1997 MERCEDES-BENZ ML320 engine

Check values for cylinder bore
Permissible
deviation of
cylinder shapemm0.0140.007
contact surface
peak-to-valley
heightµm--
NumberDesignation
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-
1001-01FCylinder dia.Standard
marking Xmm83.200...83.21589.900...89.915
Auxiliary stage
Marking mm83.250...83.26583.250 ... 83.265
Repair sizemm90.150 ...
90.16590.150...90.165
BE01.40-P-
1002-01FCylinder dia.,
setting for
repair size
(+0.25)Pre-honingmm83.20089.900
Precision
honingmm83.38090.080
Polishingmm83.43090.130
BE01.40-P-
1003-01FCylinder dia.
according to
machining
phasePre-honingmm83.38090.080
Precision
honingmm83.43090.130
Polishingmm90.150 ...
90.16590.150...90.165
BE01.40-P-
1004-01FCylinder lengthmm129.5129.5
BE01.40-P-
1005-01FUndercutmm1212
BE01.40-P-
1006-01FStroke setting with 70 mm
stone length on 70th stroke
scale of machinemm130130
BE01.40-P-
1007-01FStone overrun at top and
bottommm9.59.5
BE01.40-P-
1008-01FEngine speedPre-honingrpm125125
Precision
honingrpm125125
Polishingrpm125125
Lappingrpm230230
BE01.40-P-
1009-01FFeedPre-honing44
Precision honing33

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 121 © 2006 Mitchell Repair Information Company, LLC.

Check values for cylinder bore
Polishing22
Lapping11
BE01.40-P-
1010-01FStrokePre-honingrpm5757
Precision
honingrpm5757
Polishingrpm5757
Lappingrpm8080
BE01.40-P-
1011-01FDisplayPre-honing%20 to 3020 to 30
Precision
honing%20 to 3020 to 30
Polishing%20 to 3020 to 30
Lapping%20 to 3020 to 30
BE01.40-P-
1012-01FStroke setting with 70 mm felt
length on 70th stroke scale of
machinemm115115
BE01.40-P-
1013-01FFelt insert overrun at top and
bottommm2 to 42 to 4
BE01.40-P-
1014-01FOperating time of honing
machineS4040
NumberDesignation
Engine
112.951/961
Engine 112.970
BE01.40-P-
1001-01FCylinder dia.Standard
marking Xmm89.900...89.91597.000 to 97.015
Auxiliary stage
Marking mm89.950 to 89.96597.050 to 97.065
Repair sizemm90.150...90.16597.250 to 90.165
BE01.40-P-
1002-01FCylinder dia.,
setting for repair
size (+0.25)Pre-honingmm-97.000
Precision honingmm-97.180
Polishingmm-97.230
BE01.40-P-
1003-01FCylinder dia.
according to
machining phasePre-honingmm-97.180
Precision honingmm-97.230
Polishingmm-97.250 ... 97.265
BE01.40-P-
1004-01FCylinder lengthmm-130.90 to 131.00
BE01.40-P-
1005-01FUndercutmm-0.6...1.0
BE01.40-P-
1006-01FStroke setting with 70 mm stone
length on 70th stroke scale of
machinemm-132
BE01.40-P-
1007-01FStone overrun at top and bottommm-9.5

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 122 © 2006 Mitchell Repair Information Company, LLC.

Check values for cylinder bore
BE01.40-P-
1008-01FEngine speedPre-honingrpm-125
Precision honingrpm-125
Polishingrpm-125
Lappingrpm-230
BE01.40-P-
1009-01FFeedPre-honing-4
Precision honing-3
Polishing-2
Lapping-1
BE01.40-P-
1010-01FStrokePre-honingrpm-57
Precision honingrpm-57
Polishingrpm-57
Lappingrpm-80
BE01.40-P-
1011-01FDisplayPre-honing%-20 to 30
Precision honing%-20 to 30
Polishing%-20 to 30
Lapping%-20 to 30
BE01.40-P-
1012-01FStroke setting with 70 mm felt
length on 70th stroke scale of
machinemm-115
BE01.40-P-
1013-01FFelt insert overrun at top and
bottommm-2 to 4
BE01.40-P-
1014-01FOperating time of honing machineS-70
NumberDesignation
Engine
112.946/947/
948/960
Engine 112.912
BE01.40-P-
1001-01FCylinder dia.Standard
marking Xmm89.900...89.91583.200...83.215
Auxiliary stage
marking mm89.950 to 83.26583.250...83.265
Repair sizemm90.150...90.16583.450 to 83.465
BE01.40-P-
1002-01FCylinder dia.,
setting for repair
size (+0.25)Pre-honingmm89.90083.200
Precision honingmm90.08083.380
Polishingmm90.13083.430
BE01.40-P-
1003-01FCylinder dia.
according to
machining phasePre-honingmm90.08083.380
Precision honingmm90.13083.430
Polishingmm90.150...90.16583.450 to 83.465
BE01.40-P-
1004-01FCylinder lengthmm129.5129.5
BE01.40-P-Undercutmm1212

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 123 © 2006 Mitchell Repair Information Company, LLC.

Check values for cylinder bore
1005-01F
BE01.40-P-
1006-01FStroke setting with 70 mm stone
length on 70th stroke scale of
machinemm130130
BE01.40-P-
1007-01FStone overrun at top and bottommm9.59.5
BE01.40-P-
1008-01FEngine speedPre-honingrpm125125
Precision honingrpm125125
Polishingrpm125125
Lappingrpm230230
BE01.40-P-
1009-01FFeedPre-honing44
Precision honing33
Polishing22
Lapping11.
BE01.40-P-
1010-01FStrokePre-honingrpm5757
Precision honingrpm5757
Polishingrpm5757
Lappingrpm8080
BE01.40-P-
1011-01FDisplayPre-honing%20 to 3020 to 30
Precision honing%20 to 3020 to 30
Polishing%20 to 3020 to 30
Lapping%20 to 3020 to 30
BE01.40-P-
1012-01FStroke setting with 70 mm felt
length on 70th stroke scale of
machinemm115115
BE01.40-P-
1013-01FFelt insert overrun at top and
bottommm2 to 42 to 4
BE01.40-P-
1014-01FOperating time of honing machineS4040
NumberDesignation
Engine
113.960/961/
962/963/964/
965/967/968/
971/980/981/
982/984/987/
988/989/990/
991/992/993/ 995
BE01.40-P-1001-
01FCylinder dia.Standard marking Xmm97.000 to 97.015
Auxiliary stage
Marking mm97.050 to 97.065
Repair sizemm97.250 to 97.265

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 124 © 2006 Mitchell Repair Information Company, LLC.

Commercially available tools
BE01.40-P-1002-
01FCylinder dia.,
setting for repair
size (+0.25)Pre-honingmm97.000
Precision honingmm97.180
Polishingmm97.230
BE01.40-P-1003-
01FCylinder dia.
according to
machining phasePre-honingmm97.180
Precision honingmm97.230
Polishingmm97.250 to 97.265
BE01.40-P-1004-
01FCylinder lengthmm129.5
BE01.40-P-1005-
01FUndercutmm12
BE01.40-P-1006-
01FStroke setting with 70 mm stone length
on 70th stroke s cale of machinemm130
BE01.40-P-1007-
01FStone overrun at top and bottommm9.5
BE01.40-P-1008-
01FEngine speedPre-honingrpm125
Precision honingrpm125
Polishingrpm125
Lappingrpm230
BE01.40-P-1009-
01FFeedPre-honing4
Precision honing3
Polishing2
Lapping1
BE01.40-P-1010-
01FStrokePre-honingrpm57
Precision honingrpm57
Polishingrpm57
Lappingrpm80
BE01.40-P-1011-
01FDisplayPre-honing%20 to 30
Precision honing%20 to 30
Polishing%20 to 30
Lapping%20 to 30
BE01.40-P-1012-
01FStroke setting with 70 mm felt length on
70th stroke scale of machinemm115
BE01.40-P-1013-
01FFelt insert overrun at top and bottommm2 to 4
BE01.40-P-1014-
01FOperating time of honing machineS70
NumberDesignation
WH58.30-Z-1030-04A
Honing head CK-3000 for 76-127 mm dia. CK-2600,
Firma Hommel Prazision GmbH D-50767 Koln
Firma Sunnen Products Comp. USA- -7910 Manchester St. Louis, Mo.63143

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 125 © 2006 Mitchell Repair Information Company, LLC.

Workshop equipment
Repair materials
MEASURE CYLINDER BORES - AR01.40-P-9202AV
ENGINE 113 in MODELS 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230
ENGINES 112 /945, 113.962 /982
WH58.30-Z-1031-04A
Pre-honing, stone set C 30-A 53, or C30 J64, 70 mm long,
Firma Hommel Prazision GmbH D-50767 Koln
Firma Sunnen Products Comp. USA- -7910 Manchester St. Louis, Mo.63143
WH58.30-Z-1032-04A
Precision honing, stone set C 30-J 84, 70 mm long,
Firma Hommel Prazision GmbH D-50767 Koln
Firma Sunnen Products Comp. USA- -7910 Manchester St. Louis, Mo.63143
WH58.30-Z-1033-04A
Polishing, stone set C 30-C 03-81, 70 mm long,
Firma Hommel Prazision GmbH D-50767 Koln
Firma Sunnen Products Comp. USA- -7910 Manchester St. Louis, Mo.63143
WH58.30-Z-1034-04A
Stone holder for felt insert CK-30 35,
Firma Hommel Prazision GmbH D-50767 Koln
Firma Sunnen Products Comp. USA- -7910 Manchester St. Louis, Mo.63143
WH58.30-Z-1035-04A
Felt insert holder set CK3130,
Firma Hommel Prazision GmbH D-50767 Koln
Firma Sunnen Products Comp. USA- -7910 Manchester St. Louis, Mo.63143
WH58.30-Z-1036-04A
Felt insert C 30-F 85,
Firma Hommel Prazision GmbH D-50767 Koln
Firma Sunnen Products Comp. USA- -7910 Manchester St. Louis, Mo.63143
WE58.40-Z-1002-
21AAutomatic cylinder repair machine
WE58.40-Z-1003-
21AInternal measuring device (50... 150 mm dia., with 0.01 mm display and measuring
point for pressure relief)
WE58.40-Z-1004-
21AAdjusting micrometer for internal measur ing device (with adjustment range 50-200
mm)
NumberDesignationOrder number
BR00.45-Z-1050-06APolmot honing paste Order no. 600.11Polmat - Poliertechnik
GmbH Troggberg 11
38302 Wolfenbuttel
Germany

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 126 © 2006 Mitchell Repair Information Company, LLC.

Fig. 101: Identifying Measurin g Points Of Cylinder Bore
Check values for cylinder bore
Figure
item, etc.Work instructions
Cylinder bore
Measure diameter of the cleaned cylinder bores with
an internal measuring instrument in the longitudinal
and transverse directions.

1,2,3
Cylinder bore diameter
at the measuring points
Measure

Fig. 102
*WH58.30-Z-
1001-12A

*WH58.30-Z-
1011-12A
Cylinder diameter code letter X*BE01.40-P-
1001-01F
Cylinder diameter code letter *BE01.40-P-
1001-01F
Repair size*BE01.40-P-
1001-01F
Engines
113.960/961/
962/963/964/

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 127 © 2006 Mitchell Repair Information Company, LLC.

Check values for cylinder bore
Fig. 102: Identifying Dial Indicator (001 589 53 21 00)

Commercially available tools
OIL PAN BOLT DIAGRAM - AR01.45-P-7500-06F
Upper part of oil pan shown on engine 112 with 4 MATIC
NumberDesignation
965/967/968/
971/980/981/
982/984/987/
988/989/990/
991/992/993/ 995
BE01.40-P-1001-
01FCylinder dia.Standard Marking Xmm97.000 to 97.015
Auxiliary stage
Marking mm97.050 to 97.065
Repair sizemm97.250 to 97.265
NumberDesignation
Engine
112.910/ 911
Engines
112.913/920/921/922/
923/940/941/942/943/
944/945/949
113.940/941/942/943/
945
BE01.40-P-
1001-01FCylinder dia.Standard
Marking Xmm83.200...83.21589.900...89.915
Auxiliary stage
Marking mm83.250...83.26589.950 to 83.265
Repair sizemm83.450 to
83.46590.150...90.165
NumberDesignation
WH58.30-Z-1001-12AQuick calipers for internal measurements
WH58.30-Z-1011-12AInternal measuring instrument

2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 128 © 2006 Mitchell Repair Information Company, LLC.