1997 MERCEDES-BENZ ML350 check engine

28Unscrew bolts,
cylinder head -->
timing case cover
(20) *BA01.40-P-
1002-01C
29Slacken cylinder
head bolts (21) in
stages, unscrew Slacken cylinder head bolts according to
loosening pattern only once the engine has
cooled down, in order to avoid that the cylinder
head warps.AR01.30-P-5800-
09B
Installation: Observe tightening pattern and
tightening instructions of cylinder head bolts.
Oil thread and head cont act surface of cylinder
head bolts.AR01.30-P-5800-
07B
Screwdriver insertFig. 72
Screwdriver insertFig. 73
*BA01.30-P-
1001-01D
30Remove cylinder
head Installation: On Engine 112/113 observe
porous points in the le ft 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, 113AH01.30-P-1000-
04VA
The sealant must be applied within 10
minutes.
Loctite 5900 sealant.*BR00.45-Z-
1013-01A
31
Inspect version of
cylinder head gasket
Information for
assigning the
cylinder head gasketsAssignment of cylinder head gasket
Engine 112, 113AH01.30-P-1000-
06V
32Check cylinder head
bolts (21) AR01.30-P-5800-
03B
*BE01.30
-P-
1001-04B
33Clean sealing
surfaces, check for
cracks, shrink holes
and flatness, clean
bolt 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 se ries production. Silicone
sealant is applied in the gasket area when
carrying out repairs only if shrink holes are
present.
The sealant must be applied within 10
minutes.
*BR00.45-Z-

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 89 © 2006 Mitchell Repair Information Company, LLC.

Engine 113 in model 129, 202, 208, 210
Engine 113 (except 113.965/981) in model 163
24.1Remove oil
reservoir on
power steering
pump (11)Model 163
Removal: Extract oil from rese rvoir. Remove circlip.
Installation: Replace sealing ring. Ch eck that circlip is
correctly seated.
Power steering -
checking and
correcting oil
level AP46.00-P-
4611BB
Hand pumpFig. 95
24.2Detach power
steering pump
(11) with oil
reservoir. Do not disconnect lines.
*BA46.30-P-
1005-01A
*BA46.30-P-
1010-01A
*BA46.30-P-
1010-01C
25.1Detach guide
pulley at timing
case coverModel 230.474
*BA13.25-P-
1008-01D
25.2Take off guide
pulley (15) at
coolant pump Except model 230.474
Take plastic cover off guide pulley.
*BA20.10-P-
1001-01C
*BA20.10-P-
1001-01M
26.1Remove
compressorEngine 112.960 in model 170.466
Engine 113.992 in model 230.474AR09.50-P-
4705SVK
27Remove air pump
(20)Engine 112 (except 112.960) in model 170
Engine 112 in 163, 202, 208, 210
Engines 113 in 163, 202, 208, 210AR14.30-P-
7251A
Engine 112.922 in model 220.063AR14.30-P-
7251AA
Engine 112.923 in model 129.059
Engine 112.943 in model 129.064
Engine 112.944 in model 220.065 /165
Engine 112.972 in model 220.067 /167
Engine 112.975 in model 220.087 /187
Engine 113.941 in models 220.070/170
Engine 113.948 in model 220.083 /183
Engine 113.960 in model 220.075/175
Engine 113.960 in model 215.375
Engine 113.961 in model 129.068
Engine 113.963 in models 230.475
Engine 113.966 in model 220.084 /184

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 103 © 2006 Mitchell Repair Information Company, LLC.

Check values for crankcase
Operating time of honing
machine
*BE01.40-P-1014-01F
17Coat filter insert again
with honing paste Do not coat cylinder
bore with honing paste.
Polmot honing paste order
no. 600.11
*BR00.45-Z-1050-06A
18Lap cylinder bore and
expose silicone crystals. Without honing oil
feed, removed material
cannot be measured.
Operating time of honing
machine
*BE01.40-P-1014-01F
19Clean cylinder bore and
dry Clean crankcase very
carefully with honing
paste. If possible, clean
crankcase in a major
assembly washing
machine, so that no
cylinder wall damage will
be caused by residues
when running the engine
later.
20Inspect cylinder boreAllow crankcase to cool
down to approx. 20°C
before inspecting.
Cylinder diameter of repair
size
*BE01.40-P-1001-01F
NumberDesignation
Engine 112
except 112.951,
113.940/941/
942/943/944/
945/946/948/
960/961/963/
965/966/967/
968/980/981/
984/986/992/
995
Engine
113.962/982/
987/988/989/
990/991/993
BE01.40-P-
1001-02E Cylinder borePeak-to-valley
height (R
Z ) of
top separating
surface
mm0.001 to 0.00450.001 to 0.0045
Wear limit at
BDC and TDC
of 1st piston ringmm< or = 30.03< or = 0.03

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 120 © 2006 Mitchell Repair Information Company, LLC.

Check values for cylinder bore
Permissible
deviation of
cylinder shapemm0.0140.007
contact surface
peak-to-valley
heightµm--
NumberDesignation
Engine
112.910/ 911
Engine
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...83.26583.250 ... 83.265
Repair sizemm90.150 ...
90.16590.150...90.165
BE01.40-P-
1002-01FCylinder dia.,
setting for
repair size
(+0.25)Pre-honingmm83.20089.900
Precision
honingmm83.38090.080
Polishingmm83.43090.130
BE01.40-P-
1003-01FCylinder dia.
according to
machining
phasePre-honingmm83.38090.080
Precision
honingmm83.43090.130
Polishingmm90.150 ...
90.16590.150...90.165
BE01.40-P-
1004-01FCylinder lengthmm129.5129.5
BE01.40-P-
1005-01FUndercutmm1212
BE01.40-P-
1006-01FStroke setting with 70 mm
stone length on 70th stroke
scale of machinemm130130
BE01.40-P-
1007-01FStone overrun at top and
bottommm9.59.5
BE01.40-P-
1008-01FEngine speedPre-honingrpm125125
Precision
honingrpm125125
Polishingrpm125125
Lappingrpm230230
BE01.40-P-
1009-01FFeedPre-honing44
Precision honing33

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 121 © 2006 Mitchell Repair Information Company, LLC.

Check values for cylinder bore
Polishing22
Lapping11
BE01.40-P-
1010-01FStrokePre-honingrpm5757
Precision
honingrpm5757
Polishingrpm5757
Lappingrpm8080
BE01.40-P-
1011-01FDisplayPre-honing%20 to 3020 to 30
Precision
honing%20 to 3020 to 30
Polishing%20 to 3020 to 30
Lapping%20 to 3020 to 30
BE01.40-P-
1012-01FStroke setting with 70 mm felt
length on 70th stroke scale of
machinemm115115
BE01.40-P-
1013-01FFelt insert overrun at top and
bottommm2 to 42 to 4
BE01.40-P-
1014-01FOperating time of honing
machineS4040
NumberDesignation
Engine
112.951/961
Engine 112.970
BE01.40-P-
1001-01FCylinder dia.Standard
marking Xmm89.900...89.91597.000 to 97.015
Auxiliary stage
Marking mm89.950 to 89.96597.050 to 97.065
Repair sizemm90.150...90.16597.250 to 90.165
BE01.40-P-
1002-01FCylinder dia.,
setting for repair
size (+0.25)Pre-honingmm-97.000
Precision honingmm-97.180
Polishingmm-97.230
BE01.40-P-
1003-01FCylinder dia.
according to
machining phasePre-honingmm-97.180
Precision honingmm-97.230
Polishingmm-97.250 ... 97.265
BE01.40-P-
1004-01FCylinder lengthmm-130.90 to 131.00
BE01.40-P-
1005-01FUndercutmm-0.6...1.0
BE01.40-P-
1006-01FStroke setting with 70 mm stone
length on 70th stroke scale of
machinemm-132
BE01.40-P-
1007-01FStone overrun at top and bottommm-9.5

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 122 © 2006 Mitchell Repair Information Company, LLC.

Check values for cylinder bore
BE01.40-P-
1008-01FEngine speedPre-honingrpm-125
Precision honingrpm-125
Polishingrpm-125
Lappingrpm-230
BE01.40-P-
1009-01FFeedPre-honing-4
Precision honing-3
Polishing-2
Lapping-1
BE01.40-P-
1010-01FStrokePre-honingrpm-57
Precision honingrpm-57
Polishingrpm-57
Lappingrpm-80
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
machinemm-115
BE01.40-P-
1013-01FFelt insert overrun at top and
bottommm-2 to 4
BE01.40-P-
1014-01FOperating time of honing machineS-70
NumberDesignation
Engine
112.946/947/
948/960
Engine 112.912
BE01.40-P-
1001-01FCylinder dia.Standard
marking Xmm89.900...89.91583.200...83.215
Auxiliary stage
marking mm89.950 to 83.26583.250...83.265
Repair sizemm90.150...90.16583.450 to 83.465
BE01.40-P-
1002-01FCylinder dia.,
setting for repair
size (+0.25)Pre-honingmm89.90083.200
Precision honingmm90.08083.380
Polishingmm90.13083.430
BE01.40-P-
1003-01FCylinder dia.
according to
machining phasePre-honingmm90.08083.380
Precision honingmm90.13083.430
Polishingmm90.150...90.16583.450 to 83.465
BE01.40-P-
1004-01FCylinder lengthmm129.5129.5
BE01.40-P-Undercutmm1212

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 123 © 2006 Mitchell Repair Information Company, LLC.

Check values for cylinder bore
1005-01F
BE01.40-P-
1006-01FStroke setting with 70 mm stone
length on 70th stroke scale of
machinemm130130
BE01.40-P-
1007-01FStone overrun at top and bottommm9.59.5
BE01.40-P-
1008-01FEngine speedPre-honingrpm125125
Precision honingrpm125125
Polishingrpm125125
Lappingrpm230230
BE01.40-P-
1009-01FFeedPre-honing44
Precision honing33
Polishing22
Lapping11.
BE01.40-P-
1010-01FStrokePre-honingrpm5757
Precision honingrpm5757
Polishingrpm5757
Lappingrpm8080
BE01.40-P-
1011-01FDisplayPre-honing%20 to 3020 to 30
Precision honing%20 to 3020 to 30
Polishing%20 to 3020 to 30
Lapping%20 to 3020 to 30
BE01.40-P-
1012-01FStroke setting with 70 mm felt
length on 70th stroke scale of
machinemm115115
BE01.40-P-
1013-01FFelt insert overrun at top and
bottommm2 to 42 to 4
BE01.40-P-
1014-01FOperating time of honing machineS4040
NumberDesignation
Engine
113.960/961/
962/963/964/
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

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 124 © 2006 Mitchell Repair Information Company, LLC.

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
Saturday, October 02, 2010 3:17:57 PMPage 127 © 2006 Mitchell Repair Information Company, LLC.