MERCEDES-BENZ ML350 1997 Complete Repair Manual

Removing
1Remove camsha ft bearing
bridge
Pay attention to slackening diagram.
All models except 171.473, 164.175, 251.075/175,
219.375/376AR05.20-P-
7103AU
Model 164.175AR05.20-P-
7103GZ
Models 251.075/175AR05.20-P-
7103RT
Models 219.375/376AR05.20-P-
7103TY
Model 171.473AR05.20-P-
7103VT

Risk of injury to skin and eyes
caused by handling hot or
glowing objects.Wear safety gloves, protec tive clothing and safety
glasses, if necessary.AS00.00-Z-
0002-01A
2Remove the rocker arm
spindles (3)
If the rocker arm spindle (3) is not able to move
easily in its bearings (clamps), the camshaft bearing
bridge must be warmed up: ?

Warm up camshaft bearing bridgeAR05.20-P-
2350AU
Drift punchFig. 53
Support plateFig. 56
Recirculated ai r warming cabinet*WH58.30-Z-
1001-28A
Heating oven*WH58.30-Z-
1003-28A
3Remove rocker arm (2) Take out 15 mm dia. drift (1).
Install
4Check bearing surfaces of
rocker arm (2) for damage

Pay attention to any l ong score marks caused by
the removal of the rocker arm spindles (3).
If damage is present ? Replace rocker arms (2).

5Introduce guide shaft into
camshaft bearing bridge
At the same time preassemble the rocker arms (2)
on the guide shaft.
16 mm dia. guide shaftFig. 54
18 mm dia. guide shaftFig. 55

Risk of injury to skin and eyes
caused by handling hot or
glowing objects.Wear safety gloves, protec tive clothing and safety
glasses, if necessary.AS00.00-Z-
0002-01A
If the rocker arm spindle (3) cannot be easily
introduced into its bearings (clamps), the camshaft
bearing bridge must be warmed up: ?

Heat the camshaft bearing bridge and drive out the AR05.20-P-

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 50 © 2006 Mitchell Repair Information Company, LLC.

Camshaft
Camshaft
6Install the rocker arm spindles
(3)
guide shaft with the rocker arm spindle (3).2350AU
Ensure that the rocker arms (2) do not get
jammed.
Recirculated ai r warming cabinet*WH58.30-Z-
1001-28A
Heating oven*WH58.30-Z-
1003-28A
7Install camshaft bearing bridge
Observe tightening pattern.
All models except 171.473, 164.175, 251.075/175,
219.375/376AR05.20-P-
7103AU
Model 164.175AR05.20-P-
7103GZ
Models 251.075/175AR05.20-P-
7103RT
Models 219.375/376AR05.20-P-
7103TY
Model 171.473AR05.20-P-
7103VT
*BA05.20-P-
1002-01B
*BA05.20-P-
1004-01B
NumberDesignationEngine 112 except
112.951/976Engine
112.951/ 976
BA05.20-P-
1002-01BBolt,
camshaft
bearing
bridge to
cylinder headM7x45Stage 1Nm1515
Stage 2Angle°--
BA05.20-P-
1004-01BBolt,
camshaft
bearing
bridge to
cylinder headM7x84Stage 1Nm1010
Stage 2Angle°9090
NumberDesignationEngines
113.940/941/
942/943/944/
948/961/962/
963/964/965/
966/967/968/
969/971/980/ Engine
113.960
without
code
479

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 51 © 2006 Mitchell Repair Information Company, LLC.

Camshaft
Fig. 53: Identifying Extraction Drift (112 589 00 15 00)
981/982/984/
986/992/995
BA05.20-P-
1002-01BBolt,
camshaft
bearing
bridge to
cylinder headM7x45Stage 1Nm1515
Stage 2Angle°--
BA05.20-P-
1004-01BBolt,
camshaft
bearing
bridge to
cylinder headM7x84Stage 1Nm1010
Stage 2Angle°9090
NumberDesignationEngine
113.987/988/
990/993Engine
113.989/Engine
113.991
BA05.20-P-
1002-01BBolt,
camshaft
bearing
bridge to
cylinder
headM7x45Stage 1Nm888
Stage 2Angle°120120120
BA05.20-P-
1004-01BBolt,
camshaft
bearing
bridge to
cylinder
headM7x84Stage 1Nm888
Stage 2Angle°120120120

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 52 © 2006 Mitchell Repair Information Company, LLC.

Fig. 54: Identifying Guide Shaft (112 589 02 31 00)
Fig. 55: Identifying Guide Shaft (112 589 03 31 00)

Fig. 56: Identifying Board (112 589 10 59 00)

Commercially available tools
REMOVING/INSTALLING THE ROCK ER ARM SHAFT - AR05.20-P-2350AU
ENGINE 112
ENGINE 113 (except 113.960)
ENGINE 113
ENGINE 113.960 except CODE (479) Cylinder shutoff
NumberDesignation
WH58.30-Z-1001-28ARecirculated air warming cabinet
WH58.30-Z-1003-28AHeating oven

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 53 © 2006 Mitchell Repair Information Company, LLC.

Shown on engine 112 1 Drift punch
Fig. 57: Identifying Rocker Arm Shaft Components
- Shown On Engine 112
Removing
1Remove camshaft
bearing bridge
Engines 112, 113 except engine s 113.967/990 in models 219,
engines 113.964 /971 /989 /993AR05.20-P-
7103AU
Engine 113.993 in model 463AR05.20-P-
7103GX
Engines 113.967/990 in model 219AR05.20-P-
7103TY
Engine 113.964 in model 164AR05.20-P-
7103GZ
Engine 113.971 in model 251AR05.20-P-
7103RT
Engine 113.989 in model 171AR05.20-P-
7103VT

Risk of injury to skin
and eyes caused by
handling hot or glowing
objects.
Wear safety gloves, protective cl othing and safety glasses, if
necessary.AS00.00-Z-
0002-01A
2
Heat camshaft bearing
bridge to approx. 150°
C
Heat the camshaft bearing bridge uniformly, but do not
heat it over 160°C; there is a danger of structural changes.
i040*WH58.30-Z-
1001-28A

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 54 © 2006 Mitchell Repair Information Company, LLC.

i040*WH58.30-Z-
1003-28A
3Place camshaft bearing
bridge on board (4) Fig. 56
4
Remove the rocker arm
spindle (3) by tapping
gently with a hammer If it is tapped very hard, th ere is a danger of distorting the
camshaft bearing bridge and da maging the hollow rocker arm
spindle (3).

Fig. 53
Check
5
Inspect bearing
surfaces of rocker arms
for damage Pay attention to any long score marks caused by the
removal of the rocker arm spindl es (3). Replace the rocker arm
if damaged.

Installing
6
Insert the guide shafts
into the camshaft
bearing bridge. At the same time, preassemble the rocker arm on guide
shaft.
Fig. 54
Fig. 55

Risk of injury to skin
and eyes caused by
handling hot or glowing
objects.
Wear safety gloves, protective cl othing and safety glasses, if
necessary.AS00.00-Z-
0002-01A
7
Heat camshaft bearing
bridge to approx. 150°
C
Heat the camshaft bearing bridge uniformly, but do not
heat it over 160°C; there is a danger of structural changes.
WH58.30-Z-
1001-28A
*WH58.30-Z-
1003-28A
8Cool the rocker arm
spindle (3)
9
Place heated camshaft
bearing bridge on board
(4) Fig. 56
10Install rocker arm
spindle (3)
Insert the rocker arm spindle (3) in the camshaft bearing
bridge by tapping gently with a hammer and simultaneously
remove the guide shaft. Ensure that the rocker arms do not get
jammed.

11Align the rocker arm
spindle (3)
In order to align and secure the rocker arm spindle (3), fit
two screws through the mount ing bores in the camshaft
bearing bridge. The oil supply bores of the rocker arm spindle
(3) point towards the cylinder head.

Engines 112, 113 except engines 113.967 /990 in models 219,
engines 113.964 /971 /989 /993AR05.20-P-
7103AU
Engine 113.993 in model 463AR05.20-P-
7103GX

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 55 © 2006 Mitchell Repair Information Company, LLC.

Fig. 58: Identifying Board (112 589 10 59 00)
Fig. 59: Identifying Extraction Drift (112 589 00 15 00)

Fig. 60: Identifying Guide Shaft (112 589 02 31 00)
12Install camshaft bearing
bridge
Engines 113.967/ 990 in model 219AR05.20-P-
7103TY
Engine 113.964 in model 164AR05.20-P-
7103GZ
Engine 113.971 in model 251AR05.20-P-
7103RT
Engine 113.989 in model 171AR05.20-P-
7103VT

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 56 © 2006 Mitchell Repair Information Company, LLC.

Fig. 61: Identifying Guide Shaft (112 589 03 31 00)
Commercially available tools
SET THE BASIC POSITION OF CAMSHAFTS - AR05.20-P-6020AU
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
Shown on engine 112
NumberDesignation
WH58.30-Z-1001-28ARecirculated air warming cabinet
WH58.30-Z-1003-28AHeating oven

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 57 © 2006 Mitchell Repair Information Company, LLC.

Fig. 62: Identifying Basic Position Of Camshafts - Shown On Engine 112
Modification notes
26.11.97M112/113 Operation note modifiedStep 3AR05.10-P-7800C
Removing
1Remove
cylinder
head
coversAir filter located at vehicle side.AR01.20-
P-5014B
Air filter located on engine side.AR01.20-
P-5014BV
2Check
basic
position o
f
camshafts
If the basic position of the camshafts is not correct: ?
Turn engine to 40° after ignition TDC at cylinder 1.
The engine must not be turned back; otherwise the timing chain can get
jammed.
AR05.10-
P-6858V
3Remove
chain
tensioner
Engine 112 in models 211.080/082/261/ 265/280/282,
Engine 113 in model 211.083/270/283
Engine 112.945 in model 463.209/232/ 233/244/245/250,AR05.10-
P-7800C
Engine 112 in models 163, 129,
Engine 113.962 in model 463.206/240/241 /247/248/249/254,
Engine 113 (except 113.965/981) in Model 210, 208, 202, 163, 129,

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 58 © 2006 Mitchell Repair Information Company, LLC.

Engine 113.982 in model 463.243/246
Engine 112 in Model 170, 202, 203, 208, 209, 210,AR05.10-
P-7800CA
Engine 113 in models 163.174/175, 209
Engine 112 in Model 211.061 /065, 220, 230.467,AR05.10-
P-
7800AM
Engine 113 in models 211.070/076/276,
215.373/374/375,220.070/073/074/075 /083/ 084/170/173/174/175/183/184/875,
230.474/475
4Remove
camshaft
Hall
sensor
Engine 112 in models 211.080/082/261/265 /280/282,
Engine 113 in model 211.083/270/283
Engine 112.945 in model 463.209/232/233 /244/245/250,AR15.10-
P-2000A
Engine 112 in Model 129, 163, 170, 202, 203, 208, 209.361/365/461/465, 210,
211.061 /065, 220, 230.467,
Engine 113 (except 113.990/991) in Model 129, 163, 202, 208,
209.375/376/475/476, 210, 211.070, 215, 220, 230.474/475,
Engine 113.962 in model 463.206/240/241 /247/248/249/254,
Engine 113.982 in model 463.243/246
Engine 113.990 in model 211.076/276,
Engine 113.991 in models 215.374, 220.074 /174AR15.10-
P-
2000RVK
5Remove
right-hand
camshaft
sprocket Lift timing chain from camshaft sprocket.
Open-end wrenchFig. 22
Insertion toolFig. 66
Torque wrenchFig. 23
6Remove
left-hand
camshaft
sprocket Lift timing chain from camshaft sprocket.
Open-end wrenchFig. 22
Insertion toolFig. 66
Torque wrenchFig. 23
Install
7Rotate
left-hand
camshaft
to the
basic
position
and fit
locating
plate to
the Open-end wrenchFig. 22
Groove of camshaft (6) must point to the center of the cylinder head cover
separating surface in direction of inner V.
Locating plateFig. 12
Place locating plate flush onto left cylinder head and insert into the groove
(6) of the camshaft.
At a 40° crank angle afte r ignition TDC of cylinder 1 it is possible to rotate

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 59 © 2006 Mitchell Repair Information Company, LLC.