MERCEDES-BENZ ML430 1997 Complete Repair Manual

Cylinder head/cyl inder head bolts
flatness of contact
surface in
longitudinal
direction
permissible
difference of
flatness of contact
surface in
transverse
directionmm-0.05
Peak-to-valley
heightµM-10
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--
NumberDesignationEngine 272Engine 273
BE01.30-P-1001-
04BCylinder head
boltThread diameterM1111
Length (L) when
newmm170170
Length (L)mm172172
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
directionmm--
permissible
difference of
flatness of contact
surface in
transverse
directionmm--

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 145 © 2006 Mitchell Repair Information Company, LLC.

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.

2
The fresh air openings, the windshield and the
front fenders must be generously masked off
before cleaning and preserving.
be determined by each workshop itself.
Masking is necessary in order to ensure that
no materials whatsoever, e.g. cold cleaning
solvent, wax or similar, penetrate inside the
car (difficult to clean).

3
The screw joint holding the brake fluid
reservoir must be masked off with adhesive
tape, which is to be removed again after
preservation of the engine compartment.

4
Mask off the ventilation hole for the
diaphragm chamber in the pressure control
valve in the cylinder head cover.
Engines 601, 602, 603
AP01.00-
P-8503-
01A
5
Cleaning is to be performed when the engine
is no hotter than hand-hot (at the exhaust)
using a demulsifying cold cleaning solvent
(short action time) and a high-pressure hot-
water cleaner, depending on how dirty the
engine is.
"Demulsifying" means that a mixture of oils
and greases in water separated in the oil
separator pipe.

6
When cleaning the component compartment
behind the engine compartment: Spray only as
much water as necessary under very low
pressure.Electronic control modul es must be covered
beforehand; any that become wet must be
dried afterwards.

7After washing/preserving the engineLubricate throttle cont rol linkage and check
for ease of movement and wear.
8
Preservation is to be performed only when the
engine compartment is dry and using properly
functioning commercially available
equipment.Only use approved wax preservation agents.
Airless devices produce the least
contamination.

9Do not spray the follow ing with preservation
wax:Electrical and electroni c components, belt
drive (belts and pulleys), exhaust pipe and
muffler in component compartment.


2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 153 © 2006 Mitchell Repair Information Company, LLC.

AD91.29-P-1000GHZ
Electric seat adjustment (ESA) diagnosis contents
23.5.97

MODEL
163 with CODE (221b) electrically-adjustable driver's and front passenger's seat

A15.5
j
11
Electric seat adjustment diagnosis, advanced

information (ESA)

AD91.29-P-2001GH

A15.5
j
12
Electric seat adjustment diagnosis, function

check (ESA)

AD91.29-P-3000GH

A15.5
j
13
Electric seat adjustment diagnosis,

troubleshooting (ESA)

AD91.29-P-5001GH

A15.5
j
21
Electric seat adjustment diagnosis, testing

electrical system (ESA)

AD91.29-P-6002GH

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d by Modification services.
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