length MERCEDES-BENZ ML430 1997 Complete Workshop Manual

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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Continuous individual traces of scratch
Caused by dirt, for example, through back pul sation of soot particles from the exhaust.
The crankcase can be reused.
Piston seizure
Most of cylinder wall perceptibly roughened over the entire length.
Material deposits and perceptible scoring ma rks on cylinder wall and at piston skirt.
The cylinder barrel is unusable.
Brown coloring of cylinder upper surface.
A brown coloration over large areas of the cylinder barrel is oil varnish and indicates that the engine has been
driven at a high temperature level.
The crankcase can be reused if no im permissible cylinder warping is visible
Oil varnish above piston ring zone is nor mal and is not a reason for complaint.
GENERAL NOTES: PASSENGER CARS: COMPLETE ENGINE, CRANKCASE VENTILATION, CYLINDER HEAD,
CRANKCASE - AH01.00-Z-9999AZ
MODEL all

Notes on application of
sealant to front cover of
cylinder head
ENGINE 629AH01.30-P-
1000-02TJ
Notes on sealant path for
oil panENGINE 642.970 in MODEL 463.303 /340 /341AH01.45-P-
0001-01GY
Notes on application of
sealant to oil panENGINE 629AH01.45-P-
0001-01TJ
General information on
inspecting cylinder wallsENGINE 272, 273AH01.00-P-
0300-01VA

Notes on the application of
sealant to the cylinder head
cover
ENGINE 122.9 in MODEL 454.0AH01.30-P-
1000-08FB
Notes on application of
sealant to oil panENGINE 113, 156...AH01.45-P-
0001-01GZ

Notes on the application of
sealing compound to the
cylinder head cover
ENGINE 273AH01.30-P-
1000-08SX
AH01.45-P-

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Fig. 63: Identifying Pilot Bushing, Stop Ring, Guide Tube And Combination Tap
4. Select heli-coil threaded inse rt (8) with block length 10.2 mm.
5. Insert threaded insert (8) with primary pump drive pointing in direction of prestessing cartridge (16) in
the installation tool (13) (arrow).
6. Screw in threaded insert (8) flush to prestessing cartridge (16) (arrow).
Fig. 64: Identifying Installation T ool, Threaded Insert And Cartridge

7. Position HC-installat ion tool on tapped hole

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Saturday, October 02, 2010 3:17:56 PMPage 71 © 2006 Mitchell Repair Information Company, LLC.

Fig. 70: Identifying Heli-Coil Repair Set (102 589 00 99 00)
CHECKING CYLINDER HEAD BOLTS - AR01.30-P-5800-03B
Cylinder head/Cylinder head bolts
Cylinder head/cyl inder head bolts
1. Measure length (L) of cylinder head bolts.
If the length (L) exceeds the maximu m permissible dimension then the cyli nder head bolts must be replaced.
NumberDesignation
Engines
112.910/911/
912/913/914/
915/916/917/
920/921/922/
923/940/941/
942/943/944/
945/946/947/
949/951/953/
954/955/960/
961/970/972/
973/975/976Engines
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/
993/995
BE01.30-P-
1001-04BCylinder head
boltThread diameterM1111
Length (L) when
newmm141.5141.5
Length (L)mm< or = 144.5< or = 144.5
See pictureAR01.30-P-
5800-03B
AR01.30-P-
5800-03B
NumberDesignationEngine 113.989
BE01.30-P-1001-
04BCylinder head boltThread diameterM11
Length (L) when
newmm141.5
Length (L)mm< or = 144.5
See pictureAR01.30-P-5800-
03B

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Saturday, October 02, 2010 3:17:56 PMPage 77 © 2006 Mitchell Repair Information Company, LLC.

Fig. 71: Identifying Length Of Cylinder Head Bolts
TIGHTENING INSTRUCTIO NS FOR CYLINDER HEAD BOLTS - AR01.30-P-5800-07B
Cylinder head
Cylinder head
NumberDesignation
Engines
112.910/911/
912/913/914/
915/916/917/
920/921/922/
923/940/941/
942/943/944/
945/946/947/
949/951/953/
954/955/960/
961/970/972/
973/975/976
Engines
113.940/941/
942/943/944/
948/960/961/
962/963/965/
966/967/968/
969/971/980/
981/982/984/
986
Engine
113.987/
988
Engine
113.987/
991/992/
993/995
BA01.30-P-
1001-01DBolt,
cylinder
head to
crankcaseStage 1Nm10101010
Stage 2Nm30303030
Stage 3Angle °90909090
Stage 4Angle °90909090
NumberDesignationEngine 113.989Engine 113.964
BA01.30-P-
1001-01DBolt, cylinder
head to
crankcaseStage 1Nm1010
Stage 2Nm3030
Stage 3Angle °9090
Stage 4Angle °9090

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Fig. 74: Identifying Tightening Pattern/Bolt Assignment (Left And Right Cylinder Head M 112)
Tightening instructions for left and right cylinder heads M 112
Use wrench bit to tight en cylinder head bolts.
Observe sequence, see tightening pattern.
If the tightening torque is exceeded on a cylinder he ad bolt, unscrew the cylinder head bolt, inspect shank
length of the cylinder head bolt in question (replace bolt if necessary) and tighten again fully, beginning with
stage 1.
Cylinder head bolts must not be retightened.
Tightening diagram/bolt assignment
Left and right cylinder head M 113
Fig. 75: Identifying Left And Right Cylinder Head M 112 (Left And Right Cylinder Head M 113)

Tightening instructions for left and right cylinder heads M 113
Use wrench bit to tight en cylinder head bolts.
Observe sequence, see tightening pattern.
If the tightening torque is exceeded on a cylinder he ad bolt, unscrew the cylinder head bolt, inspect shank
length of the cylinder head bolt in question (replace bolt if necessary) and tighten again fully, beginning with
stage 1.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Saturday, October 02, 2010 3:17:56 PMPage 80 © 2006 Mitchell Repair Information Company, LLC.

Cylinder head/cyl inder head bolts
Loctite 5900 sealant.1013-01A
34Install in the reverse
order

35Risk of accident
caused by vehicle
starting off by itself
when engine is
running. Risk of
injury caused by
contusions and burns
during starting
procedure or when
working near the
running engine
Run engine and
inspect for leaksSecure vehicle to prev ent it from moving by
itself.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.AS00.00-Z-0005-
01A
36Inspect cooling
system for leaks Warm up engine to operating temperature
and then inspect cooling system or leaks.AR20.00-P-
1010HA
37Read fault memory,
erase. Stored faults which can result from cables
being disconnected or from simulation during
removal and installation or test work, have to
be processed and erased in the fault memories
after completing the work: ?
Diagnosis Manual Volume 2 Index 0:
Connecting and using test equipment.
NumberDesignation
Engine
112.910/911/
912/913/914/
915/916/917/
920/921/922/
923/940/941/
942/943/944/
945/946/947/
949/951/953/
954/955/960/
961/970/972/
973/975/976Engines
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/
993/995
BE01.30-P-
1001-04BCylinder head
boltThread diameterM1111
Length (L) when
newmm141.5141.5
Length (L)mm< or = 144.5< or = 144.5
See pictureAR01.30-P-
5800-03B
AR01.30-P-
5800-03B

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1998-2005 ENGINE Complete engine - 163 Chassis
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Saturday, October 02, 2010 3:17:57 PMPage 90 © 2006 Mitchell Repair Information Company, LLC.

longitudinal direction (A)
and transverse direction
(B).
Cylinder diameter*BE01.40-P-1001-01F
Cylinder bore*BE01.40-P-1001-02E
Cylinder length*BE01.40-P-1004-01F
Undercut*BE01.40-P-1005-01F
Internal measuring
instrument ø 50 to 150
mm,
with 0.01 mm indication
and measuring point
pressure relief*WE58.40-Z-1003-21A
Setting micrometer for
internal measuring
instrument GRM 2125
with setting range 50 to
200 mm*WE58.40-Z-1004-21A
3Set honing machine for
pre-honingCylinder diameter setting
for repair size (+0.25)*BE01.40-P-1002-01F
Stroke setting with 70 mm
stone length on 70th stroke
scale of machine*BE01.40-P-1006-01F
Stone overrun at top and
bottom*BE01.40-P-1007-01F
Engine speed*BE01.40-P-1008-01F
Feed*BE01.40-P-1009-01F
Stroke*BE01.40-P-1010-01F
Display*BE01.40-P-1011-01F
Automatic cylinder
repair machine*WE58.40-Z-1002-21A
Set of stones for rough
honing C 30-A 53, or C30
J64, 70 mm long*WH58.30-Z-1031-04A
4Cylinder bore pre-honing With full honing oil
feed.
5Measure cylinder bore Immediately after pre-
honing, the measurement
deviates by approx.
+0.02 mm due to heat
expansion.*BE01.40-P-1003-01F
Internal measuring
instrument ø 50 to 150
mm, with 0.01 mm
indication and measuring *WE58.40-Z-1003-21A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Saturday, October 02, 2010 3:17:57 PMPage 117 © 2006 Mitchell Repair Information Company, LLC.

point pressure relief
6Set honing machine for
precision honingCylinder diameter setting
for repair size (+0.25)*BE01.40-P-1002-01F
Stroke setting with 70 mm
stone length on 70th stroke
scale of machine*BE01.40-P-1006-01F
Stone overrun at top and
bottom*BE01.40-P-1007-01F
Engine speed*BE01.40-P-1008-01F
Feed*BE01.40-P-1009-01F
Stroke*BE01.40-P-1010-01F
Display*BE01.40-P-1011-01F
Finish-honing, stone set
C 30-J 84, 70 mm long*WH58.30-Z-1032-04A
7Cylinder bore precision
honing With full honing oil
feed.
8Measure cylinder bore Immediately after
precision honing, an
oversize of approx. +0.01
mm is obtained because of
heating.*BE01.40-P-1003-01F
Internal measuring
instrument ø 50 to 150
mm, with 0.01 mm
indication and measuring
point pressure relief*WE58.40-Z-1003-21A
9.1Chamfer cylinder bore Except engines
112.945, 113.962 /982 in
model 463.AR01.40-P-9201-01A
10Set honing machine for
polishingCylinder diameter setting
for repair size (+0.25)*BE01.40-P-1002-01F
Stroke setting with 70 mm
stone length on 70th stroke
scale of machine*BE01.40-P-1006-01F
Stone overrun at top and
bottom*BE01.40-P-1007-01F
Engine speed*BE01.40-P-1008-01F
Feed*BE01.40-P-1009-01F
Stroke*BE01.40-P-1010-01F
Display*BE01.40-P-1011-01F
Set of stones for
polishing C 30-C 03-81, 70
mm long*WH58.30-Z-1033-04A
11Polish cylinder bore Polish with full honing *BE01.40-P-1003-01F

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1998-2005 ENGINE Complete engine - 163 Chassis
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Saturday, October 02, 2010 3:17:57 PMPage 118 © 2006 Mitchell Repair Information Company, LLC.

oil feed up to final repair
size.
12Measure cylinder boreAllow crankcase to cool
down to approx. 20°C
before measuring
Cylinder diameter*BE01.40-P-1001-01F
Internal measuring
instrument ø 50 to 150
mm, with 0.01 mm
indication and measuring
point pressure relief*WE58.40-Z-1003-21A
13Clean cylinder bore and
dry
14Set honing machine for
lapping Set to same diameter as
after polishing (final
diameter).
Cylinder diameter
according to machining
stage.*BE01.40-P-1003-01F
Stroke setting with 70 mm
felt length on 70th stroke
scale of machine*BE01.40-P-1012-01F
Felt insert overrun at top
and bottom*BE01.40-P-1013-01F
Engine speed*BE01.40-P-1008-01F
Feed*BE01.40-P-1009-01F
Stroke*BE01.40-P-1010-01F
Display*BE01.40-P-1011-01F
Felt insert C 30-F 85*WH58.30-Z-1036-04A
Set of felt insert holders
CK3130*WH58.30-Z-1035-04A
Stone holder for felt
insert CK-30 35*WH58.30-Z-1034-04A
15Rub-in cylinder bore and
filter insert using honing
paste Without honing oil
feed, the cylinder wall
must be dry. Only the
specified honing paste may
be used. Only this one
guarantees the specified
final result.
Polmot honing paste order
no. 600.11
*BR00.45-Z-1050-06A
16Lap cylinder bore and
expose silicone crystals. Without honing oil
feed.

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
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Saturday, October 02, 2010 3:17:57 PMPage 119 © 2006 Mitchell Repair Information Company, LLC.