Mercedes-Benz ML320. Manual — part 366

8

Attach guard plate for radiator/condenser

y

Guard plate for radiator/condenser

Engine 606 in model 124,

Engine 606.961 in model 140,

Engine 112, 113, 604, 605, 611.960 in model
202,
Engine 602.983, 612.966 in model 461,

Engine 628.962, 612.965, 606.964, 112.945,
113.962/ 982 in model 463,
Engine 111, 112, 611.962, 612.962 in model
203,
Engine 112, 113, 611.961, 612.961, 613.961
in model 210,
Engine 112 in model 170,

Engine 112 in model 220,

Engine 113 in model 211, 215, 220,

Engine 112 in model 208,

Engine 112, 113, 612.963, 628.963 in model
163,
Engine 112.923 /943, 113.961 in model 129,

Engine 137, 275 in model 215, 220,

Engine 613.960, 628.960 in model 220,

Engine 113.992 in model 230.474,

Engine 271 in model 209, 203,

Engine 285.950 in model 240.078 /178,

Engine 612.967 in model 209.316,

Engine 648 in model 220

Engine 112.951 in model 639.601/603/ 605/
701 /703 /705 /801 /803 /805
Engine 646.983 /984 in model 639.601/

603 /605 /701 /703 /705 /801 /803 /805

Engine 646.982 in model 639.601/ 603/ 605/
701 /703 /705

WF58.50-P-0110-01A

9

Remove air cleaner housing (5)

10

Remove air intake pipe (6) with resonance
tube (7)

Separate connector of hot film mass air

flow sensor (HFM) for this step and unbolt air
intake pipe at cylinder head cover

The air intake pipe is attached at the rear

at the intake manifold with a plastic plate.

Do not damage the plastic strap.

Engine 112.942/ 970

AR07.07-P-1454A

Engine 113.942/ 965/ 981

AR07.07-P-1454MV

Danger!

Risk of explosion caused by fuel igniting,
risk of poisoning caused by inhaling and
swallowing fuel as well as risk of injury to
eyes and skin caused by contact with fuel.

No fire, sparks, open flames or smoking.
Pour fuels only into suitable and appropriately
marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

11

Disconnect fuel line at fuel rail

Release fuel pressure at service valve!

Collect fuel!

Engine 112:

#

*BA07.52-P-1001-01A

Engine 113:

#

*BA07.52-P-1001-01A

Pressure hose

*119589046300

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 the 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.

AR09.20-P-1310A

The intake manifold system must not be

disassembled.

Remove intake manifold with fuel distributor

15.1

Remove camshaft position sensor (15)

Only necessary if the right cylinder head is

removed.

AR15.10-P-2000A

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Page 3

16

Remove poly V-belt (8)

Installation: Lock tensioning device with

a drift or pin (diameter 5 mm).

Model 163.154 /157 /172.

AR13.22-P-1202B

Model 163.174 /175.

AR13.22-P-1202BA

17

Detach the coolant line (16) at the cylinder
head on the left

6 mm socket hexagon

*WH58.30-Z-1001-06A

7 mm socket hexagon

*WH58.30-Z-1002-06A

18.1

Remove fender liner (9)

Only with engine 113.113.942 /965 / 981.

AR88.10-P-1300GH

19.1

Remove shield (10)

Only with engine 113.942 /965 /981.

20.1

Remove exhaust bracket (11)

Only with engine 113.942 /965 /981.

Support exhaust system.

21

Detach exhaust system at exhaust manifold

Installation: On vehicles with engine

damage, the exhaust system must be
examined for swarfs before assembling and
any swarfs present must be removed, in order
to avoid consequential damage.

*BA14.10-P-1002-01B

22

Position crankshaft to 40° after ignition TDC
on cylinder 1

The engine must not be turned back;

otherwise the timing chain can get jammed.

AR05.10-P-6858V

Rotate engine at the crankshaft in running

direction until scribe mark 40° on pulley/
vibration damper corresponds with scribe
mark on timing case.
The grooves on the camshafts must be
pointing toward the inner V.

23

Lock camshafts with locating plates

Locating plate

*112589003200

Locating plate

*112589013200

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) together with oil-
water heat exchanger

Engine 113.942.

AR18.20-P-3471B

Engine 112.942/970.

AR18.20-P-3471BA

26

Unscrew camshaft sprockets (19)

If camshaft sprockets are removed,

engine must no longer be cranked, otherwise
timing chain might jam.

Engine 113.942 /965 /981:

#

Tie timing chain tight on both camshaft
sprockets with tie straps.

Engine 112.942 /970:

#

Right-hand camshaft sprocket:

Tie timing chain tight on camshaft sprocket
with tie 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.

AR05.10-P-6858V

If necessary after checking:

#

Set the basic position of camshafts

AR05.20-P-6020AU

Open-end wrench

*112589000100

Insertion tool

*112589010300

Torque wrench

*001589722100

*BA05.20-P-1001-01B

27

Remove camshaft bearing bridges (28)

Pay attention to slackening and tightening

pattern!

AR05.20-P-7103AU

28

Unscrew bolts, cylinder head

!

timing case

cover (20)

*BA01.40-P-1002-01C

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services.

Page 4

29

Slacken cylinder head bolts (21) in stages,
unscrew

Loosen cylinder head bolts according to

loosening schematic only after engine has
cooled down to prevent cylinder head from
distorting.

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

*000589031000

Screwdriver insert

*000589041000

*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-1015-01A

31

Inspect version of cylinder head gasket

Assignment of cylinder head gasket

Information for assigning the cylinder head
gaskets

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, inspect for cracks,
shrink holes and flatness, clean threaded
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.
At the time of repair installation, silicone
sealant is applied to the sealing area only in
case of any shrink holes.

The sealant must be applied within

10 minutes.

Loctite 5900 sealant.

*BR00.45-Z-1015-01A

34

Install in the reverse order

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

35

Run engine and inspect for leaks

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 out and erase fault memory

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.

Cylinder head/cylinder head bolts

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

Engine
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/987/
988/990/991/
992/993

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

T

144.5

T

144.5

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Page 5

Fig., see

AR01.30-P-5800-03B

AR01.30-P-5800-03B

Cylinder head

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

Engine
113.940/941/
942/943/944/
948/960/961/
962/963/965/
966/967/968/
969/980/981/
982/984/986/
992

BA01.30-P-1001-01D

Bolt of cylinder head to
crankcase

1st stage

Nm

10

10

2nd stage

Nm

30

30

3rd stage

(

°

90

90

4th stage

(

°

90

90

Crankcase, timing case cover, end cover

Number

Designation

Engine
112
except
112.951

Engine
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/992

BA01.40-P-1002-01C

Bolt, cylinder head to timing case cover

Nm

20

20

Camshaft

Number

Designation

Engine
112
except 112.951

Engine
113.940/941/
942/943/944/
948/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/992

BA05.20-P-1001-01B

Bolt of camshaft sprocket

M12 x 45

1st stage

Nm

50

50

2nd stage

(

°

90

90

Fuel rail

Number

Designation

Engine
112 except
112.945/951/
960/961

BA07.52-P-1001-01A

Fuel feed line to fuel rail

Nm

38

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Page 6