MERCEDES-BENZ ML350 1997 Complete Repair Manual

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.

REAM BASIC BORE TO REPAIR STAGE I - AR05.30-P-3731-04AV
Test and adjustment values for valve guides
NumberDesignationEngine 112 except
112.951/976,
Engines 113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/987/988/
990/991/992/
993/995Engine 112.951/976
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

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 95 © 2006 Mitchell Repair Information Company, LLC.

Fig. 108: Identifying Supports(1 Pair) (606 589 00 31 00)
Fig. 109: Identifying Reaming Tool (119 589 01 53 00)

Fig. 110: Identifying Guide Sleeve (113 589 02 63 00)

Fig. 111: Identifying Cylinder Brush (000 589 10 68 00)
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 96 © 2006 Mitchell Repair Information Company, LLC.

1. Place cylinder head onto the supports (1). Align th e supports so that the reaming tool is not able to
strike the supports when it is pressed through.
Fig. 112: Identifying Cylinder Head Supports

2. Insert reaming tool (2) into the basic bore.
3. Press reaming tool (2) through. Lubricate with petroleum during this step. Clean reaming tool (2)
with compressed air or a plastic brush after each reaming operation. Use a matching aluminum drift as
an extension in the area of th e guide sleeve (3) for pressing th rough the reaming tool (2).
Fig. 113: Identifying Reaming Tool

INSPECT VALVE GUID ES - AR05.30-P-3731-06AV

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 97 © 2006 Mitchell Repair Information Company, LLC.

Test and adjustment values for valve guides
NumberDesignationEngine 112 except
112.951/976,
Engines 113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/987/988/
990/991/992/
993/995Engines 112.951/976
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 98 © 2006 Mitchell Repair Information Company, LLC.

Fig. 114: Identifying Feeler (102 589 01 23 00)
1. Clean bore of valve guide (1) (never use a hard object).
2. Inspect surface of bore for scores or signs of rubbi ng. If damage to the surface is present, the valve
guide must be replaced and the valve stem inspected for uneven areas. If the stem is damaged, the valve
must be replaced together with the valve guide.
Fig. 115: Identifying Valve Guide

3. If it is possible to inse rt the side of the hole gauge (3) marked with "+220" over its full length (5 mm)
into the valve guide, it is then necessary to repl ace the valve guide. Inspect bore of valve guide in
longitudinal and tran sverse direction.
Fig. 116: Inserting Side Of Hole Gauge

CHECK, REMOVE, INSTALL VA LVE GUIDES - AR05.30-P-3731AV

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 99 © 2006 Mitchell Repair Information Company, LLC.