engine MERCEDES-BENZ ML320 1997 Complete Repair Manual

Fig. 91: Identifying Valve Components
Remove/install
Risk of death caused
by vehicle slipping or
toppling off the lifting
platform.Align vehicle between columns of
vehicle lift and position four support
plates at vehicle lift support points
specified by vehicle manufacturer.AS00.00-Z-0010-01A
1Remove cylinder head
(1)Model 163.154/157/172/174/175AR01.30-P-5800MV
Model 129 with engine 112, 113
Model 202, 208, 210 with engine
113AR01.30-P-5800B
Model 170, 202, 208, 210, 220 with
engine 112
Model 211.076/276, 215.374, 220,
230.474/475 with engine 113AR01.30-P-5800BA
Model 203 except 203.764, 209, 211AR01.30-P-5800PV
Model 463.2 with engine 112, 113
Model 203.764 AR01.30-P-5800GV

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 85 © 2006 Mitchell Repair Information Company, LLC.

Model 215.373/375
2Mount cylinder head
(1) onto the assembly
board (2) with the
associated insertion
plate (3) Insert insertion plate (3) with
arrow indicating the direction of
travel (insertion pl ate) (4) pointing
to the front and, according to the
cylinder head, for the right or left
side into the assembly board (2).
i004 Mount cylinder head (1)with its
front end pointing to the arrow
indicating the dir ection of travel
(assembly board) (5) with one bolt
(6) each at the front and rear onto
the assembly board (2). The cylinder
head (1) can be mounted on the
assembly board (2) without
removing the exhaust manifold.
Assembly boardFig. 92
3Attach assembly tool
(valves) (7) to
cylinder head (1) and
position vertically at
the valve disk (top)
(8) Use parts 2, 3, 4, 5, 7, 14, 19
from the valve assembly tool case
(valves) (7).
Valve assembly tools caseFig. 89
4Remove valve disk
(upper) (8) and valve
disk (lower) (11) Press valve spring (9) together
with assembly tool (valves) (7),
remove split valve spring retainer
locks (10)
Check valve disk (top) (8) and
valve disk (bottom) (11) for
formation of burrs, replace if
necessary.
The valve springs (9) of the inlet
valves and exhaust valves are
identical.
Magnetic pinFig. 95
Magnetic fingerFig. 90
5Use pliers (15) to
remove valve stem
seals (12) Installation: Fit protective sleeve
for valve stem seal (13) onto valve
stem. Oil valve stem seal (12) and
press on with drift (16). The
protective sleeve for the valve stem
seal (13) must be removed from the
valve stem after pressing on the
valve stem seal (12).
PliersFig. 77

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 86 © 2006 Mitchell Repair Information Company, LLC.

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.

Fig. 92: Identifying Assembly Board (112 589 11 59 00)
Fig. 93: Identifying Case For Valv e Installation Tools (111 589 25 61 00)

Fig. 94: Identifying Magnetic Finger (116 589 06 63 00)

Fig. 95: Identifying Magnetic Pin (210 589 00 40 00)

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 89 © 2006 Mitchell Repair Information Company, LLC.

Fig. 96: Identifying Pl iers (606 589 00 37 00)
Fig. 97: Identifying Drift (119 589 00 43 00)

KNOCKING OUT VALVE GUIDE - AR05.30-P-3731-01AV
Fig. 98: Identifying Supports (1 Pair) (606 589 00 31 00)
Fig. 99: Identifying Drift (11 589 02 15 00)

1. Place the cylinder head on both the supports (1). Align the supports (1) so that the valve guide

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 90 © 2006 Mitchell Repair Information Company, LLC.

to be knocked out cannot hit the supports (1).
Fig. 100: Identifying Cylinder Head Support

2. Knock out the valve guide (2) from the side of the combustion chamber using a drift (3)
Fig. 101: Identifying Knock Out Valve Guid e From Side Of Combustion Chamber

INSERT VALVE GUIDE, INSPECT - AR05.30-P-3731-03AV
Test and adjustment values for valve guides
NumberDesignationEngine 112 except
112.951/976,
Engines 113.940/941/
942/943/944/ Engines 112.951/976

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 91 © 2006 Mitchell Repair Information Company, LLC.

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
BE05.30-P-
1001-02DOutside
diameter of
exhaust and
intake valve
guideStandard
seriesmm12.540...12.55112.540...12.551
Standard I
series
(color:
blue)mm12.560...12.57112.560...12.571
Repair
stage I
(color: red)mm12.740...12.75112.740...12.751
Repair
stage II
(color:
yellow)mm13.140...13.15113.140...13.151
BE05.30-P-
1002-02DBore
diameter in
cylinder
head of
exhaust and
intake valve
guideStandard
seriesmm12.500...12.51112.500...12.511
Standard I
series
(color:
blue)mm12.520...12.53112.520...12.531
Repair
stage I
(color: red)mm12.700...12.71112.700...12.711
Repair
stage II
(color:
yellow)mm13.100...13.11113.100...13.113.100...13.11113.100...13.1
BE05.30-P-
1003-02DOverlap in cylinder headmm0.029...0.0510.029...0.051
BE05.30-P-
1004-02DLengthLmm5050
BE05.30-P-
1005-02DDimensionAmm14.3 (±0.2)14.3 (±0.2)

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 92 © 2006 Mitchell Repair Information Company, LLC.

Fig. 102: Identifying Supports (1 Pair) (606 589 00 31 00)
Fig. 103: Identifying Drift (113 589 00 15 00)

Fig. 104: Identifying Feeler Gauge (102 589 01 23 00)

1. Place cylinder head onto the supports (1).
Fig. 105: Identifying Cylinder Head Supports

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 93 © 2006 Mitchell Repair Information Company, LLC.

2. Coat the outside of valve guide (5) with oil.
3. Position the valve guide (5) and knock into the cylinder head as far as the stop (arrow) of the insertion
drift (3). Check the secure seati ng of the valve guide (5). The instal lation depth of the valve guide (5)
is set by the drift punch (3).
Fig. 106: Identifying Valve Guide

4. Check the valve guide (5) with the feeler gauge (4). The side of the feeler gauge (4) marked
with '0' must be inserted completely into the valve gui de (5). The valve guide (5) must be replaced if the
feeler gauge (4) cannot be insert ed completely. The valve guide (5) is made of powdered metal, so
reaming is not possible.
Fig. 107: Identifying Valve Guide And Feeler Gauge

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 94 © 2006 Mitchell Repair Information Company, LLC.