Mercedes-Benz ML320. Service manual - part 461

 

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Mercedes-Benz ML320. Service manual - part 461

 

 

oil feed up to final repair 
size.

12

Measure cylinder bore

Allow crankcase to cool 

down to approx. 20°C 
before measuring

 

Cylinder diameter

*BE01.40-P-1001-01F

 Internal measuring 

instrument ø 50 to 150 
mm, with 0.01 mm 
indication and measuring 
point pressure relief

*WE58.40-Z-1003-21A

13

Clean cylinder bore and 
dry

 

 

14

Set honing machine for 
lapping

 Set to same diameter as 

after polishing (final 
diameter).

 

Cylinder diameter 
according to machining 
stage.

*BE01.40-P-1003-01F

Stroke setting with 70 mm 
felt length on 70th stroke 
scale of machine

*BE01.40-P-1012-01F

Felt insert overrun at top 
and bottom

*BE01.40-P-1013-01F

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

 Felt insert C 30-F 85

*WH58.30-Z-1036-04A

 Set of felt insert holders 

CK3130

*WH58.30-Z-1035-04A

 Stone holder for felt 

insert CK-30 35

*WH58.30-Z-1034-04A

15

Rub-in cylinder bore and 
filter insert using honing 
paste

 Without honing oil 

feed, the cylinder wall 
must be dry. Only the 
specified honing paste may 
be used. Only this one 
guarantees the specified 
final result. 
Polmot honing paste order 
no. 600.11

*BR00.45-Z-1050-06A

16

Lap cylinder bore and 
expose silicone crystals.

 Without honing oil 

feed. 

 

2001 Mercedes-Benz ML320 

1998-2005 ENGINE Complete engine - 163 Chassis

  

me 

 

Check values for crankcase 

Operating time of honing 
machine

*BE01.40-P-1014-01F

17

Coat filter insert again 
with honing paste

 Do not coat cylinder 

bore with honing paste. 
Polmot honing paste order 
no. 600.11

*BR00.45-Z-1050-06A

18

Lap cylinder bore and 
expose silicone crystals.

 Without honing oil 

feed, removed material 
cannot be measured. 
Operating time of honing 
machine

*BE01.40-P-1014-01F

19

Clean cylinder bore and 
dry

 Clean crankcase very 

carefully with honing 
paste. If possible, clean 
crankcase in a major 
assembly washing 
machine, so that no 
cylinder wall damage will 
be caused by residues 
when running the engine 
later.

 

20

Inspect cylinder bore

Allow crankcase to cool 

down to approx. 20°C 
before inspecting. 
Cylinder diameter of repair 
size

*BE01.40-P-1001-01F

Number

Designation

Engine 112 
except 112.951, 
113.940/941/ 
942/943/944/ 
945/946/948/ 
960/961/963/ 
965/966/967/ 
968/980/981/ 
984/986/992/ 
995

Engine 
113.962/982/ 
987/988/989/ 
990/991/993

BE01.40-P-
1001-02E

Cylinder bore

Peak-to-valley 
height (R

Z

 ) of 

top separating 
surface

mm 0.001 to 0.0045 0.001 to 0.0045

Wear limit at 
BDC and TDC 
of 1st piston ring

mm < or = 30.03

< or = 0.03

 

2001 Mercedes-Benz ML320 

1998-2005 ENGINE Complete engine - 163 Chassis

  

me 

 

Check values for cylinder bore 

Permissible 
deviation of 
cylinder shape

mm 0.014

0.007

contact surface 
peak-to-valley 
height

µm -

-

Number

Designation

Engine 
112.910/ 911

Engine 
112.913/920/921/922/ 
923/940/941/942/943/ 
944/945/949 
113.940/941/942/943/945

BE01.40-P-
1001-01F

Cylinder dia.

Standard 
marking X

mm

83.200...83.215 89.900...89.915

Auxiliary stage 
Marking 

mm

83.250...83.265 83.250 ... 83.265

Repair size

mm

90.150 ... 
90.165

90.150...90.165

BE01.40-P-
1002-01F

Cylinder dia., 
setting for 
repair size 
(+0.25)

Pre-honing

mm

83.200

89.900

Precision 
honing

mm

83.380

90.080

Polishing

mm

83.430

90.130

BE01.40-P-
1003-01F

Cylinder dia. 
according to 
machining 
phase

Pre-honing

mm

83.380

90.080

Precision 
honing

mm

83.430

90.130

Polishing

mm

90.150 ... 
90.165

90.150...90.165

BE01.40-P-
1004-01F

Cylinder length

mm

129.5

129.5

BE01.40-P-
1005-01F

Undercut

mm

12

12

BE01.40-P-
1006-01F

Stroke setting with 70 mm 
stone length on 70th stroke 
scale of machine

mm

130

130

BE01.40-P-
1007-01F

Stone overrun at top and 
bottom

mm

9.5

9.5

BE01.40-P-
1008-01F

Engine speed

Pre-honing

rpm

125

125

Precision 
honing

rpm

125

125

Polishing

rpm

125

125

Lapping

rpm

230

230

BE01.40-P-
1009-01F

Feed

Pre-honing

4

4

Precision honing

3

3

 

2001 Mercedes-Benz ML320 

1998-2005 ENGINE Complete engine - 163 Chassis

  

me 

 

Check values for cylinder bore 

Polishing

2

2

Lapping

1

1

BE01.40-P-
1010-01F

Stroke

Pre-honing

rpm

57

57

Precision 
honing

rpm

57

57

Polishing

rpm

57

57

Lapping

rpm

80

80

BE01.40-P-
1011-01F

Display

Pre-honing

%

20 to 30

20 to 30

Precision 
honing

%

20 to 30

20 to 30

Polishing

%

20 to 30

20 to 30

Lapping

%

20 to 30

20 to 30

BE01.40-P-
1012-01F

Stroke setting with 70 mm felt 
length on 70th stroke scale of 
machine

mm

115

115

BE01.40-P-
1013-01F

Felt insert overrun at top and 
bottom

mm

2 to 4

2 to 4

BE01.40-P-
1014-01F

Operating time of honing 
machine

S

40

40

Number

Designation

Engine 
112.951/961

Engine 112.970

BE01.40-P-
1001-01F

Cylinder dia.

Standard 
marking X

mm

89.900...89.915 97.000 to 97.015

Auxiliary stage 
Marking 

mm

89.950 to 89.965 97.050 to 97.065

Repair size

mm

90.150...90.165 97.250 to 90.165

BE01.40-P-
1002-01F

Cylinder dia., 
setting for repair 
size (+0.25)

Pre-honing

mm

-

97.000

Precision honing mm

-

97.180

Polishing

mm

-

97.230

BE01.40-P-
1003-01F

Cylinder dia. 
according to 
machining phase

Pre-honing

mm

-

97.180

Precision honing mm

-

97.230

Polishing

mm

-

97.250 ... 97.265

BE01.40-P-
1004-01F

Cylinder length

mm

-

130.90 to 131.00

BE01.40-P-
1005-01F

Undercut

mm

-

0.6...1.0

BE01.40-P-
1006-01F

Stroke setting with 70 mm stone 
length on 70th stroke scale of 
machine

mm

-

132

BE01.40-P-
1007-01F

Stone overrun at top and bottom

mm

-

9.5

 

2001 Mercedes-Benz ML320 

1998-2005 ENGINE Complete engine - 163 Chassis

  

me 

 

 

 

 

 

 

 

 

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