Mercedes-Benz ML320. Service manual - part 460

 

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Mercedes-Benz ML320. Service manual - part 460

 

 

Fig. 97: Identifying Installation Tool (111 589 08 43 00) 

Repair materials 

CHAMFER CYLINDER BORES - AR01.40-P-9201-01A 

1. Chamfer off the burr which has accumulated on the cylinder bores after drilling out using a suitable tool 

(e.g. hand milling cutter).  

 Equalize the bottom edge of chamfer with a polishing stone. 

Fig. 98: Removing Chamfer Burr From Cylinder Bore

Number

Designation

986/992/995

991/993

BA01.40-P-
1004-01C

End cover screw Thread not 

pretapped

Nm -

-

Thread pre-
tapped

Nm 10

8

Number

Designation

Order number

BR00.45-Z-1013-01A

Sealant

A 003 989 98 20

 

2001 Mercedes-Benz ML320 

1998-2005 ENGINE Complete engine - 163 Chassis

  

me 

 

Fig. 99: Identifying Chamfer Angle Of Cylinder Bore 

MEASURING, BORING AND HONING CYLINDER BORES - AR01.40-P-9201AA 

ENGINES 112.910/911 /912 /920 /921 /922 /923 /940 /941 /942 /943 /944 /945 /946 /947 /960 /961 /970  

ENGINES 113.940 /941 /942 /943 /960 /961 /962 /963 /965 /968 /981 /982 /990 /991 /992 /993 /995  

Fig. 100: Identifying Measuring Points Of Cylinder Bore 

1

Clean cylinder bores

 

 

2

Measure cylinder bore

 Measure cylinder bores 

with an internal measuring 
instrument at 3 measuring 
points (1, 2, 3) in a 

 

 

2001 Mercedes-Benz ML320 

1998-2005 ENGINE Complete engine - 163 Chassis

  

me 

 

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

3

Set honing machine for 
pre-honing

Cylinder 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

4

Cylinder bore pre-honing

 With full honing oil 

feed.

 

5

Measure 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

  

me 

 

point pressure relief

6

Set honing machine for 
precision honing

Cylinder 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

7

Cylinder bore precision 
honing

 With full honing oil 

feed.

 

8

Measure 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

9.1

Chamfer cylinder bore

 Except engines 

112.945, 113.962 /982 in 
model 463.

AR01.40-P-9201-01A

10

Set honing machine for 
polishing

Cylinder 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

11

Polish cylinder bore

 Polish with full honing  *BE01.40-P-1003-01F

 

2001 Mercedes-Benz ML320 

1998-2005 ENGINE Complete engine - 163 Chassis

  

me 

 

 

 

 

 

 

 

 

Content   ..  458  459  460  461   ..