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Remove/install valve springs and / or valve stem seals - AR05.30-P-3500GZ (ML500): Notes

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ENGINE 113.964 in MODEL 164.175 

Fig 1: Identifying Valve Springs And Valve Stem Seals Components
G05257438Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVINGINSTALLING Remove/install    
DANGER Risk of injury  caused by fingers being jammed or pinched  when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof. When moving components, ensure that no body parts or limbs are within the operating range of moving parts. AS00.00-Z-0011-01A
1 Open engine hood and raise to vertical position   AR88.40-P-1000GZ
2 Remove air filter housing   AR09.10-P-1150GZ
3 Remove electric fan   AR20.40-P-5000GZ
4 Remove poly-V-belt IMPORTANTInstallation:  Lock clamping device with 5 mm dia. drift or pin. AR13.22-P-1202GZ
5 Remove cylinder head covers   AR01.20-P-5014GZ
6 Remove a spark plug from each cylinder IMPORTANT See: ↓  
REFER TO MAINTENANCE   Replace spark plugs AP15.10-P-1580GZ
7 Set crankshaft to a 40° crank angle after ignition TDC and interlock camshaft with the locating plates NOTES The engine must not be turned back; otherwise the timing chain could skip.
IMPORTANT Rotate engine at center bolt on crankshaft in the direction of rotation of the engine until marking 40° on the belt pulley/vibration damper and marking on the timing case cover match.
IMPORTANT The grooves on the camshafts must be pointing toward the inner V.		  
    SPECIAL TOOL Locating plate on the right Fig 2
    SPECIAL TOOL Locating plate on the left Fig 3
8 Remove chain tensioner   AR05.10-P-7800GZ 
9 Remove the camshaft Hall sensor   AR15.10-P-2000GZ
10 Remove camshaft sprockets IMPORTANTInstallation:  Check engine valve timing.
IMPORTANT If necessary after testing: ↓		 AR05.10-P-6858GZ 
    Set the basic position of camshafts AR05.20-P-6020GZ 
    TORQUE SPECIFICATION *BA05.20-P-1001-01B 
    SPECIAL TOOL Open-end wrench Fig 4
    SPECIAL TOOL Insertion tool Fig 5
    SPECIAL TOOL Torque wrench Fig 6
11 Remove the camshaft bearing bridges   AR05.20-P-7103GZ 
12 Position piston of cylinder to be processed to TDC NOTES Rotate engine at crankshaft center bolt by holding timing chain up for this step so that it does not jam.
IMPORTANTInstallation:  Before installing the camshaft sprockets, again turn back the crankshaft in the starting position of a 40° crank angle after ignition TDC on cylinder 1.		  
13 Secure vehicle to prevent it from moving. IMPORTANT Attach park pawl. If necessary install retaining lock for crankshaft: ↓  
    Install retaining lock for crankshaft/starter ring gear AR03.30-P-5000GZ
14 Connect cylinder leak tester   AR01.00-P-1300GZ
15 Pressurize compression chamber to about 5 bar    
16 Screw in assembly lever (02) with counterholder (01) in cylinder head SPECIAL TOOL Valve assembly tools case Fig 7
17 Attach and align assembly lever (02) and thrust piece (03) in the counterholder IMPORTANT Attach the thrust piece vertically to the upper valve plate (8) and align with the assembly tool.  
    SPECIAL TOOL Valve assembly tools case Fig 7
18 Remove upper valve disk (8) and valve spring (9) NOTES Do not allow valves to touch the piston crowns otherwise they will be damaged.
IMPORTANT Compress valve spring and remove split valve spring retainer locks (10) with tweezers or magnetic rod. The valve springs of the inlet and exhaust valves are identical.		  
    SPECIAL TOOL Magnetic finger Fig 8
    COMMERCIALLY AVAILABLE TOOLS Tweezers *WH58.30-Z-1040-02A 
19 Remove bottom valve disc (11)    
20 Replace valve stem seal (12) IMPORTANT Pull valve stem seal out of valve stem using pliers.
IMPORTANTInstallation:  Before fitting the new valve stem seal with the drift, a protective sleeve must be fitted to valve stem to protect the valve stem seal from damage.		 AR05.30-P-3500-02A 
    SPECIAL TOOL Pliers Fig 9
    SPECIAL TOOL Drift Fig 10
INSPECT Checking     
21 Inspect surface of valve stem for roughness and ridging IMPORTANT Visual inspection or with nail. Replace valves with a rough stem surface or formation of ridging: ↓  
    Replace valves. AR05.30-P-3511GZ 
22 Check upper valve disk (8) and lower valve disk (11) IMPORTANT Check valve disk for pitting; replace if necessary.  
23 Install in the reverse order    
CAMSHAFT

Number Designation Engines 113.940/941/942/943/944/948/961/962/963/964/965/966/967/968/969/971/980/981/982/984/986/992/995
BA05.20-P-1001-01B Bolt for camshaft sprocket M12 x 45 Stage 1 Nm 50
Stage 2 ∠° 90
Fig 2: Identifying Locating Plate (112 589 00 32 00)
G05257439Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Locating Plate (112 589 01 32 00)
G05257440Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Identifying Open End Wrench (112 589 00 01 00)
G05257441Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 5: Identifying Insertion Tool (112 589 01 03 00)
G05257442Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 6: Identifying Torque Wrench (001 589 72 21 00)
G05257443Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 7: Identifying Valve Assembly Tool Case (111 589 25 61 00)
G05257444Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 8: Identifying Magnet Finger (116 589 06 63 00)
G05257445Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 9: Identifying Pliers (606 589 00 37 00)
G05257446Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 10: Identifying Drift (119 589 00 43 00)
G05257447Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1040-02A Tweezers, straight 160 mm with rounded tips
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