1997 MERCEDES-BENZ ML500 oil

longitudinal direction (A)
and transverse direction
(B).
Cylinder diameter*BE01.40-P-1001-01F
Cylinder bore*BE01.40-P-1001-02E
Cylinder length*BE01.40-P-1004-01F
Undercut*BE01.40-P-1005-01F
Internal measuring
instrument ø 50 to 150
mm,
with 0.01 mm indication
and measuring point
pressure relief*WE58.40-Z-1003-21A
Setting micrometer for
internal measuring
instrument GRM 2125
with setting range 50 to
200 mm*WE58.40-Z-1004-21A
3Set honing machine for
pre-honingCylinder diameter setting
for repair size (+0.25)*BE01.40-P-1002-01F
Stroke setting with 70 mm
stone length on 70th stroke
scale of machine*BE01.40-P-1006-01F
Stone overrun at top and
bottom*BE01.40-P-1007-01F
Engine speed*BE01.40-P-1008-01F
Feed*BE01.40-P-1009-01F
Stroke*BE01.40-P-1010-01F
Display*BE01.40-P-1011-01F
Automatic cylinder
repair machine*WE58.40-Z-1002-21A
Set of stones for rough
honing C 30-A 53, or C30
J64, 70 mm long*WH58.30-Z-1031-04A
4Cylinder bore pre-honing With full honing oil
feed.
5Measure cylinder bore Immediately after pre-
honing, the measurement
deviates by approx.
+0.02 mm due to heat
expansion.*BE01.40-P-1003-01F
Internal measuring
instrument ø 50 to 150
mm, with 0.01 mm
indication and measuring *WE58.40-Z-1003-21A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 117 © 2006 Mitchell Repair Information Company, LLC.

point pressure relief
6Set honing machine for
precision honingCylinder diameter setting
for repair size (+0.25)*BE01.40-P-1002-01F
Stroke setting with 70 mm
stone length on 70th stroke
scale of machine*BE01.40-P-1006-01F
Stone overrun at top and
bottom*BE01.40-P-1007-01F
Engine speed*BE01.40-P-1008-01F
Feed*BE01.40-P-1009-01F
Stroke*BE01.40-P-1010-01F
Display*BE01.40-P-1011-01F
Finish-honing, stone set
C 30-J 84, 70 mm long*WH58.30-Z-1032-04A
7Cylinder bore precision
honing With full honing oil
feed.
8Measure cylinder bore Immediately after
precision honing, an
oversize of approx. +0.01
mm is obtained because of
heating.*BE01.40-P-1003-01F
Internal measuring
instrument ø 50 to 150
mm, with 0.01 mm
indication and measuring
point pressure relief*WE58.40-Z-1003-21A
9.1Chamfer cylinder bore Except engines
112.945, 113.962 /982 in
model 463.AR01.40-P-9201-01A
10Set honing machine for
polishingCylinder diameter setting
for repair size (+0.25)*BE01.40-P-1002-01F
Stroke setting with 70 mm
stone length on 70th stroke
scale of machine*BE01.40-P-1006-01F
Stone overrun at top and
bottom*BE01.40-P-1007-01F
Engine speed*BE01.40-P-1008-01F
Feed*BE01.40-P-1009-01F
Stroke*BE01.40-P-1010-01F
Display*BE01.40-P-1011-01F
Set of stones for
polishing C 30-C 03-81, 70
mm long*WH58.30-Z-1033-04A
11Polish cylinder bore Polish with full honing *BE01.40-P-1003-01F

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 118 © 2006 Mitchell Repair Information Company, LLC.

oil feed up to final repair
size.
12Measure cylinder boreAllow crankcase to cool
down to approx. 20°C
before measuring
Cylinder diameter*BE01.40-P-1001-01F
Internal measuring
instrument ø 50 to 150
mm, with 0.01 mm
indication and measuring
point pressure relief*WE58.40-Z-1003-21A
13Clean cylinder bore and
dry
14Set honing machine for
lapping Set to same diameter as
after polishing (final
diameter).
Cylinder diameter
according to machining
stage.*BE01.40-P-1003-01F
Stroke setting with 70 mm
felt length on 70th stroke
scale of machine*BE01.40-P-1012-01F
Felt insert overrun at top
and bottom*BE01.40-P-1013-01F
Engine speed*BE01.40-P-1008-01F
Feed*BE01.40-P-1009-01F
Stroke*BE01.40-P-1010-01F
Display*BE01.40-P-1011-01F
Felt insert C 30-F 85*WH58.30-Z-1036-04A
Set of felt insert holders
CK3130*WH58.30-Z-1035-04A
Stone holder for felt
insert CK-30 35*WH58.30-Z-1034-04A
15Rub-in cylinder bore and
filter insert using honing
paste Without honing oil
feed, the cylinder wall
must be dry. Only the
specified honing paste may
be used. Only this one
guarantees the specified
final result.
Polmot honing paste order
no. 600.11
*BR00.45-Z-1050-06A
16Lap cylinder bore and
expose silicone crystals. Without honing oil
feed.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 119 © 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
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.

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
Saturday, October 02, 2010 3:17:57 PMPage 129 © 2006 Mitchell Repair Information Company, LLC.

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
Saturday, October 02, 2010 3:17:57 PMPage 130 © 2006 Mitchell Repair Information Company, LLC.

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
me
Saturday, October 02, 2010 3:17:58 PMPage 131 © 2006 Mitchell Repair Information Company, LLC.