Mercedes-Benz ML320. Service manual - part 453

 

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Mercedes-Benz ML320. Service manual - part 453

 

 

 

*BA07.52-P-
1001-01A

 Pressure hose

Fig. 52

12

Remove right and 
left ignition coils 
(12)

 

AR15.12-P-
2003A
 

13

Remove right and 
left cylinder head 
covers (13)

 

AR01.20-P-
5014B

14

Remove 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
 

15.1

Remove camshaft 
angle position sensor 
(15)

 Only necessary if right cylinder head is 

removed.

AR15.10-P-
2000A
 

16

Remove 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
 

17

Detach 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

18.1

Remove inner fender 
(9)

 Only for engine 113.942 /965 /981.

AR88.10-P-
1300GH
 

19.1

Remove shield (10)

 Only for engine 113.942 /965 /981.

 

20.1

Remove exhaust 
bracket (11)

 Only for engine 113.942 /965 /981. 
 Support exhaust system.

 

21

Detach exhaust 
system at exhaust 
manifold

 Installation: On vehicles with engine 

damage check exhaust system for chips before 
assembly and remove any chips present to 
prevent later damage

 

 

*BA14.10-P-
1002-01B

22

Position 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 

 

TDC on first cylinder

 Rotate engine at crankshaft in direction of 

rotation until 40° marking on belt pulley/ 
vibration damper is aligned with marking on 
timing case cover. 
The grooves on the camshafts must be pointing 
toward the inner V.

23

Lock camshafts with 
locating plate

 Locating plate

Fig. 85

 Locating plate

Fig. 86

24

Remove 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 

25.1

Remove oil filter 
housing (18) with 
oil/water heat 
exchanger

Engine 113.942.

AR18.20-P-
3471B
 

Engines 113.965/981.

AR18.20-P-
3471BA
 

26

Remove 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 position of camshafts. 
If necessary after checking: ?

AR05.10-P-
6858V
 

Set the basic position of camshafts.

AR05.20-P-
6020AU
 

 Open-end wrench

Fig. 87

 Insertion tool

Fig. 88

 Torque wrench

Fig. 92

 

*BA05.20-P-
1001-01B

27

Remove 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 

 

28

Unscrew bolts, 
cylinder head --> 
timing case cover 
(20)

 

*BA01.40-P-
1002-01C

29

Slacken cylinder 
head bolts (21) in 
stages, unscrew

 Slacken cylinder head bolts according to 

loosening pattern only once the engine has 
cooled down, in order to avoid that the cylinder 
head warps.

AR01.30-P-5800-
09B

 Installation: Observe tightening pattern and 

tightening instructions of cylinder head bolts. 
Oil thread and head contact surface of cylinder 
head bolts.

AR01.30-P-5800-
07B

 Screwdriver insert

Fig. 72

 Screwdriver insert

Fig. 73

 

*BA01.30-P-
1001-01D

30

Remove cylinder 
head

 Installation: On Engine 112/113 observe 

porous points in the left and right cylinder 
head. If porous points are present, sealant must 
be applied to the cylinder head gasket.

 

 

Notes on application 
of sealant to cylinder 
head gasket.

Engine 112, 113

AH01.30-P-1000-
04VA

 The sealant must be applied within 10 

minutes.

 

Loctite 5900 sealant.

*BR00.45-Z-
1013-01A

31 

 

Inspect version of 
cylinder head gasket 
Information for 
assigning the 
cylinder head gaskets

Assignment of cylinder head gasket 
Engine 112, 113

AH01.30-P-1000-
06V

32

Check cylinder head 
bolts (21)

 

AR01.30-P-5800-
03B
 
*BE01.30-P-
1001-04B

33

Clean sealing 
surfaces, check for 
cracks, shrink holes 
and flatness, clean 
bolt holes

 Pay attention to dowel sleeves (26) for 

locating the cylinder head. 

 Sealing surfaces of crankcase and cylinder 

head are provided with an 0.8 mm thick 
silicone layer during series production. Silicone 
sealant is applied in the gasket area when 
carrying out repairs only if shrink holes are 
present. 

 The sealant must be applied within 10 

minutes. 

*BR00.45-Z-

 

2001 Mercedes-Benz ML320 

1998-2005 ENGINE Complete engine - 163 Chassis

  

me 

 

Cylinder head/cylinder head bolts 

Loctite 5900 sealant.

1013-01A

34

Install in the reverse 
order

 

 

  

35

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 engine 
Run engine and 
inspect for leaks

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
 

36

Inspect cooling 
system for leaks

 Warm up engine to operating temperature 

and then inspect cooling system or leaks.

AR20.00-P-
1010HA
 

37

Read fault memory, 
erase.

 Stored 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.

 

Number

Designation

Engine 
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/ 
973/975/976

Engines 
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-
1001-04B

Cylinder head 
bolt

Thread diameter

M 11

11

Length (L) when 
new

mm 141.5

141.5

Length (L)

mm < or = 144.5

< or = 144.5

See picture

AR01.30-P-
5800-03B

AR01.30-P-
5800-03B

 

2001 Mercedes-Benz ML320 

1998-2005 ENGINE Complete engine - 163 Chassis

  

me 

 

 

 

 

 

 

 

 

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