height MERCEDES-BENZ ML320 1997 Complete Workshop Manual

AR63.20-P-2010GH
Remove/install D-pillar paneling
26.1.99

MODEL
163.113 /128 /136 /154 /157 /172 /174 /175

P63.20-3336-11

1
D-pillar paneling

2
Bonding material


Remove

1
Remove D-pillar paneling (1)

Separate glue bead with cutting wire.

Additional pull handle for cutting wire

*WH58.30-Z-1017-02A

2
Remove any residual bonding material on the

D-pillar flange

Not more than 2 mm of glue must remain.


Install

3
Clean D-pillar paneling

In order to ensure a good adhesion.

4
Apply primer to damaged paint areas on D-

pillar flange

Use 2K primer
. Allow primer to air for at

least 5 minutes.

5
Prepare D-pillar flange

If the remaining glue (cut glue bead) is

older than 24 hours, also apply
primer
for

paint to body to obtain optimum glued joint.

*BR00.45-Z-1059-02A

If the
body
has been damaged or if there

is no bonding material then apply the
primer

to the bonding first. Allow the primer to flash

off for at least 10 minutes, but not for longer

than 15 minutes.

6
Prepare D-pillar paneling (1)

Apply primer to bonding. Allow the primer

to flash off for at least 10 minutes, but not for

longer than 15 minutes.

*BR00.45-Z-1059-02A

7
Prepare glue cartridge

AR67.10-P-1000-07P

Betapower II (2-component electric

cartridge gun)

*WH58.30-Z-1015-20A

2-component glue kit

*BR00.45-Z-1055-02A

8
Apply glue (2) as glue bead to D-pillar

paneling (1)


The paneling must be put on within 5

minutes, otherwise the adhesion quality of the

bonding material will be impaired.

Height of adhesive bead approx. 13 mm

Use reference points on inside of D-pillar

paneling.

Betapower II (2-component electric

cartridge gun)

*WH58.30-Z-1015-20A

9
Align D-pillar paneling (1)

10
Install D-pillar paneling (1)

Firmly press D-pillar paneling to D-pillar

flange.

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e. g.)
Order number

WH58.30-Z-1017-02A
Additional handle for cutting wire
Stahlwille

Eduard Wille GmbH &

Co.Lindenallee 27

D-42331 Wuppertal

10351/1

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

DriftFig. 78
6Remove cylinder head
(1) from assembly
board (2)
Risk of explosion
and poisoning caused
by the melting down
or improper handling
of sodium-filled
valves. Risk of injury
caused by skin contact
with sodium resulting
in heat or chemical
burns.Do not open sodium-filled valves.
Wear protective gloves and safety
glasses when handling damaged
valves.AS05.30-Z-0001-01A
7Remove valve (14) Installation: Check surface of
valve stems for roughness and
formation of ridging (visual
inspection or with a nail). Replace
valves (14) with a rough stem
surface or formation of burrs. Grind
new or reused valves (14) with valve
grinding compound before
installation.
Disposal of sodium-
filled valvesExhaust valves with sodium fillingOS05.30-P-0001-01A
Checking
8Check valves (14) Intake and exhaust valves must
not be machined.
If the specified tolerances are
below the required limit, the valve
(14) must be replaced to ensure
functioning.AR05.30-P-4201-
01AV
Valve disk ø*BE05.30-P-1001-
01E
Valve disk height*BE05.30-P-1002-
01E
Valve seat angle (a)*BE05.30-P-1003-
01E
Valve stem ø*BE05.30-P-1004-
01E
Valve length*BE05.30-P-1005-
01E
9Inspect valve guides,
replace if necessary AR05.30-P-3731AV
10Install in the reverse

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 87 © 2006 Mitchell Repair Information Company, LLC.

Check values for valves
Check values for valves
order
NumberDesignationEngine
113.940/941/
942/943/944Engine
113.960/
961/962/963/
965/967/968/
980/981/982/
984/987/988/
990/991/992/
993/995
BE05.30-P-
1001-01EValve disk øExhaustmm41 ±0.143±0.1
Intakemm36±0.138±0.1
BE05.30-P-
1002-01EValve disk
heightExhaust when
newmm1.61.6
Intake when newmm1.21.2
BE05.30-P-
1003-01EValve seat
angle(a Exhaust)Angle°45±15'45±15'
IntakeAngle°45°15'45±15'
BE05.30-P-
1004-01EValve stem øExhaustmm6.9706.970
Intakemm6.9756.975
BE05.30-P-
1005-01EValve lengthExhaustmm122.25±0.2121.80±0.2
Intakemm119.40±0.2119.10±0.2
NumberDesignationEngine
112.910/911Engine
112.912/913/
914/915/920/
921/922/923/
940/941/942/
943/944/945/
946/947/948/
949/960
BE05.30-P-
1001-01EValve disk øExhaustmm34±0.141±0.1
Intakemm30±0.136±0.1
BE05.30-P-
1002-01EValve disk
heightExhaust when
newmm1.61.6
Intake when newmm1.21.2
BE05.30-P-
1003-01EValve seat
angle (a)ExhaustAngle°45 (+15')45 (+15')
IntakeAngle°45 (+15')45 (+15')
BE05.30-P-
1004-01EValve stem øExhaustmm6.9706.970
Intakemm6.9756.975
BE05.30-P-
1005-01EValve lengthExhaustmm121.65±0.2122.25±
Intakemm120.70±0.2119.40±0.2

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 88 © 2006 Mitchell Repair Information Company, LLC.

Test values for valve seat rings
1001-03CøRep. size 1mm32, 138, 3
BE05.30-P-
1002-03CExhaust valve seat ring
outer-øStandardmm35.1 (-0.01)42.1 (-0.01)
Rep. size 1mm36,343,3
BE05.30-P-
1003-03CHeight of
valve seat
ringIntakeStandardmm5.9 (-0.08)5.9 (-0.08)
Rep. size 1mm5.9 (-0.08)5.9 (-0.08)
ExhaustStandardmm7.9 (-0.08)7.9 (-0.08)
Rep. size 1mm7.9 (-0.08)7.9 (-0.08)
BE05.30-P-
1004-03CValve seat ring - overlap in
cylinder headIntakemm0.084...0.1150.084...0.115
Exhaustmm0.074...0.1000.074...0.100
BE05.30-P-
1005-03CDistance between contact
face of cylinder head and
end face of valve seat ringIntakemm6.86...6.948.22...8.30
Exhaustmm9.72...9.809.12...9.20
BE05.30-P-
1006-03CBasic bore diameter of inlet
valve seat rings in cylinder
headStandardmm31.000...31.01637.000...37.016
Rep. size 1mm32.000...32.01638.200...38.216
BE05.30-P-
1007-03CBasic bore diameter of
exhaust valve seat rings in
cylinder headStandardmm35.000...35.01642.000...42.016
Rep. size 1mm36.200...36.21643.200...43.216
BE05.30-P-
1008-03CBore depth of
valve seat
rings in
cylinder headIntakeStandardmm12,7614,12
ExhaustStandardmm17,6217,02
NumberDesignationEngine
113.960/
961/962/963/
964/965/967/
968/971/980/
981/982/984/
987/988/990/
991/992/993/
995Engine 137.970
BE05.30-P-
1001-03CIntake valve seat ring outer-
øStandardmm39.1 (+0.015)34,1
Rep. size 1mm40,335,3
BE05.30-P-
1002-03CExhaust valve seat ring
outer-øStandardmm44.1 (-0.01)37,1
Rep. size 1mm45,338,3
BE05.30-P-
1003-03CHeight of
valve seat
ringIntakeStandardmm5.9 (-0.08)5.9 (-0.08)
Rep. size 1mm5.9 (-0.08)5.9 (-0.08)
ExhaustStandardmm7.9 (-0.08)5.9 (-0.08)
Rep. size 1mm7.9 (-0.08)5.9 (-0.08)
BE05.30-P-
1004-03CValve seat ring - overlap in
cylinder headIntakemm0.084...0.1150.084...0.115
Exhaustmm0.074...0.01000.074...0.0100

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:39 PMPage 103 © 2006 Mitchell Repair Information Company, LLC.

Fig. 122: Identifying Valve Setback - Shown On Engine 606
CHECK VALVES - AR05.30-P-4201-01AV
Modification notes
Test values for valves
Test values for valves
19.11.04Value changed from 45 (±15') mm to
45 (+15') mmFigure for series 1003 for engine
112 complete*BE05.30-P-1003-
01E
NumberDesignationEngine
112.910/911Engine
112.912/913/
914/915/920/
921/922/923/
940/941/942/
943/944/945/
946/947/948/
949/960Engine
112.951
BE05.30-P-
1001-01EValve disk
dia.Exhaustmm34±0,141±0,141 ±0,1
Intakemm30±0,136±0,136±0,1
BE05.30-P-
1002-01EValve disk
heightExhaust when
newmm1.61.61.6
Intake valve
when newmm1.21.21.2
BE05.30-P-
1003-01EValve seat
angle (a)ExhaustAngle°45 (+15')45 (+15')45 (+15')
IntakeAngle°45 (+15')45 (+15')45 (+15')
BE05.30-P-
1004-01EValve stem
dia.Exhaustmm6,9706,9706.970 (-0.02)
Intakemm6,9756,9756.975 (-0.015)
BE05.30-P-
1005-01EValve lengthExhaustmm121,65±0,2122,25±0,2122,25 (±0,2)
Intakemm120,70±0,2119,40±0,2119,40 (±0,2)
NumberDesignationEngines
113.940/941/
942/943/944Engine
113.960/
961/962/963/ Engine
137.970

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:39 PMPage 110 © 2006 Mitchell Repair Information Company, LLC.

Fig. 123: Identifying Valve Dimensions
CHECKING AND MACHINING DIMENSIONS FOR VALVE SEATS - AR05.30-P-4510-01AV
Test values for valve seat rings
965/967/968/
980/981/982/
984/987/988/
990/991/992/
993/995
BE05.30-P-
1001-01EValve disk
dia.Exhaustmm41±0,143±0,136±0,1
Intakemm36±0,138±0,133±0,1
BE05.30-P-
1002-01EValve disk
heightExhaust when
newmm1.61.61.6
Intake valve
when newmm1.21.21.1
BE05.30-P-
1003-01EValve seat
angle(aExhaust)Angle°45±15'45±15'45±15'
IntakeAngle°45±15'45±15'45±15'
BE05.30-P-
1004-01EValve stem
dia.Exhaustmm6,9706,9706,970
Intakemm6,9756,9755,975
BE05.30-P-
1005-01EValve lengthExhaustmm122,25±0,2121,80±0,2104,30 ±0,2
Intakemm119,40±0,2119,10±0,2103,60 ±0,2
NumberDesignationEngine
112.910/
911Engine 112.912/
914/915/920/
921/922/923/
940/941/942/
943/944/945/

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:39 PMPage 111 © 2006 Mitchell Repair Information Company, LLC.

1002-01M
*BA20.10-P-
1003-01C
*BA20.10-P-
1003-01M
*BA20.10-P-
1004-01C
*BA20.10-P-
1004-01M
*BA46.30-P-
1010-01A
*BA46.30-P-
1010-01C
Clean sealing surfaces, appl y sealant only to specified
surfaces in form of bead with height and width of 2.0 mm
± 0.5 mm. The sealant must be applied within 10 minutes!
The silicone bead must not be spread!*BR00.45-Z-
1013-01A
Notes on
application of
sealant to timing
case cover AH01.40-P-
1000-01B
Installation: If sealing compound enters the oil ducts,
this is carried by the oil flow and will clog the oil supply
bores.
Do not damage cylinder head gasket.
Replace seals on ti ming case (19).
Replace front crankshaft radial sealing ring: ?

Engine 112 in model 129
Engine 113 in model 129
Engine 113 in model 163, 202, 208, 210AR03.20-P-
3000B
Engine 112 in models 170, 202, 208, 210, 220
Engine 113 in model 215, 220
Engine 113.981 in model 163.174
Engine 113.963 in models 230.475
Engine 113.992 in model 230.474AR03.20-P-
3000BA
32Install in the
reverse order

Risk of accident
caused by vehicle
starting off by
itself when engine
is running. Risk
of injury caused
by contusions and
burns during
starting procedure
Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.AS00.00-Z-
0005-01A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 105 © 2006 Mitchell Repair Information Company, LLC.

Check values for crankcase
Operating time of honing
machine
*BE01.40-P-1014-01F
17Coat filter insert again
with honing paste Do not coat cylinder
bore with honing paste.
Polmot honing paste order
no. 600.11
*BR00.45-Z-1050-06A
18Lap cylinder bore and
expose silicone crystals. Without honing oil
feed, removed material
cannot be measured.
Operating time of honing
machine
*BE01.40-P-1014-01F
19Clean cylinder bore and
dry Clean crankcase very
carefully with honing
paste. If possible, clean
crankcase in a major
assembly washing
machine, so that no
cylinder wall damage will
be caused by residues
when running the engine
later.
20Inspect cylinder boreAllow crankcase to cool
down to approx. 20°C
before inspecting.
Cylinder diameter of repair
size
*BE01.40-P-1001-01F
NumberDesignation
Engine 112
except 112.951,
113.940/941/
942/943/944/
945/946/948/
960/961/963/
965/966/967/
968/980/981/
984/986/992/
995
Engine
113.962/982/
987/988/989/
990/991/993
BE01.40-P-
1001-02E Cylinder borePeak-to-valley
height (R
Z ) of
top separating
surface
mm0.001 to 0.00450.001 to 0.0045
Wear limit at
BDC and TDC
of 1st piston ringmm< or = 30.03< or = 0.03

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 120 © 2006 Mitchell Repair Information Company, LLC.

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
Saturday, October 02, 2010 3:17:57 PMPage 121 © 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.