MERCEDES-BENZ ML350 1997 Complete Repair Manual

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
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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.

Notes on application of
sealant to the timing case
cover
ENGINE 266.920 /940 /960 /980 in MODEL 169.0 /3, 245.2AH01.40-P-
1000-01AK
Notes on application of
sealant to timing case coverENGINE 640AH01.40-P-
1000-01AL
Notes on application of
sealant to timing case coverENGINE 156
AH01.40-P-
1000-
01AMG

Information on application
of sealant to timing case
cover
ENGINE 137.970, 275AH01.40-P-
1000-01C
Notes on application of
sealant to timing case coverENGINE 166.940 /960 /961 /990 /991,
668.914 /940 /941 /942AH01.40-P-
1000-01D
Notes on application of
sealant to timing case coverENGINE 134.9, 135.9 in MODEL 454.0AH01.40-P-
1000-01FF

Notes on application of
sealing compound to
timing case cover
ENGINE 639.939 in MODEL 454.0AH01.40-P-
1000-01FG
Notes on application of
sealant to timing case coverENGINE 642.970 in MODEL 463.303 /340 /341AH01.40-P-
1000-01GY

Notes on application of
sealant to a timing case
cover
ENGINE 642 in MODEL 164, 203, 209, 251.0 /1AH01.40-P-
1000-01PI
Notes on application of
sealant to timing case coverENGINE 642 in MODEL 221AH01.40-P-
1000-01SXI
Notes on application of
sealant to timing case coverENGINE 642 in MODEL
211.020 /022 /084 /089 /220 /222 /284 /289 /620AH01.40-P-
1000-01TI
Notes on application of
sealant to timing case coverENGINE 271AH01.40-P-
1000-01TK
Notes on application of
sealant to timing case coverENGINE 642 in MODEL 219.322AH01.40-P-
1000-01TQ
Notes on application of
sealant to timing case coverENGINE 272, 273AH01.40-P-
1000-01VA

Notes on application of
sealant to right-hand
crankcase
ENGINE 137.970AH01.40-P-
1000-02A

Information on application
of sealant to crankcase
bottom section
ENGINE 137.970, 275, 285AH01.40-P-
1000-03A

Information on application
of sealant to crankcase
bottom section
ENGINE 156.980/982/983
AH01.40-P-
1000-
03AMG

Information on application
of sealant to bottom part of
crankcase
ENGINE 628 ...AH01.40-P-
1000-03B

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:55 PMPage 9 © 2006 Mitchell Repair Information Company, LLC.

Information on application
of sealant to bottom part of
crankcase
ENGINE 629AH01.40-P-
1000-03TJ

Information on application
of sealant to end cover of
crankcase
ENGINE 137.970, 275AH01.40-P-
1000-04A

Information on application
of sealant to end cover of
crankcase
ENGINE 629 at the motor aheadAH01.40-P-
1000-04TJT
Notes on application of
sealant to crankcase coverENGINE 137.970AH01.40-P-
1000-05A

Notes application of sealant
to end cover with radial
shaft seal
ENGINE 112, 113AH01.40-P-
1000-06A

Notes application of sealant
to end cover with radial
shaft seal
ENGINE 266, 640 in MODEL 169.0 /3, 245.2AH01.40-P-
1000-06AK

Notes on the sealant
process for the end cover
with radial shaft sealENGINE 166.940 /960 /961 /990 /995 /991,
668.914/940/941 /942AH01.40-P-
1000-06C

Notes application of
sealing compound to end
cover with radial shaft seal
ENGINE 134.9, 135.9 in MODEL 454.0AH01.40-P-
1000-06FF

Notes concerning
application of sealant to an
end cover with radial shaft
seal
ENGINE 642 in MODEL 203, 209AH01.40-P-
1000-06PI

Notes on application of
sealant to end cover with
radial shaft sealENGINE 642 in MODEL
211.020 /022 /084 /089 /220 /222 /284 /289AH01.40-P-
1000-06TI

Notes application of sealant
to end cover with radial
shaft seal
ENGINE 642 in MODEL 219.322AH01.40-P-
1000-06TQ
Notes on application of
sealant to oil panENGINE 137.970, 275AH01.45-P-
0001-01A
Notes on application of
sealant to oil panENGINE 266.920 /940 /960 / 980 in MODEL 169.0/3,245.2AH01.45-P-
0001-01AK
Notes on application of
sealant to oil panENGINE 640 in MODEL 169, 245AH01.45-P-
0001-01AL
Notes on application of
sealant to oil panENGINE 156 ...
AH01.45-P-
0001-
01AMG
Notes on application of
sealant oil panENGINE 112.912/946AH01.45-P-
0001-01B
Notes on application of AH01.45-P-

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:55 PMPage 10 © 2006 Mitchell Repair Information Company, LLC.

sealant oil panENGINE 1120001-01C
Notes on application of
sealant oil panENGINE 113.940 /943 /944 /961 /980 /984AH01.45-P-
0001-01D

Notes on application of
sealing compound to oil
pan
ENGINE 113.941 /942 /960 /962 /965 /981 /982 /993AH01.45-P-
0001-01E
Notes on application of
sealant to oil panENGINE 166.940/960/961 /990/991 /995,
668.914/940/941 /942AH01.45-P-
0001-01F
Information on application
of sealant to oil panENGINE 628.960 /961 /962 /963AH01.45-P-
0001-01MA

Notes application of sealant
to end cover with radial
shaft seal
ENGINE 132.9 in MODEL 451.3/4
AH01.40-P-
1000-
06MCC
Notes on application of
sealant to oil panENGINE 122.9 in MODEL 454.0AH01.45-P-
0001-01FB
Notes on application of
sealant to oil panENGINE 285AH01.45-P-
0001-01H
Notes on sealant path for
oil panENGINE 132.9 in MODEL 451.3/4
AH01.45-P-
0001-
01MCC
Notes on sealant path for
oil panENGINE 642AH01.45-P-
0001-01OM
Notes on application of
sealant to oil panENGINE 155 in MODEL 199
AH01.45-P-
0001-
01SLR
Notes on application of
sealant to oil panENGINE 160,660...AH01.45-P-
0001-01SM
Notes on sealant path for
oil panENGINE 273AH01.45-P-
0001-01SY
Notes on application of
sealant to oil panENGINE 272 in MODEL 203.08 /28 /09 /29,
211.08/28/09/29 ENGINE 273 in MODEL 211.09/29AH01.45-P-
0001-01TW
Notes on application of
sealant to oil panENGINE 272, 273 ...AH01.45-P-
0001-01TZ
Notes on application of
sealant to oil panENGINE 272AH01.45-P-
0001-01VA
Notes on application of
sealant to oil panENGINE 272AH01.45-P-
0001-01VB
Notes on sealant path for
front cover to cylinder headENGINE 611, 612, 613, 628, 646, 647, 648 ...AH01.30-P-
1000-02B

Notes on application of
sealant to cylinder head
gasket
ENGINE 113AH01.30-P-
1000-04V
Notes on application of
sealant timing case coverENGINE 112, 113AH01.40-P-
1000-01B

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Saturday, October 02, 2010 3:17:55 PMPage 11 © 2006 Mitchell Repair Information Company, LLC.

USE OF ENGINE NO. WHEN INSTALLING RECONDITIONED ENGINES AND FACTORY-NEW REPLACEMENT
ENGINES OR CRANKCAS ES - AH01.10-P-0001-01A
All engines
The engine number has a different le gal significance in individual countries. In the Federal Republic of
Germany, for example, it has been cl assified by the legislative authorities since mid-1972 as "insignificant in
terms of traffic legi slation". It is therefore no longer included in the vehicl e title document and vehicle
registration document.
Practically all other countries continue to require the indication of the engine number on motor vehicles which
are registered in such countries. In dealing with internat ional traffic, the authorities proceed on the basis of the
provisions of the country in which the vehicle is registered.
In order to avoid any problems on the occasion of vehicl e checks or when crossing international frontiers as a
result of the lack of or in correct engine number, the fo llowing directives have to be observed when carrying out
repairs.
1. Directives for vehicles wh ich are registered in the Fe deral Republic of Germany
a. In the case of vehicles for which no engine number is indicated in the vehicle registration
document (first registration after a pprox. mid-1972), it is not necessa ry to stamp or revise an
engine number if a replacement engine or crankcase of the same type is fitted.
b. If an engine number is indicated in th e vehicle registration document , it is possible, if an
engine of the same type is fitted, to transfer the number of the removed component to the new
engine, or the appropriate authority (vehicle in spection authority, vehicle registration authority)
should be requested to delete the engine numbe r in the vehicle title document or registration
document. The German Federal Mini ster of Transport has issued appropriate ministerial orders in
Transport Gazette 1973, p. 66.
2. Vehicles which are registered outside of the Federal Republic of Germany
If a reconditioned engine or factory-new replacement engine or crankcase is fitted and this is of the
identical type, it is then necessary to adopt the engine number of the engine removed and to transfer it to
the new engine or crankcase.
For this reason, pay attention to th e particular directives stated in Para 3 for the installation of
reconditioned en
gines, crankcases and shortblocks.

Notes on application of
sealant to the timing case
cover
ENGINE 611, 612, 613, 646, 647, 648 ...AH01.40-P-
1000-01E

Information on applying
sealant to a cylinder head
gasketENGINE 112 ENGINE 113 ENGINE 112.951 ENGINE
112.976AH01.30-P-
1000-04VA
NOTE: It is possible in the case of vari ous engines only to stamp the engine
number in place when the engine is removed.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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3. Special directives
3.1 Installation of factory-new repl acement engine of identical type
a. If a factory-new engine is installed and an engine num ber is required (e.g. vehicle registered
outside of the Federal Republic of Germany), the number of the factory-new engine must be
ground off and the number of the originally instal led engine of identical type stamped in its
place.
b. If the factory-new engine is fitted with an e ngine type plate (older car engines) and it is
necessary to indicate an engine number in the ve hicle documents, in this case take the engine
type plate off the engine remove d and affix it at the same point on the engine of identical
type to be installed.
3.2 Installation of recondition ed engine of identical type
a. The reconditioned engine plate must not be re moved either from the reconditioned engine to
be installed, nor from the engine removed, if the latter was a reconditioned engine.
b. If the engine removed is fitt ed with an engine type plate (older car engines) and it is
necessary to indicate an engine number in the vehicle documents, the engine type plate then
has to be taken off the engine removed and a ffixed at the same point to the reconditioned
engine to be installed. This plate should be affixed in addition to the reconditioned engine
plate.
In the event that a vehicle owner has problems on the occasion of vehicle checks or when crossing
international frontiers be cause of the lack of an engine num ber, the workshop in question may in
certain circumstances be held liable.
After replacing an engine , the engine number has to be altere d in the vehicle maintenance booklet
and on the vehicle data cards as well as in the re pair customer file. These documents should clearly
show which engine is installed in the vehicl e in order to ensure smooth parts service.
In addition, the copy of the vehicle data card which is held at the Parts Department of the relevant
Branch or Importer shoul d also be altered.
3.3 Model designation id entification of crankcases and shortblocks
Crankcases and shortblocks available in the parts sector are not provided with an engine model designation
identification and also not with an engine number.
To make it possible to identify the engine on the occas ion of vehicle inspections (e.g. by an inspection authority
when a vehicle is taken out of service or at the Customs on the occasion of importation of vehicle), the
workshop carrying out the repairs has to stamp the engine model designation in the crankcase or the shortblock
in the space provided fo r the engine number.
Example:
Type Engine model designation
201.024 102.962

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1998-2005 ENGINE Complete engine - 163 Chassis
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Saturday, October 02, 2010 3:17:55 PMPage 13 © 2006 Mitchell Repair Information Company, LLC.

Extract from Transpor t Gazette 1973 p. 66
(applies only to the Federal Republic of Germany)
Official Gazette of the Fede ral Minister of Transport
Directive in respect of vehicl e title document (VkBl 1972 p. 354)
Bonn, 28 December 1972
StV 2/36.15.17
Pursuant to the directive relating to the vehicle ti tle document dated 20 June 1972, Part C. No. 9.1, a dash
should be inserted at the relevant poi nt in the place of data which are no longer required in future (e.g. in the
case of the "factory number of engine") in those instances where the olde r type of title documents are used for
the preparation of the vehicle title document.
The question which is now posed is what procedure shoul d be adopted in respect of the vehicle title document
or the vehicle registration document in the event that th e factory number of the engine from the past is still
entered in the older type of title documents and a repl acement engine with a new number is now installed in the
vehicle in question. Following consul tation with the competent authorities in the regions, I now provide the
following instructions:
I. In view of the fact that the fact ory number of the engine is regarded as insignificant in respect of traffic
legislation, no change requires to be made to the vehicle documents. This also does not conflict with 27
Para 1 StVZO pursuant to which the data in the vehi cle title and registration documents constantly have
to reflect actual circumstances. This requirement namely covers only those particulars relating to actual
circumstances which are of significance in terms of traffic legislation. This is no longer the case,
however, in respect of the fa ctory number of the engine.
II. In order to spare the relevant vehicle owner any misunderstandings or indeed possible disadvantages (e.g.
on the occasion of checks when abroad), I recommend proceeding as follows:
In the event that the replacement engine installed has a different number than that entered in the title and
registration document, the figures in the column "e ngine factory number" shall be deleted and the following
endorsement made at a suitable point both in th e title as well as in the registration document:
"Entry of engine factory number no longer necessary".
If the endorsement is made close to th e deletion, it is sufficient to state:
"Entry no longer required".
The Federal Minister of Transport Ip. p.
Wagner
NOTES ON APPLICATION OF SEALANT TO CYLINDER HEAD GASKET - AH01.30-P-1000-04V

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:55 PMPage 14 © 2006 Mitchell Repair Information Company, LLC.