Mercedes-Benz ML320. Manual — part 778

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 3.5

97.0 X 1.5 X 3.1

97.0 X 1.2 X 3.5

Taper-faced hook
scraper ring

mm

97.0 X 1.5 X 4.0

97.0 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 engine

Models 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

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Page 1

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

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

Page 3