engine MERCEDES-BENZ ML320 1997 Complete Repair Manual

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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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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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
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Saturday, October 02, 2010 3:17:55 PMPage 14 © 2006 Mitchell Repair Information Company, LLC.

Engine 113
Engine 113
Before installing the left cylinder hea d, it is necessary to apply sealant to the cylinder head gasket in the area
of the timing case cover because of po rous areas in the left cylinder head.
Repair note
The sealant must be applied only in the ma nner shown, with a bead of 2.0 mm ± 0.5mm.
The sealant must be used within 10 min.
The silicone bead must not be spread.
Fig. 6: Identifying Application Of Sealant To Cylinder Head Gasket

INFORMATION ON APPLYING SEALANT TO A CYLINDER HEAD GASKET - AH01.30-P-1000-04VA
Engine 112, 113
If porous points are visible on the cylinder heads or on the rump of the engine in the area of the sealing
surface of the cylinder head gasket , apply sealant at these points.
Repair information:
The sealant must only be applied onl y with a bead of 2.0 mm ± 0.5 mm.
The sealin
g compound must be applied within 10 min.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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The sealing compound bead must not be spread.
INFORMATION ON CYLIND ER HEAD CONTACT SURFACE - AH01.30-P-1000-05A
Engine 112, 113
The cylinder head contact surface mu st only be machined if mechanically damaged points are present.
The cylinder head contact surface must not be re-worked (face-ground) if a variation exists in the flatness of the
cylinder head contact surface in the longitudinal direction and transverse direction (distortion).
When the cylinder head is fitted on again, the distor tion is compensated for by tightening the cylinder head
bolts.
Stock removal on the cylinder head and at the crankcase of an engine must together be not more than 0.3 mm.
The valve seats must be re-set if the cy linder head separating surface is machined.
INFORMATION FOR ASSIGNING THE CYLIND ER HEAD GASKETS - AH01.30-P-1000-06V
Engines 112, 113
The assignment of the applicable cylinder head gasket on the left and right to the matching engine can be
verified when the cylinder heads are installed at the visible round notch between cylinder head and front of
crankcase.
Incorrectly installed cylinder head gaskets, e.g. with marking B instead of A, cause a knocking engine noise,
particularly at high idling speeds, as the pistons touch the projecting cylinder head gasket. If a complaint exists,
replace cylinder head gasket.
Illustration shows M112/113

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Fig. 7: Information For Assigning Cylinder Head Gaskets (1 Of 2)
The assignment of the applicable cylinder head gasket on the left and right to the matching engine can be
verified when the cylinder heads are installed at the visible round notch between cylinder head and front of
crankcase.
Incorrectly installed cylinder head gaskets, e.g. with marking B instead of A, cause a knocking engine noise,
particularly at high idling speeds, as the pistons touch the projecting cylinder head gasket. If a complaint exists,
replace cylinder head gasket.
Illustration shows M112/113

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Fig. 8: Information For Assigning Cylinder Head Gaskets (2 Of 2)
NOTES ON APPLICATION OF SEALANT TIMING CASE COVER - AH01.40-P-1000-01B
Engine 112, 113
Application of sealant to timing case cover
The timing case cover is sealed with a silicone sealant at points A, C, D.
No sealant must be applied to the timing case cover at points B , pressure oil galleries to crankcase, with the
exception around the bolt hole G . Sealant which is applied to the points B , is entrained by the oil flow and
blocks the oil supply drillings of: Main bearings, camshaft bearings, rocker arms and oil spray nozzles.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Fig. 9: Identifying Application Of Sealant Timing Case Cover
Clean sealing surfaces
Apply sealant only to the specified surf aces with a bead of 2.0 mm ± 0.5 mm.
The sealant must be applied within 10 minutes!
The silicone bead must not be spread. Only the silicone sealant listed in the section Repair products may be
used.
NOTES APPLICATION OF SEALAN T TO END COVER WITH RADIAL SHAFT SEAL - AH01.40-P-1000-06A
Engine 112, 113
Application of sealant to end cover
The lines drawn G, E and the arrow D mark the application of sealant.
Clean sealing surfaces, apply sealant only to the sp ecified surfaces with a bead of 2.0 mm ± 0.5 mm.
The sealant must be applied within 10 minutes!
The silicone bead must not be spread. Only the silicone sealant listed in the section Repair products may be
used.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Saturday, October 02, 2010 3:17:56 PMPage 19 © 2006 Mitchell Repair Information Company, LLC.

Fig. 10: Identifying Application Of Sealan t To End Cover With Radial Shaft Seal
NOTES ON APPLICATION OF SEALANT OIL PAN - AH01.45-P-0001-01C
Engine 112
Application of sealant to top part of oil pan
The line drawn F marks the application of sealant.
Fig. 11: Identifying Application Of Sealant To Top Part Of Oil Pan
- Engine 112
Clean sealing surfaces, apply sealant only to the sp ecified surfaces with a bead of 2.0 mm ± 0.5 mm.
The sealant must be applied within 10 minutes!
The silicone bead must not be spread. Only the silicone sealant listed in the section Repair products may be
used.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Saturday, October 02, 2010 3:17:56 PMPage 20 © 2006 Mitchell Repair Information Company, LLC.