1997 MERCEDES-BENZ ML350 check engine

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
Saturday, October 02, 2010 3:17:57 PMPage 128 © 2006 Mitchell Repair Information Company, LLC.

Cylinder head/cyl inder head bolts
CHECK VALUES FOR CYLINDER BORE - BE01.40-P-1000-01F
ENGINES 112, 113, 155
Check values for cylinder bore
Peak-to-valley
heightµM--
BE01.30-P-1004-
04BCylinder head
when newReference
dimension "H1"mm--
Reference
dimension "H2"mm--
BE01.30-P-1005-
04BCylinder head
after necessary
stock removalReference
dimension "H1"mm--
Reference
dimension "H2"mm--
NumberDesignationEngines 275, 285
BE01.30-P-1001-
04BCylinder head boltThread diameterM10
Length (L) when newmm132/1685
Length (L)mm< or = 133.5/170
See picture-
BE01.30-P-1002-
04BCylinder headOverall height "H"
mmmm-
Heightmm-
See picture-
BE01.30-P-1003-
04BCylinder headpermissible difference
of flatness of contact
surface in
longitudinal directionmm0.03
permissible difference
of flatness of contact
surface in transverse
directionmm0.03
Peak-to-valley heightµM10
BE01.30-P-1004-
04BCylinder head when
newReference dimension
"H1"mm-
Reference dimension
"H2"mm-
BE01.30-P-1005-
04BCylinder head after
necessary stock
removalReference dimension
"H1"mm110.87... 110.95
Reference dimension
"H2"mm-

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 146 © 2006 Mitchell Repair Information Company, LLC.

Check values for cylinder bore
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
Engines
112.913/920/921/922/
923/940/941/942/943/
944/945/949
113.940/941/942/943/
945
Engine
112.946/947/
948/960
BE01.40-P-
1001-01FCylinder dia.Standard
Marking Xmm89.900...89.91589.900...89.915
Auxiliary stage
Marking mm89.950 to 89.96589.950 to
89.965
Repair sizemm90.150...90.16590.150...90.165
BE01.40-P-
1002-01FCylinder dia.,
setting for
repair size
(+0.25)Pre-honingmm89.90089.900
Precision
honingmm90.08090.080
Polishingmm90.13090.130
BE01.40-P-
1003-01FCylinder dia.
according to
machining
phasePre-honingmm90.08090.080
Precision
honingmm90.13090.130
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
Polishing22
Lapping11

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 148 © 2006 Mitchell Repair Information Company, LLC.

Check values for cylinder bore
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 to 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
BE01.40-P-
1008-01FEngine speedPre-honingrpm-125
Precision honingrpm-125

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 149 © 2006 Mitchell Repair Information Company, LLC.

Check values for cylinder bore
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
NumberDesignationEngine 112.976
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
BE01.40-P-1002-
01FCylinder dia.,
setting for repair
size (+0.25)Pre-honingmm-
Precision honingmm-
Polishingmm-
BE01.40-P-1003-
01FCylinder dia.
according to
machining phasePre-honingmm-
Precision honingmm-
Polishingmm-
BE01.40-P-1004-
01FCylinder lengthmm-
BE01.40-P-1005-
01FUndercutmm-
BE01.40-P-1006-
01FStroke setting with 70 mm stone length
on 70th stroke s cale of machinemm-
BE01.40-P-1007-
01FStone overrun at top and bottommm-

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 150 © 2006 Mitchell Repair Information Company, LLC.

Check values for cylinder bore
BE01.40-P-1008-
01FEngine speedPre-honingrpm-
Precision honingrpm-
Polishingrpm-
Lappingrpm-
BE01.40-P-1009-
01FFeedPre-honing-
Precision honing-
Polishing-
Lapping-
BE01.40-P-1010-
01FStrokePre-honingrpm-
Precision honingrpm-
Polishingrpm-
Lappingrpm-
BE01.40-P-1011-
01FDisplayPre-honing%-
Precision honing%-
Polishing%-
Lapping%-
BE01.40-P-1012-
01FStroke setting with 70 mm felt length on
70th stroke scale of machinemm-
BE01.40-P-1013-
01FFelt insert overrun at top and bottommm-
BE01.40-P-1014-
01FOperating time of honing machineS-
NumberDesignation
Engines
113.960/961/
962/963/964/
965/967/968/
971/980/981/
982/984/987/
988/989/990/
991/992/993/
995
Engine 155
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-
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 Pre-honingmm97.180-
Precision honingmm97.230-

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 151 © 2006 Mitchell Repair Information Company, LLC.

2
The fresh air openings, the windshield and the
front fenders must be generously masked off
before cleaning and preserving.
be determined by each workshop itself.
Masking is necessary in order to ensure that
no materials whatsoever, e.g. cold cleaning
solvent, wax or similar, penetrate inside the
car (difficult to clean).

3
The screw joint holding the brake fluid
reservoir must be masked off with adhesive
tape, which is to be removed again after
preservation of the engine compartment.

4
Mask off the ventilation hole for the
diaphragm chamber in the pressure control
valve in the cylinder head cover.
Engines 601, 602, 603
AP01.00-
P-8503-
01A
5
Cleaning is to be performed when the engine
is no hotter than hand-hot (at the exhaust)
using a demulsifying cold cleaning solvent
(short action time) and a high-pressure hot-
water cleaner, depending on how dirty the
engine is.
"Demulsifying" means that a mixture of oils
and greases in water separated in the oil
separator pipe.

6
When cleaning the component compartment
behind the engine compartment: Spray only as
much water as necessary under very low
pressure.Electronic control modul es must be covered
beforehand; any that become wet must be
dried afterwards.

7After washing/preserving the engineLubricate throttle cont rol linkage and check
for ease of movement and wear.
8
Preservation is to be performed only when the
engine compartment is dry and using properly
functioning commercially available
equipment.Only use approved wax preservation agents.
Airless devices produce the least
contamination.

9Do not spray the follow ing with preservation
wax:Electrical and electroni c components, belt
drive (belts and pulleys), exhaust pipe and
muffler in component compartment.


2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 153 © 2006 Mitchell Repair Information Company, LLC.

1998-2005 DRIVELINE/AXLES
Front Axle - 163 Chassis
TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: FRONT AXLE - AR33.00-Z-9163AA
MODEL 163
ATTACH ENGINE SUPPORT BRACKET AND RAISE ENGINE - AR33.10-P-0100-01BV
Workshop equipment
Removing and installing front axleMODELS
163.113 /128 /136 /154 /157 /172 /174 /175AR33.10-P-
0100GH
Remove/install rubber bushes of front
axle transmission mountingMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.10-P-
0120GH
Remove/install front axle halfMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.10-P-
0200GH
Remove/install front axle shaft flange
and double-row angular ball bearingMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0315GH
Checking follower joint of steering
knuckle mount (installed)MODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0426GH
Replace supporting jointMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0440GH
Removing and installing upper
wishboneMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0500GH
Remove/install lower wishboneMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0510GH
Replace front bearing of lower
wishboneMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.20-P-
0526GH
Removing and installing steering
knuckleMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.25-P-
0400GH
Remove/install front axle gearMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.30-P-
0525GH
Replace shaft seal on drive pinionMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.30-P-
0530GH
Remove/install radial shaft seal at front
axle gear of front axle shaftMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.30-P-
0545GH
Remove/install front axle shaftsMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.30-P-
0620GH
Replace rubber boots on front axle shaftMODEL
163.113 /128 /136 /154 /157 /172 /174 /175AR33.30-P-
0660GH
WE58.40-Z-1007-11AEngine lifting fixture

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis

2001 Mercedes-Benz ML320
1998-2005 DRIVELINE/AXLES Front Axle - 163 Chassis
me
Saturday, October 02, 2010 3:38:21 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.
me
Saturday, October 02, 2010 3:38:25 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.