Mercedes-Benz ML320. 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