engine MERCEDES-BENZ ML320 1997 Complete Repair Manual

ENGINE 113.962 in MODEL 463.206 /240 /241 /247 /248 /249
ENGINE 113 // (except 113.990 /991 /995) in MODEL 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230
ENGINE 113.982 in MODEL 463.243/246
Shown on engine 112
Fig. 51: Identifying Slide Rail In Timing Case Cover Components
- Shown On Engine 112
Modification notes
20.12.04Engine oil filling capacity with oil filter modified.Engine 113.967*BF18.00-P-1001-01H
Remove/install
Risk of death caused by
vehicle slipping or
toppling off the lifting
platform.Align vehicle between the columns
of the and position the four support
plates below the lifting platform
support points specified by the
vehicle manufacturer.AS00.00-Z-0010-01A
1Remove engine
compartment panelingModels 129, 202, 208, 210AR61.20-P-1105AB
Model 230.474 /475AR61.20-P-1105R
Model 215, 220AR61.20-P-1105M
Models 203, 209AR61.20-P-1105P
Model 211AR61.20-P-1105T
Models 170, 202.0AR61.20-P-1105A

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 45 © 2006 Mitchell Repair Information Company, LLC.

Models 163.172/174/175AR61.20-P-1105GH
2.1Remove under-ride guardModel 463.246 with engine
113.982AR88.30-P-0010MG
3.1Remove air baffleModel 163 with engine 113.942
4Drain and collect engine
oil Installation: Replace sealing
ring of the oil drain screw.
Oil drain plug to oil pan
M14*BA01.45-P-1003-
01B
Engine lubrication*BF18.00-P-1001-
01H
5Remove cylinder headsModel 129 with engine 112AR01.30-P-5800B
Models 129, 202, 208, 210 with
engine 113
Models 170, 202, 208, 210 with
engine 112AR01.30-P-5800BA
Model 220 with engines 112, 113
Models 215.374, 230.474/ 475
Models 203.764, 215.373/ 375
Model 463AR01.30-P-5800GV
Models 203, 209,
211.061 /065 /070 /080/
082 /083 /280 /282 /283AR01.30-P-5800PV
Model 163AR01.30-P-5800MV
6Remove oil pan bottom
sectionModels 129, 202, 208, 210, 220
without 4MATICAR01.45-P-7555VA
Model 170 with engine 112
Model 463 with engines 112.945,
113.962/982
Model 220/211 with 4MATICAR01.45-P-7555IW
Models 215.374, 230.474/ 475AR01.45-P-7555R
Models 203.764, 215.373/ 375
Models 203.061/064/ 065/ 261/
264/ 265AR01.45-P-7555PV
Model 209
Models 211.061 /065/070
Model 203 with 4MATICAR01.45-P-7555PW
Models 203.076/ 276AR01.45-P-7555AC
Models 163.154/157/172AR01.45-P-7555V
Models 163.174/175AR01.45-P-7555VE
7Remove timing case
coverModel 170,
210.061 /063 /065 /261 /263/
265 /663 with engine 112AR01.40-P-8000B
Models 129, 163, 202, 208, 210,
230 with engine 113

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 46 © 2006 Mitchell Repair Information Company, LLC.

Oil pan
Oil pan
Model 220 except 220.074 /174
with engine 113
Do not remove top part of oil
pan!
Model 463AR01.40-P-8000GV
Do not remove top part of oil
pan!
Model 210 with 4MATICAR01.40-P-8000GV
Models
203.061 /064 /065 /081 /084 /261/
264 /265 /281 /284 /076 /276AR01.40-P-8000V
Models 209.361/365/ 375/ 376/
461/ 465/ 475/ 476AR01.40-P-8000PV
Models 211.061 / 065/ 070/ 080/
082/ 083/ 280/ 282/ 283
Models 220.074/174AR01.40-P-8000RVK
Model 215.374
Model 203.764
Models 210.062/262
Models 215.373/375
8Remove slide rails (1) At the same time detach slide
rails (1) toward front from the
retaining bolts.
9Install in the reverse
order
NumberDesignationEngines
112.910/911/
912/913/914/
915/917/920/
921/922/923/
940/941/942/
943/944/945/
946/947/949/
951/954/955/
960/961/970/
972/973/976Engines
113.940/941/
942/943/944/
945/946/960/
961/962/963/
965/967/968/
969/980/981/
982/984/986/
992/995
BA01.45-P-1003-
01BOil drain screw
to oil panM14Nm3030
NumberDesignationEngine
112.916/953/975, Engine 113.987/
988/991

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 47 © 2006 Mitchell Repair Information Company, LLC.

Engine lubrication
Engine lubrication
Engine lubrication
113.948/966
BA01.45-P-1003-
01BOil drain screw
to oil panM14Nm3030
NumberDesignationEngine 112
except
112.916/953/975Engine
112.916/953Engine
113.948/966
BF18.00-P-
1001-01HEngine oilFilling capacity
with oil filterLiters8.07.58.0
Filling capacity
without oil filterLiters7.57.07.5
Specifications
for Operating
FluidsSheetBB00.40-P-0229-
01A
BB00.40-P-
0229-01A
BB00.40-P-
0229-01A
SheetBB00.40-P-0229-
03A
BB00.40-P-
0229-03A
BB00.40-P-
0229-03A
SheetBB00.40-P-0229-
05A
BB00.40-P-
0229-05A
BB00.40-P-
0229-05A
NumberDesignationEngine
113.944/944/980981/984/984/986/991Engine
113.963/963/965Engines
113.987/988/990
/
BF18.00-
P-1001-
01HEngine
oilFilling
capacity with
oil filterLiters7.57.58.5
Filling
capacity
without oil
filterLiters-7.08.0
Specifications
for Operating
FluidsSheet-BB00.40-P-
0229-01A
-
Sheet-BB00.40-P-
0229-03A
-
SheetBB00.40-P-0229-05A BB00.40-P-
0229-05A
BB00.40-P-0229-
NumberDesignationEngines
113.940/941/
942/943/960/
961/962/969/
982Engine
112.975Engine
113.967
BF18.00-P-
1001-01H Engine oilFilling capacity
with oil filterLiters8.08.07.5

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 48 © 2006 Mitchell Repair Information Company, LLC.

REMOVE/INSTALL ROCKER ARMS - AR05.20-P-2340AU
ENGINE 112
ENGINE 113 except CODE (479) Cylinder shutoff
ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250
ENGINE 113.962 in MODELS 463.206 / 240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODELS 463.243 /246
Shown on engine 112
Fig. 52: Identifying Rocker Arm Components
- Shown On Engine 112
Filling capacity
without oil filterLiters-7.5-
Specifications
for Operating
FluidsSheetBB00.40-P-
0229-01A
BB00.40-P-
0229-01A
BB00.40-P-
0229-01A
SheetBB00.40-P-
0229-03A
BB00.40-P-
0229-03A
BB00.40-P-
0229-03A
SheetBB00.40-P-
0229-05A
BB00.40-P-
0229-05A
BB00.40-P-
0229-05A

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 49 © 2006 Mitchell Repair Information Company, LLC.

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.