engine MERCEDES-BENZ ML320 1997 Complete Repair Manual

Fig. 63: Identifying Pilot Bushing, Stop Ring, Guide Tube And Combination Tap
4. Select heli-coil threaded inse rt (8) with block length 10.2 mm.
5. Insert threaded insert (8) with primary pump drive pointing in direction of prestessing cartridge (16) in
the installation tool (13) (arrow).
6. Screw in threaded insert (8) flush to prestessing cartridge (16) (arrow).
Fig. 64: Identifying Installation T ool, Threaded Insert And Cartridge

7. Position HC-installat ion tool on tapped hole

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 71 © 2006 Mitchell Repair Information Company, LLC.

8. Hold jacket sleeve (5)
9. Rotate screw-in spindle (6) until the stop ring (7) is pos itioned on the jacket sleeve (5). Slightly turn back
a clamping jacket sleeve when screwing-in.
Fig. 65: Identifying Jacket Sleeve, Spindle And Stop Ring

10. Insert sleeve (9) via primary pum p drive of HELI-COIL insert
11. Guide open pliers to the marking in the sleeve (9) and fix with primary pump drive
12. Close pliers , the serrated lock of pliers must latch.
13. Rotate sleeve (9) toward left as far as the stop and hold
14. Dismount primary pump drive, to do so move pliers slightly up and down.
Remove with a ma
gnet the primary pump drive which had fallen onto the piston crown!

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 72 © 2006 Mitchell Repair Information Company, LLC.

Fig. 66: Identifying Sleeve & Pliers
CAULK THREADED INSE RT - AR01.30-P-5440-02B
Fig. 67: Identifying Heli-Coil Repair Set (102 589 00 99 00)
1. Grease caulk drift, screw into installed HELI-COI L insert and tighten with a torque of approx. 25-30
Nm.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 73 © 2006 Mitchell Repair Information Company, LLC.

Fig. 68: Identifying Caulk Drift
REPAIRING SPARK PLUG THREAD - AR01.30-P-5440BV
ENGINE 112
ENGINE 112.945 in MODEL 463.209 /232 /233 /244 /245 /250
ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODEL 463.243/246
ENGINE 113 (except 113.995) in MODEL 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 74 © 2006 Mitchell Repair Information Company, LLC.

Fig. 69: Identifying Tapped Hole Device

Remove,
Install

1Remove
cylinder
head
coverAir cleaner located at vehicle side.
Air cleaner located at engine side.AR01.20-
P-5014B
AR01.20-
P-
5014BV
2Remove
spark
plugs
Model 463.206/209/ 232/233/240/241/243/ 244/245/ 246/247/248/249 /250/254AP15.10-
P-
1580GA
Model 220, 230.474/475, 211.061/065/070AP15.10-
P-
1580AB
Model 170, 202, 203, 208, 209, 210AP15.10-
P-1580A
Model 129AP15.10-
P-
1580AC
Model Series 163AP15.10-
P-
1580GH
3Position

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 75 © 2006 Mitchell Repair Information Company, LLC.

piston of
relevant
cylinder
to 20° -
30°
before
TDC Inlet valve and exhaust valve of th e relevant cylinder must be closed.
4Remove
cylinder
head Model 230.474 with Engine 113.992 repla ce cylinder head if spark plug
thread is faulty.
It is then only necessary to remove the cylinder head if it is not possible to
insert the thread tap unit into the spark plug thread for space reasons!
Model
463.206 /209 /232 /233 /240 /241 /243 /244 /245 /246 /247 /248 /249 /250 /254.AR01.30-
P-
5800GV
Model 202, 208, 210 with Engine 113 and Model 129 with Engine 112, 113AR01.30-
P-5800B
Model 220 with Engine 112, 113 and Model 210, 170, 202, 208 with Engine
112, 230.474/475AR01.30-
P-
5800BA
Model 203, 209, 211.061/065 /070AR01.30-
P-
5800PV
Model Series 163AR01.30-
P-
5800MV
5Tap
thread in
spark
plug
hole and
screw in
threaded
insert Pack the swarf grooves of the combin ation thread tap with grease for
bonding the swarf. Blow out cylinder and spark plug thread with compressed
air before screwing in the threaded insert.AR01.30-
P-5440-
01B
Fig. 62
6Crank
engine
with
starter. If the cylinder head was not removed, the engine must be cranked several
times with the starter.
All Models except Mode l 203, 209 Model 203, 209AR01.10-
P-0110V
AR01.10-
P-
0110PV
7Caulk
threaded
insert AR01.30-
P-5440-
02B
8Install in
the
reverse
order

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 76 © 2006 Mitchell Repair Information Company, LLC.

Fig. 70: Identifying Heli-Coil Repair Set (102 589 00 99 00)
CHECKING CYLINDER HEAD BOLTS - AR01.30-P-5800-03B
Cylinder head/Cylinder head bolts
Cylinder head/cyl inder head bolts
1. Measure length (L) of cylinder head bolts.
If the length (L) exceeds the maximu m permissible dimension then the cyli nder head bolts must be replaced.
NumberDesignation
Engines
112.910/911/
912/913/914/
915/916/917/
920/921/922/
923/940/941/
942/943/944/
945/946/947/
949/951/953/
954/955/960/
961/970/972/
973/975/976Engines
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/987/988/
990/991/992/
993/995
BE01.30-P-
1001-04BCylinder head
boltThread diameterM1111
Length (L) when
newmm141.5141.5
Length (L)mm< or = 144.5< or = 144.5
See pictureAR01.30-P-
5800-03B
AR01.30-P-
5800-03B
NumberDesignationEngine 113.989
BE01.30-P-1001-
04BCylinder head boltThread diameterM11
Length (L) when
newmm141.5
Length (L)mm< or = 144.5
See pictureAR01.30-P-5800-
03B

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 77 © 2006 Mitchell Repair Information Company, LLC.

Fig. 71: Identifying Length Of Cylinder Head Bolts
TIGHTENING INSTRUCTIO NS FOR CYLINDER HEAD BOLTS - AR01.30-P-5800-07B
Cylinder head
Cylinder head
NumberDesignation
Engines
112.910/911/
912/913/914/
915/916/917/
920/921/922/
923/940/941/
942/943/944/
945/946/947/
949/951/953/
954/955/960/
961/970/972/
973/975/976
Engines
113.940/941/
942/943/944/
948/960/961/
962/963/965/
966/967/968/
969/971/980/
981/982/984/
986
Engine
113.987/
988
Engine
113.987/
991/992/
993/995
BA01.30-P-
1001-01DBolt,
cylinder
head to
crankcaseStage 1Nm10101010
Stage 2Nm30303030
Stage 3Angle °90909090
Stage 4Angle °90909090
NumberDesignationEngine 113.989Engine 113.964
BA01.30-P-
1001-01DBolt, cylinder
head to
crankcaseStage 1Nm1010
Stage 2Nm3030
Stage 3Angle °9090
Stage 4Angle °9090

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 78 © 2006 Mitchell Repair Information Company, LLC.

Fig. 72: Identifying Screwdr iver Insert (000 589 03 10 00)
Fig. 73: Identifying Screwdr iver Insert (000 589 04 10 00)

Tightening pattern/bolt assignment
Left and right cylinder head M 112
1-8 Collar bolt M11 a. a Combination bolts M850( to timing case cover)
b. b Combination bolts M830(to timing case cover)

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 79 © 2006 Mitchell Repair Information Company, LLC.

Fig. 74: Identifying Tightening Pattern/Bolt Assignment (Left And Right Cylinder Head M 112)
Tightening instructions for left and right cylinder heads M 112
Use wrench bit to tight en cylinder head bolts.
Observe sequence, see tightening pattern.
If the tightening torque is exceeded on a cylinder he ad bolt, unscrew the cylinder head bolt, inspect shank
length of the cylinder head bolt in question (replace bolt if necessary) and tighten again fully, beginning with
stage 1.
Cylinder head bolts must not be retightened.
Tightening diagram/bolt assignment
Left and right cylinder head M 113
Fig. 75: Identifying Left And Right Cylinder Head M 112 (Left And Right Cylinder Head M 113)

Tightening instructions for left and right cylinder heads M 113
Use wrench bit to tight en cylinder head bolts.
Observe sequence, see tightening pattern.
If the tightening torque is exceeded on a cylinder he ad bolt, unscrew the cylinder head bolt, inspect shank
length of the cylinder head bolt in question (replace bolt if necessary) and tighten again fully, beginning with
stage 1.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 80 © 2006 Mitchell Repair Information Company, LLC.