 // (except 113.990 /991 /995) in MODEL 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230
ENGINE 113.982 in MODEL 463.243/246
Shown on engine 112
Fig. 51: Identifying Slide Rail In Timing Case Cover Components
- Shown On Engine 112
Modification notes
20.12.04Engine oil filling capacity with oil filter modified.Engine 113.967*BF18.00-P-1001-01H
Remove/install
Risk of death caused by
vehicle slipping or
toppling off the lifting
platform.Align vehicle between the columns
of the and position the four support
plates below the lifting platform
support points specified by the
vehicle manufacturer.AS00.00-Z-0010-01A
1Remove engine
compartment panelingModels 129, 202, 208, 210AR61.20-P-1105AB
Model 230.474 /475AR61.20-P-1105R
Model 215, 220AR61.20-P-1105M
Models 203, 209AR61.20-P-1105P
Model 211AR61.20-P-1105T
Models 170, 202.0AR61.20-P-1105A
2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 45 © 2006 Mitchell Repair Information Company, LLC.
Page 2287 of 4133
Models 163.172/174/175AR61.20-P-1105GH
2.1Remove under-ride guardModel 463.246 with engine
113.982AR88.30-P-0010MG
3.1Remove air baffleModel 163 with engine 113.942
4Drain and collect engine
oil Installation: Replace sealing
ring of the oil drain screw.
Oil drain plug to oil pan
M14*BA01.45-P-1003-
01B
Engine lubrication*BF18.00-P-1001-
01H
5Remove cylinder headsModel 129 with engine 112AR01.30-P-5800B
Models 129, 202, 208, 210 with
engine 113
Models 170, 202, 208, 210 with
engine 112AR01.30-P-5800BA
Model 220 with engines 112, 113
Models 215.374, 230.474/ 475
Models 203.764, 215.373/ 375
Model 463AR01.30-P-5800GV
Models 203, 209,
211.061 /065 /070 /080/
082 /083 /280 /282 /283AR01.30-P-5800PV
Model 163AR01.30-P-5800MV
6Remove oil pan bottom
sectionModels 129, 202, 208, 210, 220
without 4MATICAR01.45-P-7555VA
Model 170 with engine 112
Model 463 with engines 112.945,
113.962/982
Model 220/211 with 4MATICAR01.45-P-7555IW
Models 215.374, 230.474/ 475AR01.45-P-7555R
Models 203.764, 215.373/ 375
Models 203.061/064/ 065/ 261/
264/ 265AR01.45-P-7555PV
Model 209
Models 211.061 /065/070
Model 203 with 4MATICAR01.45-P-7555PW
Models 203.076/ 276AR01.45-P-7555AC
Models 163.154/157/172AR01.45-P-7555V
Models 163.174/175AR01.45-P-7555VE
7Remove timing case
coverModel 170,
210.061 /063 /065 /261 /263/
265 /663 with engine 112AR01.40-P-8000B
Models 129, 163, 202, 208, 210,
230 with engine 113
2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 46 © 2006 Mitchell Repair Information Company, LLC.
Page 2288 of 4133
Oil pan
Oil pan
Model 220 except 220.074 /174
with engine 113
Do not remove top part of oil
pan!
Model 463AR01.40-P-8000GV
Do not remove top part of oil
pan!
Model 210 with 4MATICAR01.40-P-8000GV
Models
203.061 /064 /065 /081 /084 /261/
264 /265 /281 /284 /076 /276AR01.40-P-8000V
Models 209.361/365/ 375/ 376/
461/ 465/ 475/ 476AR01.40-P-8000PV
Models 211.061 / 065/ 070/ 080/
082/ 083/ 280/ 282/ 283
Models 220.074/174AR01.40-P-8000RVK
Model 215.374
Model 203.764
Models 210.062/262
Models 215.373/375
8Remove slide rails (1) At the same time detach slide
rails (1) toward front from the
retaining bolts.
9Install in the reverse
order
NumberDesignationEngines
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/
972/973/976Engines
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 panM14Nm3030
NumberDesignationEngine
112.916/953/975, Engine 113.987/
988/991
2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 47 © 2006 Mitchell Repair Information Company, LLC.
Page 2289 of 4133
Engine lubrication
Engine lubrication
Engine lubrication
113.948/966
BA01.45-P-1003-
01BOil drain screw
to oil panM14Nm3030
NumberDesignationEngine 112
except
112.916/953/975Engine
112.916/953Engine
113.948/966
BF18.00-P-
1001-01HEngine oilFilling capacity
with oil filterLiters8.07.58.0
Filling capacity
without oil filterLiters7.57.07.5
Specifications
for Operating
FluidsSheetBB00.40-P-0229-
01A
BB00.40-P-
0229-01A
BB00.40-P-
0229-01A
SheetBB00.40-P-0229-
03A
BB00.40-P-
0229-03A
BB00.40-P-
0229-03A
SheetBB00.40-P-0229-
05A
BB00.40-P-
0229-05A
BB00.40-P-
0229-05A
NumberDesignationEngine
113.944/944/980981/984/984/986/991Engine
113.963/963/965Engines
113.987/988/990
/
BF18.00-
P-1001-
01HEngine
oilFilling
capacity with
oil filterLiters7.57.58.5
Filling
capacity
without oil
filterLiters-7.08.0
Specifications
for Operating
FluidsSheet-BB00.40-P-
0229-01A
-
Sheet-BB00.40-P-
0229-03A
-
SheetBB00.40-P-0229-05A BB00.40-P-
0229-05A
BB00.40-P-0229-
NumberDesignationEngines
113.940/941/
942/943/960/
961/962/969/
982Engine
112.975Engine
113.967
BF18.00-P-
1001-01H Engine oilFilling capacity
with oil filterLiters8.08.07.5
2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 48 © 2006 Mitchell Repair Information Company, LLC.
Page 2290 of 4133
REMOVE/INSTALL ROCKER ARMS - AR05.20-P-2340AU
ENGINE 112
ENGINE 113 except CODE (479) Cylinder shutoff
ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250
ENGINE 113.962 in MODELS 463.206 / 240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODELS 463.243 /246
Shown on engine 112
Fig. 52: Identifying Rocker Arm Components
- Shown On Engine 112
Filling capacity
without oil filterLiters-7.5-
Specifications
for Operating
FluidsSheetBB00.40-P-
0229-01A
BB00.40-P-
0229-01A
BB00.40-P-
0229-01A
SheetBB00.40-P-
0229-03A
BB00.40-P-
0229-03A
BB00.40-P-
0229-03A
SheetBB00.40-P-
0229-05A
BB00.40-P-
0229-05A
BB00.40-P-
0229-05A
2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 49 © 2006 Mitchell Repair Information Company, LLC.
