1997 MERCEDES-BENZ ML430 length

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.

NumberDesignation
Engines
112.910/911
Engine 112.912
BE01.40-P-
1001-01FCylinder dia.Standard
Marking Xmm83.200...83.21583.200...83.215
Auxiliary stage
Marking mm83.250...83.26583.250...83.265
Repair sizemm83.450 to 83.46583.450 to 83.465
BE01.40-P-
1002-01FCylinder
diameter setting
for repair size
(+0.25)Pre-honingmm83.20083.200
Precision honingmm83.38083.380
Polishingmm83.43083.430
BE01.40-P-
1003-01FCylinder dia.
according to
machining phasePre-honingmm83.38083.380
Precision honingmm83.43083.430
Polishingmm83.450 to 83.46583.450 to 83.465
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.
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

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 147 © 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.

MAINTENANCE
CLEANING AND PRESERVING ENGINE AN D ENGINE COMPARTMENT - AP01.00-P-1000ZZ
ENGINE all
machining phasePolishingmm97.250 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 scale 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-
1The engine and engine compartment must be
preserved after every cleaning.Applies for vehicles up to 12/89 and in the
period 6/93-7/94
The form and materials for masking are to

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 152 © 2006 Mitchell Repair Information Company, LLC.

AR07.16-P-1100MM
Remove, install fuel cooler
5.11.99

ENGINE
612.963 in MODELS 163.113

P47.00-2042-12

1
Fuel feed hose

2
Fuel drain hose

3
Coolant feed hose

4
Coolant return flow hose

5
Fuel cooler

7
Bolts of fuel cooler

Operation no. of operation texts or standard texts and flat rates
Category

Op. no.
Operation text

P
075890
REMOVING AND INSTALLING FUEL COOLER

P
075895
REPLACE FUEL COOLER


Remove, Install


Danger!
Risk of injury
to
fingers being jammed or

squeezed
when removing and installing or

aligning hoods, doors, tailgate/tailgate and

sliding roof.
When moving components ensure that no

body parts or limbs are in the area of motion.

AS00.00-Z-0011-01A


Danger!
Risk of injury
to skin and eyes suffering

scalding from contact with hot coolant spray.
Risk of poisoning
from swallowing coolant.
Do not open cooling system unless coolant

temperature is below 90 °C. Open cap slowly

and release the pressure. Do not pour coolant

into beverage bottles.

Wear protective gloves, protective clothing

and eye protection.

AS20.00-Z-0001-01A


Danger!
Risk of explosion
from fuel igniting,
risk of

poisoning
from inhaling and swallowing fuel

as well as
risk of injury
to eyes and skin

from contact with fuel.
No fire, sparks, naked flames or smoking.

Pour fuels only into suitable and appropriately

marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1
Open engine hood and raise to vertical position


Have second person secure hood.

AR88.40-P-1000GI

2
Remove trim panel of cylinder head cover

AR01.20-P-5014-02B


*BA01.20-P-1002-01A
*BA01.20-P-1003-01A

3
Drain coolant

At radiator.

AR20.00-P-1142M

4
Close fuel feed hose (1) at the fuel cooler (5)

Set of plugs

*129589009100

*WH58.30-Z-1001-06A
*WH58.30-Z-1002-06A

5
Detach fuel outlet hose (2)

Clamp

*000589543700

Set of plugs

*129589009100

*WH58.30-Z-1001-06A
*WH58.30-Z-1002-06A

6
Disconnect coolant return flow hose (4) to

thermostat housing

Hose clamp pliers (length 210 mm;

adjustment range 80 mm)

*WH58.30-Z-1026-02A

7
Unscrew bolts (7) at fuel cooler

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
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