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Commercially available tools  
BE01.40-P-1002- 
01FCylinder dia., 
setting for repair  
size (+0.25)Pre-honingmm97.000
Precision honingmm97.180
Polishingmm97.230
BE01.40-P-1003-
01FCylinder dia. 
according to  
machining phasePre-honingmm97.180
Precision honingmm97.230
Polishingmm97.250 to 97.265
BE01.40-P-1004-
01FCylinder lengthmm129.5
BE01.40-P-1005-
01FUndercutmm12
BE01.40-P-1006- 
01FStroke setting with 70 mm stone length 
on 70th stroke s  cale of machinemm130
BE01.40-P-1007- 
01FStone overrun at top and bottommm9.5
BE01.40-P-1008-
01FEngine speedPre-honingrpm125
Precision honingrpm125
Polishingrpm125
Lappingrpm230
BE01.40-P-1009- 
01FFeedPre-honing4
Precision honing3
Polishing2
Lapping1
BE01.40-P-1010- 
01FStrokePre-honingrpm57
Precision honingrpm57
Polishingrpm57
Lappingrpm80
BE01.40-P-1011-
01FDisplayPre-honing%20 to 30
Precision honing%20 to 30
Polishing%20 to 30
Lapping%20 to 30
BE01.40-P-1012- 
01FStroke setting with 70 mm felt length on 
70th stroke scale of machinemm115
BE01.40-P-1013- 
01FFelt insert overrun   at top and bottommm2 to 4
BE01.40-P-1014- 
01FOperating time of honing machineS70
NumberDesignation
WH58.30-Z-1030-04A
Honing head CK-3000 for 76-127 mm dia. CK-2600,  
Firma Hommel Prazision GmbH D-50767 Koln  
Firma Sunnen Products Comp. USA-   -7910 Manchester St. Louis, Mo.63143
 
2001 Mercedes-Benz ML320 
1998-2005 ENGINE Complete engine - 163 Chassis  
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        Page 2482 of 4133

Workshop equipment   
Repair materials   
MEASURE CYLINDER  BORES - AR01.40-P-9202AV 
ENGINE 113 in MODELS 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230    
ENGINES 112 /945, 113.962 /982    
WH58.30-Z-1031-04A
Pre-honing, stone set C 30-A 53, or C30 J64, 70 mm long,  
Firma Hommel Prazision GmbH D-50767 Koln  
Firma Sunnen Products Comp. USA-   -7910 Manchester St. Louis, Mo.63143
WH58.30-Z-1032-04A
Precision honing, stone set C 30-J 84, 70 mm long,  
Firma Hommel Prazision GmbH D-50767 Koln  
Firma Sunnen Products Comp. USA-   -7910 Manchester St. Louis, Mo.63143
WH58.30-Z-1033-04A
Polishing, stone set C 30-C 03-81, 70 mm long,  
Firma Hommel Prazision GmbH D-50767 Koln  
Firma Sunnen Products Comp. USA-   -7910 Manchester St. Louis, Mo.63143
WH58.30-Z-1034-04A
Stone holder for felt insert CK-30 35,  
Firma Hommel Prazision GmbH D-50767 Koln  
Firma Sunnen Products Comp. USA-   -7910 Manchester St. Louis, Mo.63143
WH58.30-Z-1035-04A
Felt insert holder set CK3130,  
Firma Hommel Prazision GmbH D-50767 Koln  
Firma Sunnen Products Comp. USA-   -7910 Manchester St. Louis, Mo.63143
WH58.30-Z-1036-04A
Felt insert C 30-F 85,  
Firma Hommel Prazision GmbH D-50767 Koln  
Firma Sunnen Products Comp. USA-   -7910 Manchester St. Louis, Mo.63143
WE58.40-Z-1002- 
21AAutomatic cylinder repair machine
WE58.40-Z-1003-
21AInternal measuring device   (50... 150 mm dia., with 0.01 mm display and measuring  
point for pressure relief)
WE58.40-Z-1004- 
21AAdjusting micrometer for internal measur  ing device (with adjustment range 50-200  
mm)
NumberDesignationOrder number
BR00.45-Z-1050-06APolmot honing paste Order no. 600.11Polmat - Poliertechnik  
GmbH Troggberg 11  
38302 Wolfenbuttel  
Germany
 
2001 Mercedes-Benz ML320 
1998-2005 ENGINE Complete engine - 163 Chassis  
me  
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        Page 2483 of 4133
Fig. 101: Identifying Measurin g Points Of Cylinder Bore  
Check values for cylinder bore   
Figure  
item, etc.Work instructions  
 Cylinder bore
Measure diameter of the cleaned cylinder bores with  
an internal measuring instrument in the longitudinal  
and transverse directions.
 
1,2,3
Cylinder bore diameter  
at the measuring points
Measure
 
 Fig. 102
 *WH58.30-Z-
1001-12A
 
*WH58.30-Z-
1011-12A
Cylinder diameter code letter X*BE01.40-P-
1001-01F
Cylinder diameter code letter *BE01.40-P-
1001-01F
Repair size*BE01.40-P-
1001-01F
Engines  
113.960/961/  
962/963/964/ 
 
2001 Mercedes-Benz ML320 
1998-2005 ENGINE Complete engine - 163 Chassis  
me  
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        Page 2484 of 4133

Check values for cylinder bore   
Fig. 102: Identifying Dial Indicator (001 589 53 21 00)
  
Commercially available tools   
OIL PAN BOLT DIAGRAM - AR01.45-P-7500-06F 
Upper part of oil pan shown on engine 112 with 4 MATIC
NumberDesignation
965/967/968/  
971/980/981/  
982/984/987/  
988/989/990/  
991/992/993/ 995
BE01.40-P-1001-
01FCylinder dia.Standard Marking Xmm97.000 to 97.015
Auxiliary stage 
Marking mm97.050 to 97.065
Repair sizemm97.250 to 97.265
NumberDesignation
Engine 
112.910/ 911
Engines 
112.913/920/921/922/  
923/940/941/942/943/  
944/945/949  
113.940/941/942/943/  
945
BE01.40-P- 
1001-01FCylinder dia.Standard 
Marking Xmm83.200...83.21589.900...89.915
Auxiliary stage  
Marking mm83.250...83.26589.950 to 83.265
Repair sizemm83.450 to 
83.46590.150...90.165
NumberDesignation
WH58.30-Z-1001-12AQuick calipers for internal measurements
WH58.30-Z-1011-12AInternal measuring instrument
 
2001 Mercedes-Benz ML320 
1998-2005 ENGINE Complete engine - 163 Chassis  
me  
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        Page 2485 of 4133
Fig. 103: Identifying Oi l Pan Bolt Diagram - Upper Part Of Oil Pan Shown On Engine 112 With 4 Matic  
Upper part of oil pan shown   on engine 112 without 4 MATIC    
Fig. 104: Identifying Oi  l Pan Bolt Diagram 
- Upper Part Of Oil Pan Shown On Engine 112 Without 4 
Matic  
Upper part of oil pa  n shown on engine 113
 
2001 Mercedes-Benz ML320 
1998-2005 ENGINE Complete engine - 163 Chassis  
me  
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        Page 2486 of 4133
Fig. 105: Identifying Oi l Pan Bolt Diagram - Upper Part Of Oil Pan Shown On Engine 113 
REMOVE/INSTALL OIL  PAN - AR01.45-P-7500FB 
ENGINE 112.942 in MODEL 163.154    
ENGINE 112.970 in MODEL 163.157     
ENGINE 113.942 in MODEL 163.172     
ENGINE 113.981 in MODEL 163.174     
ENGINE 113.965 in MODEL 163.175     
Shown on engine 112    
 
2001 Mercedes-Benz ML320 
1998-2005 ENGINE Complete engine - 163 Chassis  
me  
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        Page 2487 of 4133
Fig. 106: Identifying Oil Pan  Remove/Install Components - Shown On Engine 112 
  Remove/install  
   External torx setFig. 49
1Remove oil pan bottom  
section (1)Model 163.154/157/172.AR01.45-P-7555V
Model 163.174/175.AR01.45-P-7555VE
 *BA01.45-P-1002-01B
2Disconnect electrical line  
at oil sensor (oil level,  
temperature and quality)  
(B40) Remove cable strap at oil 
pipe. 
3Remove oil pipe (2) from  
dipstick   Installation:  Replace the  
sealing ring!AR18.40-P-3510BV 
 *BA01.20-P-1001-01E
4Remove oil pan top  
section(3)Take out oil pan to the front in 
direction of travel for this step;  
rotate crankshaft slightly, if  
necessary.  
  Installation:  Observe  
different bolt length and bolt  
diameter: ? 
Screw diagram of oil panAR01.45-P-7500-06F
 Notes on application of  
sealant to oil panEngine 112AH01.45-P-0001-01C
 
2001 Mercedes-Benz ML320 
1998-2005 ENGINE Complete engine - 163 Chassis  
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        Page 2488 of 4133

 Crankcase ventilation, cylinder head cover  
 Notes on application of  
sealant to oil panEngine 
113.941/942/960/962/965/981.AH01.45-P-0001-01E
 *BA01.45-P-1001-01B
*BR00.45-Z-1013-
01A
5Install in the reverse  
order  
6Read out fault memory  
and eraseStored 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. 
  
 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  
 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 
7Run engine and inspect  
for leaks
NumberDesignation
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
Engine 113.940/  
941/942/943/  
944/948/960/  
961/962/963/  
964/965/966/  
967/968/969/  
971/980/981/  
982/984/986/  
992/995
Engine  
113.987/988/  
990/991/993
BA01.20-P-
1001-01EScrew of 
cylinder head  
coverNm8108
 
2001 Mercedes-Benz ML320 
1998-2005 ENGINE Complete engine - 163 Chassis  
me  
Saturday, October 02, 2010 3:17:58 PMPage 132 © 2006 Mitchell Repair Information Company, LLC.