1997 MERCEDES-BENZ ML320 engine

1998-2005 ENGINE
Complete engine - 163 Chassis
GENERAL INFORMATION
DETERMINE LOSS OF PR ESSURE AT CYLINDER - AH01.00-N-1300-02A
All engine
If an increased pressure loss was found with the cylinde r leak tightness tester, inspect engine by listening at
cylinder head gasket, air intake area, exhaust, oil fi ller opening and prechamber or spark plug bores of the
adjacent cylinder or cylinders.
Check the coolant in the coolant expansion reservoir for the formation of air bubbles.
Possible causes for the pressure loss are: 1. Outlet of air through prechamber or spark plug bo re of adjacent cylinder or cylinders, air bubbles
in coolant expansion reservoir:
pressure loss at cylinder head gasket
2. Outlet of air through air intake area:
For inspecting by listening, open throttle valve pressure loss at inlet valve(s)
3. Outlet of air through exhaust:
pressure loss at exhaust valve(s)
4. Outlet of air through oil filler opening:
pressure loss through pistons and piston rings
It is possible to pinpoint the pressure loss of the rele vant cylinder by spraying with engine oil. Engine oil
seals off the gap between piston and cylinder briefly.
If a reduced pressure loss now occurs for a short time, th e cause is very likely to be at the pistons, piston rings
or cylinder contact surface of the relevant cylinder.
Determining the cause can be falsified by the position of th e piston ring joints. If suspicion exists that the loss o
f
pressure is caused by the piston ring joints being positioned directly one above the other, fit parts to engine and
repeat test after running engine for a short time.
GENERAL INFORMATION ON INSPECTING CYLINDER WALLS - AH01.00-P-0300-01A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:55 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.
me
Saturday, October 02, 2010 3:18:01 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.

Engine 112, 113, 122, 134, 135, 137, 166, 275, 285, 611, 612, 613, 628, 629, 639, 642, 646, 647, 648
Pressure gloss marks, smoothings
Individual blank points, e.g. in the middle of th e cylinder barrel or around the cylinder head bolts.
The crankcase can be reused.
Fig. 1: Identifying Pressure Gloss Marks On Cylinder Walls

Visible mottling, friction marks
Starting from reverse area of th e upper piston ring tapering down.
Traces of dry rubbing which cannot be felt, caused by oi l film being washed off by fuel, for example from many
cold starts when driving for short distances.
These traces of friction occurring mainly around the cy linder head bolts and on the pressure side are not a
problem provided that they are smoothed out.
The piston rings are not damaged.
The crankcase can be reused.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:55 PMPage 2 © 2006 Mitchell Repair Information Company, LLC.

Fig. 2: Identifying Visible Mottling And Friction Marks On Cylinder Walls
Ring shaped imprints
Visible imprints on cylinder barrel in the upper and lo wer reverse area of piston rings are not a cause for
complaint.
The crankcase can be reused.
Fig. 3: Identifying Visible Imprints On Cylinder Barrel

Rotary bright, specular, polish ed upper surfaces of cylinder
Starting from the reverse area of the upper pist on ring with measurable, partial cylinder wear.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:55 PMPage 3 © 2006 Mitchell Repair Information Company, LLC.

The cylinder barrel is unusable.
Fig. 4: Identifying Cylinder Wear

Roughened mottling, friction scoring
Starting from first and second piston ring, tapering to an end only in bottom part of cylinder. Progressive signs
of friction lead to friction score marks.
Where these signs of friction are percep tible, the cylinder barrel is unusable.
The piston rings may be damaged.
Fig. 5: Identifying Friction Score Marks


2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:55 PMPage 4 © 2006 Mitchell Repair Information Company, LLC.

Continuous individual traces of scratch
Caused by dirt, for example, through back pul sation of soot particles from the exhaust.
The crankcase can be reused.
Piston seizure
Most of cylinder wall perceptibly roughened over the entire length.
Material deposits and perceptible scoring ma rks on cylinder wall and at piston skirt.
The cylinder barrel is unusable.
Brown coloring of cylinder upper surface.
A brown coloration over large areas of the cylinder barrel is oil varnish and indicates that the engine has been
driven at a high temperature level.
The crankcase can be reused if no im permissible cylinder warping is visible
Oil varnish above piston ring zone is nor mal and is not a reason for complaint.
GENERAL NOTES: PASSENGER CARS: COMPLETE ENGINE, CRANKCASE VENTILATION, CYLINDER HEAD,
CRANKCASE - AH01.00-Z-9999AZ
MODEL all

Notes on application of
sealant to front cover of
cylinder head
ENGINE 629AH01.30-P-
1000-02TJ
Notes on sealant path for
oil panENGINE 642.970 in MODEL 463.303 /340 /341AH01.45-P-
0001-01GY
Notes on application of
sealant to oil panENGINE 629AH01.45-P-
0001-01TJ
General information on
inspecting cylinder wallsENGINE 272, 273AH01.00-P-
0300-01VA

Notes on the application of
sealant to the cylinder head
cover
ENGINE 122.9 in MODEL 454.0AH01.30-P-
1000-08FB
Notes on application of
sealant to oil panENGINE 113, 156...AH01.45-P-
0001-01GZ

Notes on the application of
sealing compound to the
cylinder head cover
ENGINE 273AH01.30-P-
1000-08SX
AH01.45-P-

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:55 PMPage 5 © 2006 Mitchell Repair Information Company, LLC.

Notes on application of
sealant to oil panENGINE 272 in MODEL 164, 2510001-
01GZA
General information on
inspecting cylinder wallsENGINE 266.920 /940 /960 / 980 in MODEL 169.0/3,245.2AH01.00-P-
0300-01AK
General information on
inspecting cylinder wallsENGINE 640AH01.00-P-
0300-01AL

Notes on application of
sealant to front cover of the
cylinder head
ENGINE 272, 273AH01.30-P-
1000-02V
Notes on application of
sealant to oil panENGINE 134.9, 135.9 in MODEL 454.0AH01.45-P-
0001-01FF
Information on application
of sealant to oil panENGINE 160.921 /922 /923 in MODEL 452.3 /4AH01.45-P-
0001-01RR
Notes on application of
sealant to oil panENGINE 273AH01.45-P-
0001-01SX
General information on
inspecting cylinder wallsENGINE 155
AH01.00-P-
0300-
01SLR
Notes on application of
sealant to oil panENGINE 271AH01.45-P-
0001-01T
Information on application
of sealant to oil panENGINE 628.961 in MODEL 211.028AH01.45-P-
0001-01TD
General information on
inspecting cylinder wallsENGINE 111, 601, 604, 605, 606, 611,612, 647, 668 ...
AH01.00-
N-0300-
01A
General information on
inspecting cylinder wallsENGINE 112, 113, 122, 134, 135, 137, 166, 275, 285, 611,
612, 613, 628, 629, 639, 642, 646, 647, 648 ...AH01.00-P-
0300-01A
Information for assigning
the cylinder head gasketsENGINE 112 ENGINE 113AH01.30-P-
1000-06V

Information on application
of sealant to end cover of
crankcase
ENGINE 628 ...AH01.40-P-
1000-04B

Information on application
of sealant to end cover of
crankcase
ENGINE 628 ...AH01.40-P-
1000-04C
Notes on application of
sealant to oil panENGINE 628.960/962/963AH01.45-P-
0001-01M
Notes on application of
sealant to oil panENGINE 112...AH01.45-P-
0001-01PV
Notes on application of
sealant to oil panENGINE
113.963 /967 /968 /987 /988 /989 /990 /991 /992 /995AH01.45-P-
0001-01R
Firing orderENGINE 111 /, 601 /, 602
AH01.00-
N-0100-
01A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:55 PMPage 6 © 2006 Mitchell Repair Information Company, LLC.

Determine loss of pressure
at cylinderENGINE all
AH01.00-
N-1300-
02A
Notes for position of
engine numberENGINE 155AH01.00-P-
0001-01A
Notes for position of
engine numberENGINE 166, 266, 640, 668AH01.00-P-
0001-01B
Notes for position of
engine numberENGINE 611, 612, 613, 646, 647, 648AH01.00-P-
0001-01C
Notes for position of
engine numberENGINE 112, 113, 120, 137, 271, 272, 273, 275, 285, 628,
629, 642AH01.00-P-
0001-01D
Notes for position of
engine numberENGINE 601, 602, 603, 604, 605, 606AH01.00-P-
0001-01E
Notes for position of
engine numberENGINE 122.9, 134.9, 135.9, 639.9 in MODEL 454.0AH01.00-P-
0001-01FF
Notes for position of
engine numberENGINE 160.910, 660.940 in MODEL 450.3 /4AH01.00-P-
0001-01SM
General information on
inspecting cylinder wallsENGINE 156
AH01.00-P-
0300-
01AMG
Determining pressure loss
of cylindersENGINE 640AH01.00-P-
1300-02AL

Use of engine no. when
installing reconditioned
engines and factory-new
replacement engines or
crankcases
ENGINE allAH01.10-P-
0001-01A
Use of unleaded fuel in
reconditioned enginesENGINE 102, 110, 115, 116, 117...AH01.10-P-
1000-01A
Bolt diagram cylinder head
coverENGINE 120AH01.20-P-
5014-04AO

Notes on application of
sealant to cylinder shutoff
oil pump
ENGINE 137.970AH01.30-P-
1000-01A

Notes on application of
sealant to front cover at
cylinder head
ENGINE 668.914/940/941 /942AH01.30-P-
1000-02A

Notes on application of
sealant to front cover of the
cylinder head
ENGINE 640 in MODEL 169, 245AH01.30-P-
1000-02AL

Notes on application of
sealant to front cover at
cylinder head
ENGINE 275AH01.30-P-
1000-02C
Notes on application of
sealing compound to front ENGINE 275AH01.30-P-

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:55 PMPage 7 © 2006 Mitchell Repair Information Company, LLC.

cover at cylinder head1000-02D

Notes on application of
sealant to rear cover at
cylinder head
ENGINE 668.914/940/941 /942AH01.30-P-
1000-03A

Notes on application of
sealing compound to rear
cover at cylinder head
ENGINE 640 in MODEL 169AH01.30-P-
1000-03AL
Information on cylinder
head contact surfaceENGINE 112 ENGINE 113 ENGINE 112.951 ENGINE
112.976AH01.30-P-
1000-05A
Information for assigning
the cylinder head gasketsENGINE 642 in MODEL 164, 203, 209, 251.0 /1 ENGINE
642 in MODEL 463AH01.30-P-
1000-06PI
Information for assigning
the cylinder head gasketsENGINE 642 in MODEL 211AH01.30-P-
1000-06TI
Information for assigning
cylinder head gasketsENGINE 642 in MODEL 219.322, 221AH01.30-P-
1000-06TQ

Notes on the application of
sealing compound to the
cylinder head cover
ENGINE 266.920 /940 /960 in MODEL 169.0 /3, 245.2AH01.30-P-
1000-08AK

Notes on the application of
sealing compound to the
cylinder head cover
ENGINE 266.980 in MODEL 169.0 /3, 245.2AH01.30-P-
1000-08BK

Notes on the application of
sealing compound to the
cylinder head cover
ENGINE 642.970 in MODEL 463.303 /340 /341AH01.30-P-
1000-08GY

Notes on the application of
sealing compound to the
cylinder head cover
ENGINE 642 in MODEL 164, 203, 209, 251.0 /1AH01.30-P-
1000-08PI

Notes on the application of
sealing compound to the
cylinder head cover
ENGINE 642 in MODEL 221AH01.30-P-
1000-08SXI

Notes on the application of
sealing compound to the
cylinder head cover
ENGINE 642 in MODEL 211AH01.30-P-
1000-08TI

Notes on the application of
sealing compound to the
cylinder head cover
ENGINE 642 in MODEL 219.322AH01.30-P-
1000-08TQ

Notes on the course of the
application of sealing
compound on a cylinder
head cover
ENGINE 272AH01.30-P-
1000-08V
Notes for evaluation of
cylinder contact surfaceENGINE 160.9 in MODEL 450.3 /4, 452.3 /4AH01.40-P-
0001-03SM
Notes on application of
sealant to timing case coverENGINE 137.970AH01.40-P-
1000-01A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:55 PMPage 8 © 2006 Mitchell Repair Information Company, LLC.