engine MERCEDES-BENZ ML320 1997 Complete Repair Manual

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.

camshaftthe camshaft without th e valves coming into contact with the pistons.
8Rotate
right
camshaft
in basic
position
and insert
locating
plate for
right
camshaft
(2) in the
camshaft 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. 11
Place locating plate for right camshaft (2) flush onto the right cylinder head
and insert into the groove of the camshaft (6).
At a 40° crank angle afte r ignition TDC of cylinder 1 it is possible to rotate
the camshaft without th e valves coming into contact with the pistons.
9Install
left-hand
camshaft
sprocket Place timing chain onto camshaft sprocket.
Insertion toolFig. 66
Bolt of camshaft sprock et engine 112, 113 except 113.969
*BA05.20-
P-1001-
01B
10Install
right-hand
camshaft
sprocket Place timing chain onto camshaft sprocket.
Insertion toolFig. 66
Bolt of camshaft sprock et engine 112, 113 except 113.969
*BA05.20-
P-1001-
01B
11Install
camshaft
Hall
sensorEngine 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,AR15.10-
P-
2000RVK
Engine 113.991 in models 215.374, 220.074 /174
*BA15.10-
P-1002-
03A
12Installing
chain Engine 112 in models 211.080/082/261/265 /280/282,
Engine 113 in model 211.083/270/283

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 60 © 2006 Mitchell Repair Information Company, LLC.

Camshaft
Camshaft
tensionerEngine 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,
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
Check
13Inspect
timing AR05.10-
P-6858V
Check
general
notes on
valve
timing,
scribe
marksEngine 112, 113AH05.10-
P-1000-
01A
The engine must not be turned back; otherwise the timing chain can get
jammed.

14Install
cylinder
head
coversAir filter located at vehicle side.AR01.20-
P-5014B
Air filter located on engine side.AR01.20-
P-5014BV
NumberDesignationEngines
113.940/941/
942/943/944/
948/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/992/995Engine
112
except
112.951/976
BA05.20-P-
1001-01BBolt, camshaft
sprocketM12x45Stage 1Nm5050
Stage 2Angle°9090

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 61 © 2006 Mitchell Repair Information Company, LLC.

Camshaft
Position sensor
Fig. 63: Identifying Locating Plate (112 589 00 32 00)
NumberDesignationEngine
112.951/976Engine
113.960 with
code 479
BA05.20-P-
1001-01BBolt,
camshaft
sprocketM1x245Stage 1Nm5050
Stage 2Angle°9090
NumberDesignationEngine
113.987/988/
990/993Engine
113.987/988/1
BA05.20-P-
1001-01BBolt,
camshaft
sprocketM12x45Stage 1Nm5050
Stage 2Angle°9090
NumberDesignationEngines
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/
973/975/976Engines
113.940/941/
942/943/944/
948/960/961/
962/963/964/
965/966/967/
968/969/971/
980/981/982/
984/986/992/
993/995Engines
113.987/988/990/991
BA15.10-P-
1002-03ACamshaft Hall
sensor to
cylinder headNm888

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 62 © 2006 Mitchell Repair Information Company, LLC.

Fig. 64: Identifying Locating Plate (112 589 01 32 00)
Fig. 65: Identifying Open End Wrench (112 589 00 01 00)

Fig. 66: Identifying Insertion Tool (112 589 01 03 00)

Fig. 67: Identifying Torque Wrench (001 589 72 21 00)

REMOVE/INSTALL CAMS HAFTS - AR05.20-P-6992AU
ENGINE 112
ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 63 © 2006 Mitchell Repair Information Company, LLC.

ENGINE 113.962 in MODELS 463.206 / 240 /241 /247 /248 /249 /254
ENGINE 113.982 in MODEL 463.243/246
ENGINE 113 in MODELS 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230
Fig. 68: Identifying Camshaft Components
- Shown On Engine 112
Shown on engine 112
Modification notes
18.6.97M112: Procedure modified, new special tool.Step 1-14Fig. 66
Removing
1Remove cylinder head
coversAir filter mount ed on vehicleAR01.20-P-5014B
Air filter mounted on engineAR01.20-P-5014BV
2Position piston of
cylinder 1 at 40° after
TDC Rotate engine at
crankshaft in direction of
rotation until 40° marking on
belt pulley/ vibration damper
is aligned with marking on
timing case cover. The
AR05.10-P-6858V

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 64 © 2006 Mitchell Repair Information Company, LLC.