1997 MERCEDES-BENZ ML320 engine

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.

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
me
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
me
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.