length MERCEDES-BENZ ML430 1997 Complete Manual PDF

Check values for cylinder bore
Permissible
deviation of
cylinder shapemm0.0140.007
contact surface
peak-to-valley
heightµm--
NumberDesignation
Engine
112.910/ 911
Engine
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...83.26583.250 ... 83.265
Repair sizemm90.150 ...
90.16590.150...90.165
BE01.40-P-
1002-01FCylinder dia.,
setting for
repair size
(+0.25)Pre-honingmm83.20089.900
Precision
honingmm83.38090.080
Polishingmm83.43090.130
BE01.40-P-
1003-01FCylinder dia.
according to
machining
phasePre-honingmm83.38090.080
Precision
honingmm83.43090.130
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

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
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Check values for cylinder bore
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
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 ... 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

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 122 © 2006 Mitchell Repair Information Company, LLC.

Check values for cylinder bore
BE01.40-P-
1008-01FEngine speedPre-honingrpm-125
Precision honingrpm-125
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
NumberDesignation
Engine
112.946/947/
948/960
Engine 112.912
BE01.40-P-
1001-01FCylinder dia.Standard
marking Xmm89.900...89.91583.200...83.215
Auxiliary stage
marking mm89.950 to 83.26583.250...83.265
Repair sizemm90.150...90.16583.450 to 83.465
BE01.40-P-
1002-01FCylinder dia.,
setting for repair
size (+0.25)Pre-honingmm89.90083.200
Precision honingmm90.08083.380
Polishingmm90.13083.430
BE01.40-P-
1003-01FCylinder dia.
according to
machining phasePre-honingmm90.08083.380
Precision honingmm90.13083.430
Polishingmm90.150...90.16583.450 to 83.465
BE01.40-P-
1004-01FCylinder lengthmm129.5129.5
BE01.40-P-Undercutmm1212

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 123 © 2006 Mitchell Repair Information Company, LLC.

Check values for cylinder bore
1005-01F
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
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
113.960/961/
962/963/964/
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

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 124 © 2006 Mitchell Repair Information Company, LLC.

Commercially available tools
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
machining phasePre-honingmm97.180
Precision honingmm97.230
Polishingmm97.250 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 s cale 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
NumberDesignation
WH58.30-Z-1030-04A
Honing head CK-3000 for 76-127 mm dia. CK-2600,
Firma Hommel Prazision GmbH D-50767 Koln
Firma Sunnen Products Comp. USA- -7910 Manchester St. Louis, Mo.63143

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 125 © 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.

Workshop equipment
Repair materials
TEST & ADJUSTMENT VALUES
CYLINDER HEAD /CYLINDER HEAD BOLTS - BE01.30-P-1000-04B
Engines 103, 104, 111, 112, 113, 119, 120, 137, 155, 156, 271, 272, 273, 275, 285
Cylinder head/cyl inder head bolts
WE58.40-Z-1007-11AEngine lifting fixture
NumberDesignationOrder number
BR00.45-Z-1013-01ASealantA 003 989 98 20
NumberDesignationEngine 103Engine 104
BE01.30-P-1001-
04BCylinder head
boltThread diameterM1212
Length (L) when
newmm105160
Length (L)mm< or = 108.4< or = 162.7
See picture--
BE01.30-P-1002-
04BCylinder headOverall height "H"
mmmm89.9 to 90.0135.9 to 136.0
Heightmm> or = 89.5> or = 135.5
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--
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 Reference
dimension "H1"mm--

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 140 © 2006 Mitchell Repair Information Company, LLC.

Cylinder head/cyl inder head bolts
stock removalReference
dimension "H2"mm--
NumberDesignation
Engine
111
Engine
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
BE01.30-P-
1001-04BCylinder head
boltThread diameterM1211
Length (L) when
newmm102141.5
Length (L)mm< or = 105< or = 144.5
See pictureAR01.30-P-
5800-03HAAR01.30-P-5800-
03B
BE01.30-P-
1002-04BCylinder headOverall height
"H" mmmm135.9 to 136.0106.2 to 106.3
Heightmm> or = 135.5-
See pictureAR01.30-P-
7162A-
BE01.30-P-
1003-04BCylinder headpermissible
difference of
flatness of contact
surface in
longitudinal
directionmm0.080.1
permissible
difference of
flatness of contact
surface in
transverse
directionmm00.1
Peak-to-valley
heightµM3/1010
BE01.30-P-
1004-04BCylinder head
when newReference
dimension "H1"mm--
Reference
dimension "H2"mm--

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 141 © 2006 Mitchell Repair Information Company, LLC.

Cylinder head/cyl inder head bolts
BE01.30-P-
1005-04BCylinder head
after necessary
stock removalReference
dimension "H1"mm--
Reference
dimension "H2"mm--
NumberDesignation
Engines
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
Engine
113.989
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
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--
Peak-to-valley
heightµM--
BE01.30-P-
1004-04BCylinder head
when newReference
dimension "H1"mm--
Reference mm
--

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 142 © 2006 Mitchell Repair Information Company, LLC.

Cylinder head/cyl inder head bolts
Cylinder head/cyl inder head bolts
dimension "H2"
BE01.30-P-
1005-04BCylinder head
after necessary
stock removalReference
dimension "H1"mm--
Reference
dimension "H2"mm--
NumberDesignationEngine 119Engine 120
BE01.30-P-1001-
04BCylinder head
boltThread diameterM1212
Length (L) when
newmm160168
Length (L)mm< or = 162.7< or = 171
See picture--
BE01.30-P-1002-
04BCylinder headOverall height "H"
mmmm-135.9 to 136.0
Heightmm-> or = 135.5
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--
Peak-to-valley
heightµM--
BE01.30-P-1004-
04BCylinder head
when newReference
dimension "H1"mm130.6 to 130.7-
Reference
dimension "H2"mm145.9 to 146.0-
BE01.30-P-1005-
04BCylinder head
after necessary
stock removalReference
dimension "H1"mm130.0-
Reference
dimension "H2"mm145.3-
NumberDesignationEngine 137Engine 155.980
BE01.30-P-
1001-04B Cylinder head
boltThread diameterM1011
Length (L) when mm
126/162175 +-0.5

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:58 PMPage 143 © 2006 Mitchell Repair Information Company, LLC.