M-Class (W164) Produced 2006-2011: ML280CDI, ML320CDI, ML420CDI, ML350, ML500, ML550

Starter motor slow - ML320 CDI

Old Oct 23, 2021 | 10:24 PM
  #1  
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From: Queensalnd Australia
2006 ML320 CDI (2 of) and 2008 GL320
Starter motor slow - ML320 CDI

Have a weird issue with ML320, it has been doing it for years but seems to be getting worse (marginally) also has a new battery (and glow plugs/controller) so not either of these.

When you leave the car overnight and try to start the starter motor is slow - if you turn it off again (before engine fires) and start the starter swings normally

If you leave the car for say 4 hours and start it swings quickly - possibly still some heat in engine bay. But Live in a warm climate so doubt this is important.

The battery is good, the voltage drops to 10.5 on start (pretty well same if swinging quick or slow), I checked voltage on another ML320 and 10.6v Min - so basically same

I initially thought it was that perhaps going through the extra glow cycle was assisting the combustion (maybe in a few cylinders to it took load off the starter) but recently I took the injectors out and put in new seating washers (the cars always seem to take a 100 revs or so on the starter to build up enough pressure to start after this) and same issue - first time you turn the key it turns slow - then second go is faster but it was still another 2 or 3 starter cycle timouts before it started so no "partial assistance"

i do have a spare starter but before I change it (not a fun job by the looks) I thought I would bounce off here

i have talked to a few private mechanics and all stumped

Any thoughts appreciated
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Old Oct 24, 2021 | 05:41 AM
  #2  
Maj. Dundee's Avatar
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2002 ML 320 & 2006 ML500
There are quite a few reasons why the starter will not start properly. including corrosion.

Therefore you must check for codes in all modules with a scanner, pages 10 & 11.

Attached Files
File Type: pdf
DTC ECM 164.125 Blue USA.pdf (320.4 KB, 244 views)

Last edited by Maj. Dundee; Oct 24, 2021 at 05:46 AM.
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Old Oct 24, 2021 | 07:09 AM
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From: Queensalnd Australia
2006 ML320 CDI (2 of) and 2008 GL320
Many thanks for your help

I did do multiple scans with the Autel scanner (the problem has been there for 6 months and thought I might find an erratic code) , I had sort of expected to see a hall sensor failure on the crank angle sensor but there never was.

I did have Glow plug codes and put in a full new set, and also changed the glow plug controller. This has helped the start function overall but the starter still turned slowly on the first start - then turn key back after say 2 revs - then on next attempt the starter always turned quickly (normal speed) - even though the engine was not left grinding over on first attempt, would not normally fire when turning slowly.

This afternoon I bit the bullet and put the car up on hoist, pulled off the negative off battery, pulled off the Cat on right (so I can see starter etc) and the starter looks really good physically - not corroded - the copper from solenoid to starter is bright - the 13mm bolt for main feed is bright too (under its cover). Also no sign of oil contamination etc.

I have a spare starter (from a 2010 ML350CDI that was impact damaged) so think I am so far into it I may as well swap it over and at least rule the starter out if it is still an issue

Do you have the instructions for starter change?

I am not sure if I need to support motor and take out the right engine mount?

Thanks for the complete list of codes - really helpful - doing a print for my records

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Old Oct 24, 2021 | 10:52 AM
  #4  
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I will post the removal in a few hrs.

Last edited by Maj. Dundee; Oct 24, 2021 at 11:00 AM.
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Old Oct 24, 2021 | 12:51 PM
  #5  
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From: Bronx, N.Y.
2002 ML 320 & 2006 ML500
Here are the procedures but you might not be able to do this without a lift. Thank God I do not have a 642 vehicle.
Attached Files
File Type: pdf
R&I Starter 642 Eng. #1.pdf (119.6 KB, 707 views)
File Type: pdf
R&I Starter 642 Eng. #2.pdf (84.3 KB, 277 views)
File Type: pdf
R&I Starter 642 Eng. #3.pdf (153.9 KB, 335 views)
File Type: pdf
R&I Starter 642 Eng. #4.pdf (102.0 KB, 433 views)
File Type: pdf
R&I Starter 642 Eng. #5.pdf (153.9 KB, 257 views)
File Type: pdf
R&I Starter 642 Eng. #6.pdf (157.2 KB, 556 views)
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Old Oct 24, 2021 | 05:16 PM
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From: Queensalnd Australia
2006 ML320 CDI (2 of) and 2008 GL320
Many thanks, it does seem a big job but I know of other V motors where it is buried under the inlet manifold.

In Australia the diesel is still way cheaper to run than the Gas - Diesel is generally 5 to 40 cents per litre cheaper -

I will report back if I have problem fixed -

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Old Oct 25, 2021 | 04:41 AM
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From: Queensalnd Australia
2006 ML320 CDI (2 of) and 2008 GL320
changed the starter - turned out I had somehow got one of the removed cables hooked up around the terminals which was restricting movement

I think the Right engine mount can stay in, but definately remove the engine mount cover and the right cat

not a fun job

new starter is great -
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Old Oct 25, 2021 | 07:56 AM
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Great news.
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Old May 29, 2023 | 06:54 PM
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ML320 CDI 2008 4JGBB22EX8A368386
It's a good job you didn't need the recommended Engine Lifting Device (240589006100) as it's quoted anywhere between $3,000-$8,000+.
Lift device (assembly required)
I am about to do the same job on a 2008 ML320 CDI so any pointers would be useful. The starter is really out of the way.
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Old May 29, 2023 | 08:01 PM
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From: Queensalnd Australia
2006 ML320 CDI (2 of) and 2008 GL320
I did it on hoist - as mentioned left mount in just took off guard and cat on that side - need smaller hands than me and it would be easier - good luck - plenty of beer would help too



Originally Posted by dwwaddell
It's a good job you didn't need the recommended Engine Lifting Device (240589006100) as it's quoted anywhere between $3,000-$8,000+.
Lift device (assembly required)
I am about to do the same job on a 2008 ML320 CDI so any pointers would be useful. The starter is really out of the way.
Reply
Old May 29, 2023 | 10:46 PM
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GL320 2007
I did this in the GL320.

It was a ***** of a job. My advice is plan to take out the right engine support. I jacked up the engine by about an 1" to get enough clearance to get the motor out. In hindsight, I should have also loosened the left engine mount and trans mount. It is really tight to torque up the engine mount bolt. There is a special offset tool for doing this. It reminds me I need to still retorque this one. I'm not convinced I got it as tight as it should be (90NM from memory).
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Old Dec 2, 2023 | 11:36 AM
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From: Qualicum Beach BC
2008 ML320 CDI
I’m doing this same job on my ML320 CDI 2008. I’m having a ***** of a time getting that starter out… I’ve removed all the heat shields. Removed the pass side rubber motor mount, undid the trans mount, undid the drivers mount, jacked up motor and trans, for the life of me I cannot pull the starter back enough to get clearance to remove the front of it. It looks like the hard part of the engine mount that is bolted to the block needs to come out. Did anyone have to do this to get it out? Plenty of room to pull it down, but just can’t get it positioned right to drop down.
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Old Dec 2, 2023 | 06:16 PM
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From: Queensalnd Australia
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Originally Posted by jpd686
I’m doing this same job on my ML320 CDI 2008. I’m having a ***** of a time getting that starter out… I’ve removed all the heat shields. Removed the pass side rubber motor mount, undid the trans mount, undid the drivers mount, jacked up motor and trans, for the life of me I cannot pull the starter back enough to get clearance to remove the front of it. It looks like the hard part of the engine mount that is bolted to the block needs to come out. Did anyone have to do this to get it out? Plenty of room to pull it down, but just can’t get it positioned right to drop down.
pretty sure I took it forward (towards alternator). Then went upright a bit and taken down behind alternator. Been a few years. I remember i had given up because I couldn’t get it forward and couldn’t work out why. Have a mechanic mate come and he took it straight out ( turned out that one of the cables had fallen back over terminal bolts. ).

I had part of exhaust out but did not remove engine mount.

I am lucky enough to have a hoist (rack?)

my car is right hand drive (so have steering on that side )
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Old Dec 3, 2023 | 09:37 PM
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GL320 2007
You need patience, force won't help out. I think I needed to spin the starter through the space for the engine mount. It really takes some jiggling.

You need to have the CAT removed as well.

It doesn't get easier to put it back in either.
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