Mercedes-Benz ML320. 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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