1997 MERCEDES-BENZ ML320 engine

AR20.00-P-1250B
Remove oil from cooling and heating system
22.7.97

ENGINE
611.960 in MODEL 202.134 /193 /194 /133

ENGINE
611.961 in MODEL 210.006 /206 /007 /606

ENGINE
611.962 in MODEL 203.006 /004 /206 /204 /706

ENGINE
612.961 in MODEL 210.616 /216 /016

ENGINE
612.962 in MODEL 203.016 /216

ENGINE
612.963 in MODEL 163.113

ENGINE
613.960 in MODEL 220.026

ENGINE
613.961 in MODEL 210.026 /226

ENGINE
628.960 in MODEL 220.028 /128

ENGINE
628.961 in MODEL 211.028

ENGINE
628.963 in MODEL 163.128

ENGINE
646.951 in MODEL 211.004

ENGINE
646.961 in MODEL 211.006 /206 /606

ENGINE
647.961 in MODEL 211.016 /216 /616

ENGINE
648.961 in MODEL 211.023 /026 /223 /226

ENGINE
612.967 in MODEL 209.316

ENGINE
612.990 in MODEL 203.018 /218 /718

ENGINE
646.962 in MODEL 203.007 /207 /707

ENGINE
646.963 in MODEL 203.008 /208 /708

P20.00-2078-06

Shown on engine 611.962

1
Coolant expansion reservoir

18
Radiator

20
Coolant thermostat


Remove/Install


Danger!

Risk of accident
caused by vehicle starting

off when engine is running.
Risk of injury


caused by contusions and burns when

working in engine during starting procedure
Secure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.

Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A


Danger!

Risk of injury
from
fingers being jammed

or crushed
when removing / install / aligning
hoods, doors, trunk lid/tailgate or sliding roof.
With moving components, ensure that no

body parts or limbs are within the operating

range of moving parts.

AS00.00-Z-0011-01A


Danger!

Risk of injury
to skin and eyes suffering

scalding from contact with hot coolant spray.
Risk of poisoning
if coolant is swallowed.
Do not open cooling system unless coolant

temperature is below 90 °C. Open cap slowly

and release the pressure. Do not pour coolant

into beverage bottles.

Wear protective gloves, protective clothing

and eye protection.

AS20.00-Z-0001-01A

1
Open the engine hood and raise to vertical

position
Model 163

AR88.40-P-1000GI

Model 202

AR88.40-P-1000E

Model 203

AR88.40-P-1000P

Model 209

AR88.40-P-1000Q

Model 210

AR88.40-P-1000F

Model 211

AR88.40-P-1000T

Model 220

AR88.40-P-1000M

Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

2
Drain the coolant
Engine 611.960/961/962,

612.961/962/967/990, 613.960/961,
628.960/961/963, 646, 647, 648
AR20.00-P-1142HB

Engine 612.963

AR20.00-P-1142M

3
Remove coolant thermostat (20)

Engine 611, 612, 613, 646, 647, 648

AR20.10-P-2460PP

Engine 628.960/963

AR20.10-P-2460M

4
Mount the housing to remove oil and flush the

cooling/heating system

The housing may be used only for the

purpose of removing the oil, and must be

removed again after it has been rinsed.


Engine 611.960/961/962/ 612.961/962

/963/967/990, 613.960/961

*BA20.10-P-1005-01A


Engine 628.960/961/962/963

*BA20.10-P-1002-01F


Engine 646.962/963

*BA20.10-P-1002-01G

y
Housing for removing oil and flushing the

cooling/heating system

WF58.50-P-2000-01A


Cleaning

5
Set the heater control to full power

6
Set the auxiliary heater to full power

7
Fill the cooling/heating system with a rinsing

solution


Rinsing solution consisting of 5% cleaning

agent and 95% water.


*BF20.00-P-1001-02E

Cleaning agent

*BR00.45-Z-1001-04A

8
Warm up the engine to operating temperature

at moderate engine speed

While engine is running, hold operating

temperature at 80 °C for about 5 min.

9
Switch off engine and allow the cooling

system to

cool to about 50 °C

10
Drain the rinsing solution completely at the

drain plug of radiator (18)

Observe the environmental instructions of

the manufacturer of the cleaning agent.

11
Fill cooling system with fresh water

Pour fresh water into the coolant

expansion reservoir (1).

12
Warm up the engine to operating temperature

at moderate engine speed

While engine is running, hold the

operating temperature at 80 °C for about

5 min.

13
Drain the fresh water completely at the drain

plug of radiator (18)

Repeat the flushing process until all of the

rinsing solution has been removed.

14
Install in the reverse order


Coolant pump, coolant thermostat

Number

Designation
Engine

611.960/

961
Engine

611.962
Engine

612.961/

963
Engine

612.962/

967/990

BA20.10-P-1005-01A
Bolt of coolant thermostat housing to cylinder head
Nm
9999

Designation
Engine

613.960/

961

BA20.10-P-1005-01A
Bolt of coolant thermostat housing to cylinder head
Nm
9

Designation
Engine

628.960/961/962/

963

Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

BA20.10-P-1002-01F
Bolt of coolant thermostat housing to

crankcase
Nm
9

Designation
Engine

647, 648
Engine

646.951/

961
Engine

646.962/

963

BA20.10-P-1002-01G
Bolt of coolant thermostat housing to cylinder head
Nm
999

Designation
Engine

611.960
Engine

611.961
Engine

611.962

BF20.00-P-1001-02E
Cooling system
Total capacity
Liters
8.0
Y
10.3
Y
11.9

Capacity of anticorrosion/

antifreeze agent down to

-37 °C

Liters

4.0
Y
5.2
Y
6.0

Capacity of anticorrosion/

antifreeze agent down to

-45 °C

Liters

4.5
Y
5.7
Y
6.5

Specifications for Operating

Fluids
SheetBB00.40-P-0310-01ABB00.40-P-0310-01ABB00.40-P-0310-01A
SheetBB00.40-P-0325-00ABB00.40-P-0325-00ABB00.40-P-0325-00A


Cooling system

Number

Designation
Engine

612.961
Engine

612.962/ 967
Engine

612.963

BF20.00-P-1001-02E
Cooling system
Total capacity
Liters
Y
10.6
Y
12.4
Y
11.0

Capacity of anticorrosion/

antifreeze agent down to

-37 °C

Liters

Y
5.3
Y
6.2
Y
5.5

Capacity of anticorrosion/

antifreeze agent down to

-45 °C

Liters

Y
5.8
Y
6.8
Y
6.25

Specifications for Operating

Fluids
SheetBB00.40-P-0310-01ABB00.40-P-0310-01ABB00.40-P-0310-01A
SheetBB00.40-P-0325-00ABB00.40-P-0325-00ABB00.40-P-0325-00A


Cooling system

Number

Designation
Engine

613.960
Engine

613.961
Engine

628.960

BF20.00-P-1001-02E
Cooling system
Total capacity
Liters
Y
15.5
Y
11.2
Y
16.5

Capacity of anticorrosion/

antifreeze agent down to

-37 °C

Liters

Y
7.75
Y
5.6
Y
8.25

Capacity of anticorrosion/

antifreeze agent down to

-45 °C

Liters

Y
8.0
Y
6.2
Y
9.1

Specifications for Operating

Fluids
SheetBB00.40-P-0310-01ABB00.40-P-0310-01ABB00.40-P-0310-01A
SheetBB00.40-P-0325-00ABB00.40-P-0325-00ABB00.40-P-0325-00A

Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 3

Cooling system

Number

Designation
Engine

628.961
Engine

628.963

BF20.00-P-1001-02E
Cooling system
Total capacity
Liters
Y
15.3
Y
12.0

Capacity of anticorrosion/

antifreeze agent down to

-37 °C

Liters

Y
7.7
Y
6.0

Capacity of anticorrosion/

antifreeze agent down to

-45 °C

Liters

Y
8.5
Y
6.75

Specifications for Operating

Fluids
SheetBB00.40-P-0310-01ABB00.40-P-0310-01A
SheetBB00.40-P-0325-00ABB00.40-P-0325-00A


Cooling system

Number

Designation
Engine

646.951/961
Engine

647.961
Engine

648.961

BF20.00-P-1001-02E
Cooling system
Total capacity
Liters
Y
9.75
Y
11.25
Y
12

Capacity of anticorrosion/

antifreeze agent down to

-37 °C

Liters

Y
5.0
Y
5.75
Y
6.0

Capacity of anticorrosion/

antifreeze agent down to

-45 °C

Liters

Y
5.50
Y
6.25
Y
6.75

Specifications for Operating

Fluids
SheetBB00.40-P-0310-01ABB00.40-P-0310-01ABB00.40-P-0310-01A
SheetBB00.40-P-0325-00ABB00.40-P-0325-00ABB00.40-P-0325-00A


Cooling system

Number

Designation
Engine

612.990
Engine

646.962/963

BF20.00-P-1001-02E
Cooling system
Total capacity
Liters
Y
13.0
Y
8.5

Capacity of anticorrosion/

antifreeze agent down to

-37 °C

Liters

Y
6.5
Y
4.5

Capacity of anticorrosion/

antifreeze agent down to

-45 °C

Liters

Y
7.2
Y
5.0

Specifications for Operating

Fluids
SheetBB00.40-P-0310-01ABB00.40-P-0310-01A
SheetBB00.40-P-0325-00ABB00.40-P-0325-00A

Cleaning agent

Number

Designation
Order number

BR00.45-Z-1001-04A
Cold spray cleaner, e.g. P3 Neuproton 5226
Henkel

Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 4

AP15.10-P-1580GHReplace spark plugs
1.7.97

ENGINE
112.942 in MODEL 163.154

ENGINE
112.970 in MODEL 163.157

ENGINE
113.942 in MODEL 163.172

ENGINE
113.981 in MODEL 163.174

ENGINE
113.965 in MODEL 163.175

P15.10-0221-06

Shown on engine 112

R4
Spark plugs

T1/4
Ignition coil cylinder 4


Remove/install and replacing


Danger!

Risk of death
caused by contact with parts

conducting high voltages.
Do not touch parts which conduct high

voltages. Persons who wear electronic

implants (e.g. heart pacemakers) must not

carry out work on the ignition system.

AS15.10-Z-0001-01A


Notes on avoiding damage to ignition system
Engine 104, 111, 112, 113, 119, 120, 271

AH15.10-P-0002-01D

1
Remove/install air filter upper section

2
Removing and installing ignition coils

AR15.12-P-2003A

3
Disconnect spark plug connectors

Prise over cylinder head cover.


Double open-ended wrench

*110589010100

4
Remove/install spark plugs (R4)


*BA15.10-P-1001-01A

Spark plug wrench

*112589010900


Spark plugs

Number

Designation
Engines

104, 110, 111,

113.940/941/942/943/
944/948/960/961/962/
963/965/966/967/968/
969/980/981/982/984/

986/992/993,

115, 117, 119, 120
Engine

112.910/911/
912/913/914/
915/916/917/
920/921/922/
923/940/941/
942/943/944/
945/946/947/
949/951/953/
954/955/960/
961/970/972/

973/975

BA15.10-P-1001-01A
Spark plugs
Nm
2828

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR91.40-P-0630GH
Remove/install seat belt with emergency tensioning retractor
26.3.97

MODEL
163.113 /128 /136 /154 /157 /172 /174 /175

P91.40-0374-09

1
Cap

2
Bolt

3
Outer paneling
7

Automatic belt retractor

R12/2
Passenger ETR [GUS] ignition

squib

4

Belt end fitting

5
Screw

6
Screw


Remove/Install

Danger!

Risk of injury
when carrying out test or repair

work on airbag or emergency tensioning

retractor units
Store airbag unit with expulsion area on top,

do not subject to temperatures above 100 °C.

Interrupt power supply when working on such

units.

AS91.00-Z-0001-01A

Danger!

The spring in the inertia reel can pose an

injury hazard
when the tension is released

and it uncoils.
Never disassemble inertia reels

AS91.00-Z-0002-01A


Important instructions for performing repair,

body work and welding on vehicles with

airbags or belt tensioner units
Models 129 as of 1.7.93, 163, 168, 170, 202

as of 1.7.93, 208, 210, 414, 638, 690.6, 901,

902, 903, 904, 905

Model 461 with engine 602.983

Model 463 up to 30.11.00

MODELS WD141, WD241, WD341, WD641,

WD741, XD141, XD241, XD341, XD441,

XD541, XD641, XD741, YD141, YD241,

YD341, YD441, YD541, YD641, YD741

AH91.00-P-0002-01B


Evaluation of airbags and emergency

tensioning retractors on accident vehicles
Model 129 as of 1.7.93, 163, 168, 170, 202 as

of 1.7.93, 203, 208, 209, 210,

211.004/006/016/061/065/070, 215, 220, 230,

240, 414, 463, 638, 901, 902, 903, 904,905

Models WD141, WD241, WD341, WD641,

WD741, XD141, XD241, XD341, XD441,

XD541, XD641, XD741, YD141, YD241,

YD341, YD441, YD541, YD641, YD741

AH91.00-P-0006-01B


Legal regulations concerning the handling

and storage of airbag and emergency

tensioning retractors
Models 124, 129, 140, 163, 168, 170, 202,

203, 208, 209, 210,

211.004/006/016/061/065/070, 215, 220, 230,

240, 314, 316, 318, 414, 461, 463, 638, 668,

670, 690.6, 901, 902, 903, 904, 905, 950,

952, 953, 954, 970, 972, 974, 975, 976

Models WD141, WD241, WD341, WD641,

WD741, XD141, XD241, XD341, XD441,

XD541, XD641, XD741, YD141, YD241,

YD341, YD441, YD541, YD641, YD741

AH91.00-P-0004-01A

o

Notes on disposal of airbags and emergency

tensioning retractors
All models

OS91.00-P-0001-01A


Render emergency tensioning retractors

unusable

AR91.40-P-0611A

1
Move front seat forwards to the full extent, tilt

front seat backrest forwards

See owner's manual.

Copyright DaimlerChrysler AG 14.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR91.40-P-0681GI
Remove/install rear seat belts
16.4.99

MODEL
163.136 /154 /172 as of 1.9.99,

163.113 /128 /157 /174 /175

1
Bolt

2
Seat belt guide bracket

3
Bolt

4
Automatic belt retractor

5
Belt height adjuster

R12/7
Right rear ETR ignition squib

P91.40-2114-03


Remove/Install

Danger!

Risk of injury
when carrying out test or repair

work on airbag or emergency tensioning

retractor units
Store airbags with exit surface pointing

upward, do not expose to temperatures above

100 °C. Interrupt power supply when working

on such units.

AS91.00-Z-0001-01A

Danger!

The spring in the inertia reel can pose an

injury hazard
when the tension is released

and it uncoils.
Never disassemble inertia reels

AS91.00-Z-0002-01A


Important instructions for performing repair,

body work and welding on vehicles with

airbags or belt tensioner units
Models 129 as of 1.7.93, 163, 168, 170, 202

as of 1.7.93, 208, 210, 414, 638, 690.6, 901,

902, 903, 904, 905

Model 461 with engine 602.983

Model 463 up to 30.11.00

MODELS WD141, WD241, WD341, WD641,

WD741, XD141, XD241, XD341, XD441,

XD541, XD641, XD741, YD141, YD241,

YD341, YD441, YD541, YD641, YD741

AH91.00-P-0002-01B


Evaluation of airbags and emergency

tensioning retractors on accident vehicles
Model 129 as of 1.7.93, 163, 168, 170, 202 as

of 1.7.93, 203, 208, 209, 210,

211.004/006/016/061/065/070, 215, 220, 230,

240, 414, 463, 638, 901, 902, 903, 904, 905

Models WD141, WD241, WD341, WD641,

WD741, XD141, XD241, XD341, XD441,

XD541, XD641, XD741, YD141, YD241,

YD341, YD441, YD541, YD641, YD741

AH91.00-P-0006-01B


Legal regulations concerning the handling

and storage of airbag and emergency

tensioning retractors
Models 124, 129, 140, 163, 168, 170, 202,

203, 208, 209, 210,

211.004/006/016/061/065/070, 215, 220, 230,

240, 314, 316, 318, 414, 461, 463, 638, 668,

670, 690.6, 901, 902, 903, 904, 905, 950,

952, 953, 954, 970, 972, 974, 975, 976

Models WD141, WD241, WD341, WD641,

WD741, XD141, XD241, XD341, XD441,

XD541, XD641, XD741, YD141, YD241,

YD341, YD441, YD541, YD641, YD741

AH91.00-P-0004-01A

o

Notes on disposal of airbags and emergency

tensioning retractors
All models

OS91.00-P-0001-01A


Render emergency tensioning retractors

unusable

AR91.40-P-0611A

1
Withdraw ignition key

2
Remove paneling on C-pillar

AR68.30-P-4490GH

Copyright DaimlerChrysler AG 14.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

SI47.10-P-0004A
Service Information: Procedure when tank is filled with incorrect fuel
19.12.00

MODEL
202 with ENGINE 611

MODEL
203 with ENGINE 611, 612, 646

MODEL
210 with ENGINE 611, 612, 613

MODEL
220 with ENGINE 613, 628, 648

MODEL
163 with ENGINE 612, 628

MODEL
168 with ENGINE 668

MODEL
209 with ENGINE 612

MODEL
211 with ENGINE 628, 646, 647, 648

MODEL
463 with ENGINE 612, 628

Modification notes

26.7.04

Engines have been added and procedure has been updated

Incorrect refueling of diesel-power vehicles with a common rail
injection system. Please be aware that if the customer fills the fuel
tank with the wrong type of fuel, this is the customer's fault and

cannot be submitted as a warranty claim.

If the diesel-powered vehicle with a common rail injection system has

been refueled with gasoline, follow the steps below:

1.
If the engine was not started after fuel tank is filled with the wrong

type of fuel, then emptying the fuel tank and cleaning the fuel low-

pressure lines should be enough to solve the problem.
2.

If the engine was started after fuel tank was filled with wrong type

of fuel:

On engines 611, 612, 613, 668:
-
On the rail, open the low pressure connection of the high
pressure pump return (plastic connection in area of pressure

regulator valve) and check connecting point in rail for chips.

On engine 646, 647, 648, 628:
-
Disconnect Y-distributor unit (return line HDP/Rail) at the output

and, with ignition ON, collect the fuel in a clean container. Check

fuel for metal shavings.

If the high pressure pump is not damaged and there are no metal

shavings in the injection system:

-
As in step 1, empty fuel as per the guidelines and clean the fuel

low-pressure lines. In addition to this, remove/install/replace the

high-pressure pump and fuel filter.

If metal shavings are found in the fuel

system or the high pressure pump drive is

damaged:

#
b

Engine runs rough, surges or does not start
ENGINE 611 in MODEL 203, 202, 210
ENGINE 612 in MODEL 163, 203, 210, 209

ENGINE 613 in MODEL 210, 220

ENGINE 628 in MODEL 163, 220, 211

ENGINE 646 in MODEL 203, 211

ENGINE 647 in MODEL 211

ENGINE 648 in MODEL 220, 211

ENGINE 668 in MODEL 168

ENGINE 612, 628 in MODEL 463

AF07.00-P-9000B

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1