MERCEDES-BENZ ML350 1997 Complete Repair Manual

Fig. 122: Identifying Valve Setback - Shown On Engine 606
CHECK VALVES - AR05.30-P-4201-01AV
Modification notes
Test values for valves
Test values for valves
19.11.04Value changed from 45 (±15') mm to
45 (+15') mmFigure for series 1003 for engine
112 complete*BE05.30-P-1003-
01E
NumberDesignationEngine
112.910/911Engine
112.912/913/
914/915/920/
921/922/923/
940/941/942/
943/944/945/
946/947/948/
949/960Engine
112.951
BE05.30-P-
1001-01EValve disk
dia.Exhaustmm34±0,141±0,141 ±0,1
Intakemm30±0,136±0,136±0,1
BE05.30-P-
1002-01EValve disk
heightExhaust when
newmm1.61.61.6
Intake valve
when newmm1.21.21.2
BE05.30-P-
1003-01EValve seat
angle (a)ExhaustAngle°45 (+15')45 (+15')45 (+15')
IntakeAngle°45 (+15')45 (+15')45 (+15')
BE05.30-P-
1004-01EValve stem
dia.Exhaustmm6,9706,9706.970 (-0.02)
Intakemm6,9756,9756.975 (-0.015)
BE05.30-P-
1005-01EValve lengthExhaustmm121,65±0,2122,25±0,2122,25 (±0,2)
Intakemm120,70±0,2119,40±0,2119,40 (±0,2)
NumberDesignationEngines
113.940/941/
942/943/944Engine
113.960/
961/962/963/ Engine
137.970

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:39 PMPage 110 © 2006 Mitchell Repair Information Company, LLC.

Fig. 123: Identifying Valve Dimensions
CHECKING AND MACHINING DIMENSIONS FOR VALVE SEATS - AR05.30-P-4510-01AV
Test values for valve seat rings
965/967/968/
980/981/982/
984/987/988/
990/991/992/
993/995
BE05.30-P-
1001-01EValve disk
dia.Exhaustmm41±0,143±0,136±0,1
Intakemm36±0,138±0,133±0,1
BE05.30-P-
1002-01EValve disk
heightExhaust when
newmm1.61.61.6
Intake valve
when newmm1.21.21.1
BE05.30-P-
1003-01EValve seat
angle(aExhaust)Angle°45±15'45±15'45±15'
IntakeAngle°45±15'45±15'45±15'
BE05.30-P-
1004-01EValve stem
dia.Exhaustmm6,9706,9706,970
Intakemm6,9756,9755,975
BE05.30-P-
1005-01EValve lengthExhaustmm122,25±0,2121,80±0,2104,30 ±0,2
Intakemm119,40±0,2119,10±0,2103,60 ±0,2
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
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Saturday, October 02, 2010 3:39:39 PMPage 111 © 2006 Mitchell Repair Information Company, LLC.

Test values for valve seat rings
Shown at exhaust valve seat ring
946/947/948/
951/960/961,
113.940/941/94
2/943/944
BE05.30-P-
1009-03CInlet
valve/exhaust
valve valve seatWidthmm0.8...1.20.8...1.2
Angle (a)Angle°45(+ 30')45(+ 30')
Correction
Angle (ß)Angle°35 (±15')35 (±15')
Correction
Angle (gamma)Angle°58 (±15')58 (±15')
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-
1009-03CInlet
valve/exhaust
valve valve seatWidthmm0.60...0.650.75...0.95
Angle (a)Angle°45 (30')45 (30')
Correction
Angle (ß)Angle°35 (±15')35 (±15')
Correction
Angle (gamma)Angle°58 (±15')58 (±15')

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
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Saturday, October 02, 2010 3:39:39 PMPage 112 © 2006 Mitchell Repair Information Company, LLC.

Fig. 124: Identifying Valve Seat Dimensions -Shown At Exhaust Valve Seat Ring
INSPECTING, REMOVING , INSTALLING VALVE GUIDES - AR05.30-P-4511AV
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. 125: Removing/Installing Valve Guides

Remove
1Remove valves AR05.30-P-
3511AV
Inspection
2Inspect valve guide,
Inspect valve guide if the m easurements obtained are not
within the stated tolerances ?AR05.30-P-
3731-06AV
Replace valve guide.AR05.30-P-
3731AV
Machining

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:39 PMPage 113 © 2006 Mitchell Repair Information Company, LLC.

Commercially available tools
Workshop equipment
3Machin valve seat
ring in cylinder head
*WE58.40-Z-
1009-21A
*WE58.40-Z-
1010-21A
Observe tool manufacturer's operating instructions, maintain
dimensions in accordance with checking and machining
dimensions. ?

Checking and machining dime nsions for valve seatsAR05.30-P-
4510-01AV
If the measurements after machining are less than the
specification ?
Replace valve seat ring.AR05.30-P-
3831AV
Inspection
4Measure seat width Correct valve seat width if necessary.AR05.30-P-
4510-01AV
5Insert valve and
inspect for leaks Grind valve with valve grinding compound before
installation.
*WH58.30-Z-
1020-13A
6Measure valve set-
back to cylinder head
If measurement is less than minimum dimension no further
correct valve clearance compensation is possible; replace valve
seat ring or cylinder head ?AR05.30-P-
4100-01AV
Replace valve seat ring. ?
The valve must always be rep laced after installing a new
valve seat ring. AR05.30-P-
3831AV
Install
7Install valves AR05.30-P-
3511AV
NumberDesignation
WH58.30-Z-1020-13AVacuum testing unit
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 114 © 2006 Mitchell Repair Information Company, LLC.

1998-2005 ENGINE
Complete engine - 163 Chassis
GENERAL INFORMATION
DETERMINE LOSS OF PR ESSURE AT CYLINDER - AH01.00-N-1300-02A
All engine
If an increased pressure loss was found with the cylinde r leak tightness tester, inspect engine by listening at
cylinder head gasket, air intake area, exhaust, oil fi ller opening and prechamber or spark plug bores of the
adjacent cylinder or cylinders.
Check the coolant in the coolant expansion reservoir for the formation of air bubbles.
Possible causes for the pressure loss are: 1. Outlet of air through prechamber or spark plug bo re of adjacent cylinder or cylinders, air bubbles
in coolant expansion reservoir:
pressure loss at cylinder head gasket
2. Outlet of air through air intake area:
For inspecting by listening, open throttle valve pressure loss at inlet valve(s)
3. Outlet of air through exhaust:
pressure loss at exhaust valve(s)
4. Outlet of air through oil filler opening:
pressure loss through pistons and piston rings
It is possible to pinpoint the pressure loss of the rele vant cylinder by spraying with engine oil. Engine oil
seals off the gap between piston and cylinder briefly.
If a reduced pressure loss now occurs for a short time, th e cause is very likely to be at the pistons, piston rings
or cylinder contact surface of the relevant cylinder.
Determining the cause can be falsified by the position of th e piston ring joints. If suspicion exists that the loss o
f
pressure is caused by the piston ring joints being positioned directly one above the other, fit parts to engine and
repeat test after running engine for a short time.
GENERAL INFORMATION ON INSPECTING CYLINDER WALLS - AH01.00-P-0300-01A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:55 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.
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Saturday, October 02, 2010 3:18:01 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.

Engine 112, 113, 122, 134, 135, 137, 166, 275, 285, 611, 612, 613, 628, 629, 639, 642, 646, 647, 648
Pressure gloss marks, smoothings
Individual blank points, e.g. in the middle of th e cylinder barrel or around the cylinder head bolts.
The crankcase can be reused.
Fig. 1: Identifying Pressure Gloss Marks On Cylinder Walls

Visible mottling, friction marks
Starting from reverse area of th e upper piston ring tapering down.
Traces of dry rubbing which cannot be felt, caused by oi l film being washed off by fuel, for example from many
cold starts when driving for short distances.
These traces of friction occurring mainly around the cy linder head bolts and on the pressure side are not a
problem provided that they are smoothed out.
The piston rings are not damaged.
The crankcase can be reused.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:55 PMPage 2 © 2006 Mitchell Repair Information Company, LLC.

This manual is sold and compiled by
[email protected]. Duplication and resell is not
permitted.

Fig. 2: Identifying Visible Mottling And Friction Marks On Cylinder Walls
Ring shaped imprints
Visible imprints on cylinder barrel in the upper and lo wer reverse area of piston rings are not a cause for
complaint.
The crankcase can be reused.
Fig. 3: Identifying Visible Imprints On Cylinder Barrel

Rotary bright, specular, polish ed upper surfaces of cylinder
Starting from the reverse area of the upper pist on ring with measurable, partial cylinder wear.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:55 PMPage 3 © 2006 Mitchell Repair Information Company, LLC.

The cylinder barrel is unusable.
Fig. 4: Identifying Cylinder Wear

Roughened mottling, friction scoring
Starting from first and second piston ring, tapering to an end only in bottom part of cylinder. Progressive signs
of friction lead to friction score marks.
Where these signs of friction are percep tible, the cylinder barrel is unusable.
The piston rings may be damaged.
Fig. 5: Identifying Friction Score Marks


2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:55 PMPage 4 © 2006 Mitchell Repair Information Company, LLC.