Mercedes-Benz ML320. Service manual - part 402

 

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Mercedes-Benz ML320. Service manual - part 402

 

 

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 recorded by Modification services.

Page 1

 Fuel pump (gear pump) and electric 

shutoff valve can remain on engine.

15

Check injection system for leakage.

16

Check with HHT/DAS for proper 
function (check actual value).

17

Read DTC memory and erase after 
checking.

Copyright DaimlerChrysler AG  28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services.

Page 2

AF80.57-P-6406A

Engine sometimes fails to start and fault message "Start Error" appear in the 
instrument cluster

13.8.04

MODEL 

163.136 /154 /172 #A as of 145273, 

163.136 /154 /172 #X as of 708319, 
163.113 /128 /157 /174 /175

Operation no. of operation texts or standard texts and flat rates

Category

Op. no.

Operation text

Time

Acc. no.

Code

P

541011

Perform quick test

004 WU

---

---

P

805030

Replace drive authorization system (DAS [FBS]) control unit 
(after check)

006 WU

---

---

Damage code

Cause

Remedy

82 801 90

 When the ignition is switched on (circuit 

15), the engine control unit sends a start 
enable request to the DAS [FBS] control unit. 
If during this request circuit 15 is switched off 
or interrupted before the DAS [FBS] control 
unit could respond, the variable code sent the 
first time is used again the next time circuit 15 
is switched on, since the original request is 
saved by the DAS [FBS] control.

1

Replace the DAS [FBS] control unit.

AR54.21-P-1300GH

 

The fault message "Start Error" appears 

in instrument cluster.

 When ordering a new control unit, please 

specify the chassis number.

Parts ordering notes

Part no.

Designation

Quantity

163 545 07 16

FBS control unit

1

Copyright DaimlerChrysler AG  05.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services.

Page 1

1998-2005 ENGINE

Engine timing - 163 Chassis 

GENERAL INFORMATION 

GENERAL NOTES: PASSENGER CARS: ENGINE TIMING - AH05.00-Z-9999AZ 

MODEL all  

 

Loosening and tightening regulation for 
camshaft bearing caps

ENGINE 160.921 /922 /923 in MODEL 
452.3/4

AH05.20-P-
0300-01RR

 

Loosening and tightening regulation for 
camshaft bearing caps

ENGINE 160, 660...

AH05.20-P-
0300-01SM

 

Note concerning adjusting the valve 
seat cutter

ENGINE 160 in MODEL 450.3/4, 452.3/4

AH05.30-P-
4520-01A

 

Note concerning valve seat machining

ENGINE 160 in MODEL 450.3/4, 452.3/4

AH05.30-P-
4520-02A

 

Information on application of sealant to 
bottom part of camshaft housing

ENGINE 271

AH05.20-P-
6995-01QK

 General notes on timing, markings

ENGINE 112, 113, 112.951/976

AH05.10-P-
1000-01A

 Camshaft code number and assignment ENGINE 111.948 /978, 112, 113

AH05.20-N-
0100-01A

 Camshaft code number and assignment ENGINE 111

AH05.20-P-
0100-01AG

 Camshaft code number and assignment ENGINE 120

AH05.20-P-
0100-01AO

 

Slackening and tightening instructions 
for the camshaft bearing caps

ENGINE 275

AH05.20-P-
0300-01A

 Marking of camshaft bearing caps

ENGINE 266.920 /940 /960 /980

AH05.20-P-
6992-01AK

 Marking of camshaft bearing caps

ENGINE 120

AH05.20-P-
6992-01AO

 Camshaft, code numbers and allocation ENGINE 601, 602, 603

AH05.20-P-
6992-03HB

 

Notes on the application of sealing 
compound of the camshaft case

ENGINE 266.980 in MODEL 169.0 /3, 
245.2

AH05.20-P-
6995-02BK

 Marking of camshaft bearing caps

ENGINE 668.914 /940 /941 /942

AH05.20-P-
6992-01GD

 Marking on camshaft bearing caps

ENGINE 611, 
646.8 /951 /961 /962 /963 /966

AH05.20-P-
6992-04HB

 Marking of camshaft bearing caps

ENGINE 613, 648

AH05.20-P-
6992-04HD

Loosening and tightening regulation for  ENGINE 601.943, 

AH05.20-N-

 

2004 Mercedes-Benz ML350 

1998-2005 ENGINE Engine timing - 163 Chassis

  

 

2004 Mercedes-Benz ML350 

1998-2005 ENGINE Engine timing - 163 Chassis

  

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