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