MERCEDES-BENZ ML350 1997 Complete Repair Manual

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 in MODEL 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230
Fig. 117: Identifying Valve Guides

Remove/install
1Remove valves
Engine 113 except
113.995AR05.30-P-3511AV
Engine 113.995AR05.30-P-3511RVK
2Inspect valve guides (1, 2) AR05.30-P-3731-06AV
Installation depth of valve
guide*BE05.30-P-1005-02D
3Knock out valve guides (1,
2) The valve guides on
the exhaust and intake
sides are identical.AR05.30-P-3731-01AV
Overall length of valve *BE05.30-P-1004-02D

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 100 © 2006 Mitchell Repair Information Company, LLC.

Test and adjustment values for valve guides
guide
4Measure valve guide
external diameter Using an outside
micrometer, measure and
determine which valve
guide was installed. Fit
the next largest valve
guide according to the
valve guide installed.
*BE05.30-P-1001-02D
*WH58.30-Z-1002-12A
Valve guides of
standard stage and
standard stage I are not
supplied as replacement
parts; for this reason: ?
Ream basic bore to repair
stage I.AR05.30-P-3731-04AV
*BE05.30-P-1002-02D
*BE05.30-P-1003-02D
5Insert valve guides (1, 2),
inspect AR05.30-P-3731-03AV
6Install in the reverse order
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-
1001-02D Outside
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

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:39 PMPage 101 © 2006 Mitchell Repair Information Company, LLC.

Commercially available tools
INSPECTION AND MACHINING DIMENSIONS OF VALVE SEAT RINGS - AR05.30-P-3831-03AV
Modification notes
Test values for valve seat rings
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)
NumberDesignation
WH58.30-Z-1002-12AMicrometer
23.6.04BE05.30-P-1009-03C taken away
NumberDesignationEngine
112.910/
911Engine
112.912/
914/915/920/
921/922/923/
940/941/942/
943/944/945/
946/947/948/
951/960/961,
113.940/941/94
2/943/944
BE05.30-P- Intake valve seat ring outer- Standardmm31.1 (+0.015)37.1 (+0.015)

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:39 PMPage 102 © 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.

Shown on exhaust valve seat ring
Fig. 118: Identifying Dimension
- Shown On Exhaust Valve Seat Ring
Shown on exhaust side
BE05.30-P-
1005-03CDistance between contact
face of cylinder head and
end face of valve seat ringIntakemm8.50...8.588.16...8.36
Exhaustmm9.57...9.657.99...8.19
BE05.30-P-
1006-03CBasic bore diameter of inlet
valve seat rings in cylinder
headStandardmm39.000...39.01634.000...34.016
Rep. size 1mm40.200...40.21635.200...35.216
BE05.30-P-
1007-03CBasic bore diameter of
exhaust valve seat rings in
cylinder headStandardmm44.000...44.01637.000...37.016
Rep. size 1mm45.200...45.21638.200...38.216
BE05.30-P-
1008-03CBore depth of
valve seat
rings in
cylinder headIntakeStandardmm14,4013,99
ExhaustStandardmm17,4714,16

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:39 PMPage 104 © 2006 Mitchell Repair Information Company, LLC.

Fig. 119: Identifying Basic Bore Diameter Of Valve Seat Ring In Cylinder Head - Shown On Exhaust
Side

The overlap of the valve seat ring in the cylinder head is determined as follows: outside diameter of the valve
seat ring (B) minus the basic bore diameter of th e valve seat ring in the cylinder head (E).
Fig. 120: Identifying Outside Diameter Of Valve Seat Ring And Basic Bore Diameter Of Valve Seat Ring
In Cylinder Head
REPLACE VALVE SEAT RINGS - AR05.30-P-3831AV
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

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:39 PMPage 105 © 2006 Mitchell Repair Information Company, LLC.

ENGINE 113 in MODELS 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230
Fig. 121: Identifying Basic Bore Of Valve Seat Ring (Intake) And Basic Bore Of Valve Seat Ring
(Exhaust)
Modification notes
25.2.04Value changed from
0.084...0.110 mm to
0.074...0.1 mmFigure in BE05.30-P-1004-03C for
engine 112.910/911 modified*BE05.30-P-1004-
03C
25.2.04Value changed from
0.084...0.110 mm to
0.074...0.1 mmFigure revised in BE05.30-P-1004-03C
in case of engine
112.912/914/915/920/921/922/923/940/
941/942/943/944/945/946/947/948/960/
961, 113.940/941/942/943/944*BE05.30-P-1004-
03C
25.2.04Value changed from
0.084...0.110 mm to
0.074...0.1 mmFigure revised in BE05.30-P-1004-03C
in case of engine
113.960/961/962/963/965/967/968/
980/981/982/984/987/988/990/991 /992*BE05.30-P-1004-
03C
Remove/install
1Remove valves AR05.30-P-3511AV
2Inspect valve guide inner
diameter for wear If the measurements
obtained for the valve
guide are not within the
specified tolerance ?AR05.30-P-3731-06AV

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:39 PMPage 106 © 2006 Mitchell Repair Information Company, LLC.

Test values for valve seat rings
Replace valve guide.AR05.30-P-3731AV
3Turn valve seat ring out of
the cylinder head with
ring seat turning tool Pay attention to
operating instructions of
ring seat turning tool.
*WE58.40-Z-1009-21A
*WE58.40-Z-1010-21A
4Measure diameter of valve
seat ring basic bore (D1,
D2) in the cylinder head Overlap between valve
seat ring and basic bore
must be assured.*BE05.30-P-1006-03C
*BE05.30-P-1007-03C
*BE05.30
-P-1004-03C
If the measurements
obtained deviate from the
test
values: ? machine basic
bores to the next oversize
of the valve seat rings
Pay attention to inspection
and machining
dimensions of the valve
seat rings and of the basic
bore ?
Inspection and machining
dimensions of valve seat
ringsAR05.30-P-3831-03AV
Risk of injury to skin and
eyes caused by handling
hot or glowing objects.Wear safety gloves,
protective clothing and
safety glasses, if
necessary.AS00.00-Z-0002-01A
5Heat cylinder head in
recirculated heating
cabinet or heating oven Temperature approx.
80 °C
*WH58.30-Z-1001-28A
*WH58.30-Z-1003-28A
8Drive in valve seat ring
using a suitable drift
9Machine valve seat rings After installing a new
valve seat ring, the valve
must always be replaced.AR05.30-P-4511AV
10Install in the reverse order
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 107 © 2006 Mitchell Repair Information Company, LLC.

Test values for valve seat rings
Commercially available tools
Workshop equipment
946/947/948/
951/960/961,
113.940/941/94
2/943/944
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-
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
NumberDesignation
Engine
113.960/
961/962/963/
964/965/967/
968/971/980/
981/982/984/
987/988/990/
991/992/993/
995
BE05.30-P-1004-
03CValve seat ring - overlap in cylinder headIntakemm0.084...0.115
Exhaustmm0.074...0.100
BE05.30-P-1006-
03CBasic bore diameter of inlet valve seat rings in
cylinder headStandardmm39.000...39.016
Rep. size
1mm40.200...40.216
BE05.30-P-1007-
03CBasic bore diameter of exhaust valve seat rings in
cylinder headStandardmm44.000...44.016
Rep. size
1mm45.200...45.216
NumberDesignation
WH58.30-Z-1001-28ARecirculated air warming cabinet
WH58.30-Z-1003-28AHeating oven
WE58.40-Z-1009-21AValve seat turning device
WE58.40-Z-1010-21AValve seat turning device

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:39 PMPage 108 © 2006 Mitchell Repair Information Company, LLC.

MEASURE VALVE SETBACK TO CYLI NDER HEAD - AR05.30-P-4100-01AV
Modification notes
Test and adjustment values of cylinder head
Test and adjustment values of cylinder head
Workshop equipment
Shown on engine 606
1. Measure valve setback (a) with depth caliper
gage.
25.3.04Value changed from 8.50...8.90
mm to 8.05...8.45 mmValue in series 1001, exhaust valve, for engine
113.962/982/987/990/991/993 changed
25.3.04Value changed from 7.90...8.30
mm to 7.20...7.60 mmValue in series 1001, intake valve, for engine
113.962/982/987/990/991/993 changed
NumberDesignationEngines 112,
113.940/941/
942/943/944/
945/946/948
except 112.976Engine 112.976
BE01.30-P-
1001-02DValve setback of
new valves and
new valve seat
ringsExhaust valvemm8.05...8.458.50...8.90
Intake valvemm7.60...8.007.90...8.30
NumberDesignationEngine
113.960/961/
963/965/966/
967/968/980/
981/984/986/
992/995Engine 113.987/
988/989/
990/991/
993
BE01.30-P-
1001-02DValve setback of
new valves and
new valve seat
ringsExhaust valvemm8.5...8.98.05...8.45
Intake valvemm7.90...8.307.20...7.60
WE58.40-Z-1002-19ADepth gage

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:39 PMPage 109 © 2006 Mitchell Repair Information Company, LLC.