MERCEDES-BENZ ML430 1997 Complete Repair Manual

AR03.10-P-7311-02V
Measure gap clearance of piston rings

Test values for piston rings
Number

Designation
Engine 112.910/

911/912
Engine 112.920/

921/922/923/940/
941/942/943/944/
945/946/947/948/

960,

113.940/941/942/

943
Engine 113.944/

980/981/982/984

BE03.10-P-1002-05B
Piston ring gap clearance
Groove 1
mm
0,200...0,3500,200...0,3500,200...0,350

Groove 2
mm
0,200...0,4000,200...0,4000,200...0,400

Test values for piston rings

Number

Designation
Engine 113.960/

961/ 962/ 963/

965/ 968/
Engine

113.967

BE03.10-P-1002-05B
Piston ring gap clearance
Groove 1
mm
0,200...0,3500,200...0,350

groove 2
mm
0,200...0,4000,200...0,400

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e.g.)
Order number

WH58.30-Z-1008-12A
Feeler gage
Stiefelmayer

D-73734 Esslingen
59

P03.10-2035-01

1
Clean cylinder contact surface.

2
Insert the two compression rings one after the other into the unworn area of the cylinder

wall and measure end clearance with

feeler gauge; replace piston rings, if necessary.

The gap clearance of the oil scraper ring cannot be checked because of its three-part

design. If the compression rings are replaced, the oil scraper ring must also be replaced.

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1

AR03.10-P-7311BV
Remove/install piston rings
2.7.97

ENGINE
113 in MODEL 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230

ENGINE
112 /945, 113.962 /982

P03.10-2022-06

1
Compression ring (plain compression

ring)

2
Compression ring ( taper-faced hook

scraper ring)

3
Oil scraper ring

4
Piston

5
Piston crown

Fig. item, etc.

Work instructions

4
Remove/install pistons

AR03.10-P-7021AV

1, 2, 3
Piston rings
transmission


Pliers

*000589513700


Removal:

Oil scraper ring
with the pliers.

The oil scraper ring (3)
must be removed and

installed by hand.


Installation:
Compression rings
-
Measure width of compression rings (1, 2).

*BE03.10-P-1003-05B

-
Pay attention to installation position of

compression rings (1, 2). The inscription


"Top" or the manufacturer's designation
must
point toward the piston crown (5).

1, 2
Measure the side clearance of the

compression rings

AR03.10-P-7311-01V

1, 2
Measure end gap of the compression rings

AR03.10-P-7311-02V

Test values for piston rings

Number

Designation
Engine 112.910/

911/912
Engine 112.913
Engine 112.920/

921/922/923/940/
941/942/943/944/
945/946/947/948/

960,

113.940/941/942/

943

BE03.10-P-1003-05B
Dimension
Plain compression ring
mm
83.2 X 1.5 X 3.189.9 X 1.5 X 3.189.9 X 1.5 X 3.1

Taper-faced hook

scraper ring
mm
83.2 X 3.5 X 3.5
89.9 X 1.75 X 3.5
89.9 X 3.5 X 3.5

Test values for piston rings

Number

Designation
Engine 112.949

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Page 1

BE03.10-P-1003-05B
Dimension
Plain compression ring
mm
89.9 X 1.5 X 3.1

Taper-faced hook

scraper ring
mm
89.9 X 1.75 X 3.5

Test values for piston rings

Number

Designation
Engine 113.944/

980/981/982/984
Engine 113.960/

961/ 962/ 963/

965/ 968/
Engine

113.992 AMG

BE03.10-P-1003-05B
Dimension
Plain compression ring
mm
97.0 X 1.2 X 3.597.0 X 1.5 X 3.197.0 X 1.2 X 3.5

Taper-faced hook

scraper ring
mm
97.0 X 1.5 X 4.097.0 X 3.5 X 3.5
97.0 X 1.75 X 3.5

000 589 51 37 00

Pliers

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AR03.10-P-7021AV
Removing/installing pistons
2.7.97

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

P03.10-2029-09

Shown on engine 112

1
Circlip

2
Piston pin

3
Pistons

4
Conrod
5

Conrod bearing cap

6
Conrod bolts

7
Conrod bearing shell

8
Anti-twist lock

9
Groove

10


Clamping strap


Remove

Danger!

Risk of death
caused by vehicle slipping or

toppling off of the lifting platform.
Align vehicle between the columns of the

lifting platform and position the four support

plates
at the lifting platform support points

specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

1
Remove engineModels 463.206/ 209/ 232/ 233/ 240/ 241

AR01.10-P-2400CC

Models 463.244/ 245/ 247/ 248/ 249/ 250/ 254

AR01.10-P-2401GT

Models 463.243/ 246

AR01.10-P-2401MG

Model 230.475

AR01.10-P-2400R

Model 230.474

AR01.10-P-2400RVK

Model 220 without 4MATIC

AR01.10-P-2400AB

Model 220 with 4MATIC

AR01.10-P-2400IW

Model 210 with 4MATIC

AR01.10-P-2400C

Models 129, 202, 208, 210 without 4MATIC

AR01.10-P-2400CB

Model 203 without 4MATIC, 209 with Engine

112

AR01.10-P-2400PV

Model 203 with 4MATIC

AR01.10-P-2400PW

Model 209 with Engine 113

AR01.10-P-2400Q

Models 211.061/065/070

AR01.10-P-2400TC

Model 170

AR01.10-P-2400SV

Model 163

AR01.10-P-2400CA

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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2.1
Detach automatic transmission from engine
Models 463.206/ 209/ 232/ 233/ 240/ 241

AR27.10-P-0500BD

Models 463.243/ 244/ 245/ 246/ 247/ 248/

249/ 250/ 254

AR27.10-P-0500GA

Model 230.475

AR27.10-P-0500R

Model 230.474

Model 220 without 4MATIC

AR27.10-P-0500I

Model 220 with 4MATIC

AR27.10-P-0500IW

Models 129, 170, 202, 208, 210

AR27.10-P-0500B

Model 203 without 4MATIC, 209 with Engine

112,113

AR27.10-P-0500P

Model 203 with 4MATIC

AR27.10-P-0500PW

Model 211.061/065/070

AR27.10-P-0500T

Model 163

AR27.10-P-0500GH
2.2
Detach manual transmission from engine
Models 129, 202, 210

AR26.10-P-0020A
Models 203, 209 with Engine 112
AR26.10-P-0020P

Model 211.061

AR26.10-P-0020T

Model 208 with transmission 716.662/622

AR26.10-P-0020E

Model 170,

Model 208 with transmission 716.663

AR26.10-P-0020D

3
Detach top part of oil pan
Models 463.206/ 209/ 232/ 233/ 240/ 241/

243/ 244/ 245/ 246/ 247/ 248/ 249/ 250/ 254

AR01.45-P-7500FG

Model 230.474/
AR01.45-P-7500R

Model 220 without 4MATIC

AR01.45-P-7500I

Model 220 with 4MATIC

AR01.45-P-7500IW

Model 210 with 4MATIC

AR01.45-P-7500FA

Model 210 without 4MATIC

AR01.45-P-7500F

Models 202, 208

AR01.45-P-7500FC

Model 203 without 4MATIC, 209 with Engine

112,113

AR01.45-P-7500PV

Model 203 with 4MATIC

AR01.45-P-7500PW

Models 211.061/065/070

AR01.45-P-7500TV

Model 170

AR01.45-P-7500SV

Model 163

AR01.45-P-7500FB

Model 129

AR01.45-P-7500FD

4
Take off cylinder head

Remove intake manifold with complete

wiring loom during this step.

Models 463.206/ 209/ 232/ 233/ 240/ 241/

243/ 244/ 245/ 246/ 247/ 248/ 249/ 250/ 254

AR01.30-P-5800GV

Engine 112 in model 129 and engine 113 in

models 129, 202, 208, 210

AR01.30-P-5800B

Engine 112 in models 170, 202, 208, 210,

220 and engine 113 in models 220,

230.474 /475

AR01.30-P-5800BA

Model 163

AR01.30-P-5800MV

Models 203, 209 with engine 112, 113

Models 211.061/065/070

AR01.30-P-5800PV

5
Remove oil pump

Push back chain tensioner for this step

and take off chain.

All except models 203, 209, 211.061/065/070,

220 without 4MATIC, 230.474 /475

AR18.10-P-6020B

Model 203 without 4MATIC, 209,

211.061/065/070

AR18.10-P-6020PV

Model 203 with 4MATIC, model 220 with

4MATIC

AR18.10-P-6020PW

Model 230.474/475

AR18.10-P-6020R

6
Remove conrod bearing cap (5)

For this step, mark conrod (4) and

connecting rod bearing cap (5) on one side

relative to each other.

7
Remove conrod (4) together with pistons (3)

by lifting up and out

If pistons have been used (3), the arrows

indicating the direction of the travel and the

markings on the pistons may no longer be

visible due to carbon deposits. For this

reason, remove the carbon deposits from the

pistons. If the arrows indicating direction of
travel on the pistons are no longer

recognizable, these must be re-marked.

8
Remove circlip (1) of piston pin (2)

Do not damage piston (3). Place a clean

cloth underneath.

9
Press out piston pin (2)


Installing

10
Assign piston (3) to cylinder bore

AR03.10-P-7021-02BV

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Page 2

11
Oil piston pin (2) and conrod bush

12
Assemble piston (3) and conrod (4)

Install piston (3) with arrow in direction of

travel.

13
Push in piston pin (2) by hand

14
Insert circlip (1) of piston pin (2) in the groove

on piston (3)

Do not damage piston (3). Place a clean

cloth underneath.

15
Oil cleaned parts (cylinder bore, conrod

bearing journal, conrod bearing shells and

pistons)

16
Fit on tensioning strap (10) and tension

Piston ring gaps must be offset 120°.

Tensioning strap

*000589041400

17
Install piston (3) with arrow pointing in

direction of travel

Rotate crankshaft far enough so that the

connecting rod when inserting piston into

cylinder bore does not line up at the

connecting rod journal!

18
Inspect conrod bolts (6)

AR03.10-P-6111-01BV

Thread and shank length

*BE03.10-P-1001-03A

19
Install conrod bearings and fit on conrod

bearing cap (5)


The connecting rod bearing shell (7) with

oil drilling (arrow) must be mounted in the

connecting rod, otherwise the piston pin (2) is

not lubricated.

The anti-twist locks (8) of the connecting rod

bearing shells (7) must be seated in the

grooves (9) in the conrods (4) and connecting

rod bearing caps (5).
AR03.10-P-6111-06AV

The connecting rod and connecting rod

bearing cap are cracked (broken) (arrow).

They must not be installed the wrong side

round!

20
Tighten conrod bolts (6)

AR03.10-P-6111-02BV


*BA03.10-P-1001-01E

21
Rotate crankshaft

To inspect ease of operation.

22
Install oil pump
-
Ensure oil return flow check valve is

correctly located.

-
Clean strainer of oil pump.

-
Fill oil pump with engine oil before

installing so that it pumps oil when first

started.

All except models 203, 209, 211.061/065/070,

220 without 4MATIC, 230.474 /475

AR18.10-P-6020B

Model 203 without 4MATIC, 209,

211.061/065/070

AR18.10-P-6020PV

Model 203 with 4MATIC, model 220 with

4MATIC

AR18.10-P-6020PW

Model 230.474/475

AR18.10-P-6020R

23
Fit on cylinder head
Models 463.206/ 209/ 232/ 233/ 240/ 241/

243/ 244/ 245/ 246/ 247/ 248/ 249/ 250/ 254

AR01.30-P-5800GV

Engine 112 in model 129 and engine 113 in

models 129, 202, 208, 210

AR01.30-P-5800B

Engine 112 in models 170, 202, 208, 210,

220 and engine 113 in models 220,

230.474 /475

AR01.30-P-5800BA

Model 163

AR01.30-P-5800MV

Models 203, 209 with engines 112, 113

Models 211.061/065/070

AR01.30-P-5800PV

24
Fit on top part of oil pan
Model 463

AR01.45-P-7500FG

Model 230.474/475

AR01.45-P-7500R

Model 220 without 4MATIC

AR01.45-P-7500I

Model 220 with 4MATIC

AR01.45-P-7500IW

Model 210 with 4MATIC

AR01.45-P-7500FA

Model 210 without 4MATIC

AR01.45-P-7500F

Models 202, 208

AR01.45-P-7500FC

Model 203 without 4MATIC, 209 with engines

112,113

AR01.45-P-7500PV

Model 203 with 4MATIC

AR01.45-P-7500PW

Model 211.061/065/070

AR01.45-P-7500TV

Model 170

AR01.45-P-7500SV

Model 163

AR01.45-P-7500FB

Model 129

AR01.45-P-7500FD

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Page 3

25.1
Fit on automatic transmission
Models 463.206/ 209/ 232/ 233/ 240/ 241

AR27.10-P-0500BD

Models 463.243/ 244/ 245/ 246/ 247/ 248/

249/ 250/ 254

AR27.10-P-0500GA

Model 230.475

AR27.10-P-0500R

Model 230.474

Model 220 without 4MATIC

AR27.10-P-0500I

Model 220 with 4MATIC

AR27.10-P-0500IW

Models 210, 208, 202,170. 129

AR27.10-P-0500B

Model 203 without 4MATIC, 209 with engines

112,113

AR27.10-P-0500P

Model 203 with 4MATIC

AR27.10-P-0500PW

Models 211.061/065/070

AR27.10-P-0500T

Model 163

AR27.10-P-0500GH

25.2
Fit on manual transmission
Models 210, 202, 129

AR26.10-P-0020A

Models 203, 209 with engine 112

AR26.10-P-0020P

Model 211.061

AR26.10-P-0020T

Model 208 with transmissions 716.662/622

AR26.10-P-0020E

Model 170,

Model 208 with transmission 716.663

AR26.10-P-0020D

26
Install engine
Models 463.243/ 244/ 245/ 246/ 247/ 248/

249/ 250/ 254

AR01.10-P-2400CC

Model 230.475

AR01.10-P-2400R

Model 230.474

AR01.10-P-2400RVK

Model 220 without 4MATIC

AR01.10-P-2400AB

Model 220 with 4MATIC

AR01.10-P-2400IW

Model 210 with 4MATIC

AR01.10-P-2400C

Model 210 without 4MATIC, 208, 202, 129

AR01.10-P-2400CB

Model 203 without 4MATIC, 209 with engine

112

AR01.10-P-2400PV

Model 203 with 4MATIC

AR01.10-P-2400PW

Model 209 with engine 113

AR01.10-P-2400Q

Models 211.061/065/070

AR01.10-P-2400TC

Model 170

AR01.10-P-2400SV

Model 163

AR01.10-P-2400CA

Inspection data of conrod bolts

Number

Designation
Engine

112 except

112.951,

113.94/96/980/

981/982/984/986
Engine

113.992

BE03.10-P-1001-03A
Conrod bolts
Thread
4M8B18B1

Shank length
when new
mm
4742

max.
mm
47.642.6

Part no.
--

Designation
Engines

112 except

112.951,

113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/980/
981/982/984/
986/987/988/
990/991/992/

993

BA03.10-P-1001-01E
Connecting rod bolt
Stage 1
Nm
5

2nd stage
Nm
25

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Page 4

Stage 3
(°
90

Retaining strap

000 589 04 14 00

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Page 5

BT27.50-P-0002-02A
Plain bearing of input shaft changed to an anti-

friction bearing

TRANSMISSION
722.60# /61# /660 /662 /664 /665 /69# ## as of 1317917 as of 7.1.99,
722.62# /63# /661 /663 /666 /669 ## as of 1324240 as of 12.1.99

P27.51-2006-05

1
Needle bushing

The plain bearing in the input shaft was

replaced by an anti-friction bearing (needle

bushing).

As a result, the inside diameter of the needle

bushing in the input shaft and the outside

diameter of the journal at the output shaft

have also changed.

When repairing a vehicle, therefore, both

shafts must be replaced.

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BT27.35-P-0003-01A
Primary pump non-return valve dispensed with
722.5

k

TRANSMISSION
722.5## ## as of 3652931

Serieneinsatzdaten/Änderungen/Neuerungen

Getriebe/

Lenk-

getriebe
Füll-

Nr.
Gertr.-End-

Nr. ab
Gertr.-End-

Nr. bis
Prod.-Zeit-

raum ab
Prod.-Zeit-

raum bis
Art und Grund der Änderung
Verweis/Bemerkung

722.5
3652931

P27.35-0214-06

The primary pump non-return valve (arrow) is

dispensed with as of transmission ident. end

no. 3652931

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Page 1