1997 MERCEDES-BENZ ML500 ad blue

11
Check oil level approx. 5 min. after switching

off warm engine

Insert oil dipstick up to the stop and keep

to a residence time of at least 3 seconds.

Model 163, 210 with Engine 612
*BE18.00-P-1001-02B
Model 203, Model 209 with Engine 612

On Model 203, Model 209 after oil level

check pay attention to correct seating of the
cap, otherwise it could result in engine

damage.

Only Model 203:

Up to engine end number: 134 163 oil level

MAX. 135
mm,
MIN 110
mm.

As of engine end number: 134 164 oil level

MAX. 124,5
mm,
MIN 99,5
mm.

Measuring rod


*120589072100

12
Install trim panel of cylinder head cover

AR01.20-P-5014-02B


*BA01.20-P-1002-01A


*BA01.20-P-1003-01A

Test values for engine lubrication - general

Number

Designation
Engine

612.961
Engine

612.963

BE18.00-P-1001-02B
Dipstick marking

Color red
t
1

Color black
t
2

Color green
t
3

Color gentian blue
t
4

Numbers on handle
Number
6020760206

Round handle
Color
--

Bottle opener-shaped

handle
Color
11

Designation
Engine

612.961/962/

963/965/966,

613.961
Engine

612.967
Engine

612.990

BA01.45-P-1003-01A
Oil drain plug at oil pan
M12
Nm
---

M14
Nm
303030


Engine lubrication, oil filter

Number

Designation
Engine

612.961/962/
963/967/990,

613.960/961

BA18.20-P-1002-01G
Screw cap at oil filter
Nm
25

Crankcase ventilation, cylinder head cover

Number

Designation
Engine

612.961/

962/967
Engine

612.963
Engine

612.990

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

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
BE05.30-P-
1001-02DOutside
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
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)

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 92 © 2006 Mitchell Repair Information Company, LLC.

REAM BASIC BORE TO REPAIR STAGE I - AR05.30-P-3731-04AV
Test and adjustment values for valve guides
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/
993/995Engine 112.951/976
BE05.30-P-
1001-02DOutside
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
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

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 95 © 2006 Mitchell Repair Information Company, LLC.

Test and adjustment values for valve guides
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-
1001-02DOutside
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
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)

2004 Mercedes-Benz ML350
1998-2005 ENGINE Engine timing - 163 Chassis
me
Saturday, October 02, 2010 3:39:38 PMPage 98 © 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.

CONNECTOR PART NUMBERS - GF00.19-P-8100AB

000 153 09 424-pin SLK coupling, B,
white
Remove female contactAR00.19-P-0120-02B

000 545 22 462-pin MQS coupling, A,
black
Remove female contactAR00.19-P-0120-04A

000 545 39 3012-pin MQS coupling, A,
black
Remove female contactAR00.19-P-0120-04A

000 545 40 3012-pin MQS coupling, B,
black
Remove female contactAR00.19-P-0120-04A

000 545 42 3018-pin MQS coupling, A,
black
Remove female contactAR00.19-P-0120-04A

000 545 44 3018-pin MQS coupling, B,
black
Remove female contactAR00.19-P-0120-04A

000 545 46 3010-pin MQS coupling, A,
black
Remove female contactAR00.19-P-0120-04A

000 545 63 3014-pin MQS coupling, A,
black
Remove female contactAR00.19-P-0120-04A

000 545 70 3014-pin MQS coupling, B,
blue
Remove female contactAR00.19-P-0120-04A

000 545 71 3014-pin MQS coupling, C,
violet
Remove female contactAR00.19-P-0120-04A

000 545 72 3014-pin MQS coupling, D,
white
Remove female contactAR00.19-P-0120-04A

000 545 86 3012+2-pin MQS, LWL
coupling, -
Remove female contactAR00.19-P-0120-04A

000 545 87 3012+2-pin MQS, LWL
coupling, A, black
Remove female contactAR00.19-P-0120-04A

000 545 88 3012+2-pin MQS, LWL
coupling, B, transparent
Remove female contactAR00.19-P-0120-04A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 55 © 2006 Mitchell Repair Information Company, LLC.

MODEL 124, 126, 129, 140, 163, 164, 168, 169, 170, 171, 199, 202, 203, 208, 209, 210, 211, 215, 216, 219,
220, 221, 230, 240, 245, 251, 414, 461, 463
plugs and couplings, part initial numbers 001

Part numberDesignation, Coding,
Color

001 540 24 814-pin LKS plug, A, black
Remove contact pinAR00.19-P-0120-20A

001 540 28 816-pin MQS coupling, A,
black
Remove female contactAR00.19-P-0120-04A

001 540 32 816-pin MQS plug, A, black
Remove contact pinAR00.19-P-0120-03A

001 540 79 8118-pin MQS coupling, C,
blue
Remove female contactAR00.19-P-0120-04A

001 540 97 816-pin MQS coupling, B,
white
Remove female contactAR00.19-P-0120-04A

001 545 03 3012+2-pin MQS, LWL
coupling, A, water blue
Remove female contactAR00.19-P-0120-04A

001 545 08 3058-pin SLK coupling, -, -
Remove female contactAR00.19-P-0120-02B

001 545 09 3058-pin SLK coupling, 0,
black
Remove female contactAR00.19-P-0120-02B

001 545 12 3010-pin MQS coupling, A,
black
Remove female contactAR00.19-P-0120-04A

001 545 13 3010-pin MQS coupling, B,
transparent
Remove female contactAR00.19-P-0120-04A

001 545 14 3010-pin MQS coupling, -, -
Remove female contactAR00.19-P-0120-04A

001 545 50 4028-pin MQS plug, A, black
Remove contact pinAR00.19-P-0120-03A

001 545 59 4010-pin MQS coupling, -,
black
Remove female contactAR00.19-P-0120-04A
001 545 00 7312+4-pin MQS, JPT
coupling, A, black

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 56 © 2006 Mitchell Repair Information Company, LLC.