1997 MERCEDES-BENZ ML320 coolant reservoir

poisoning from swallowing
coolant.Wear protective gloves, protective
clothing and eye protection.
1Drain coolantEngine 111 in MODEL 163.AR20.00-P-
1142HG
Engines 112 /113 in MODEL 163.AR20.00-
P-1142HA
Engine 628.963 in MODEL 163.128.AR20.00-P-
1142HB
Engine 612.963 in MODEL 163.113.AR20.00-P-
1142M
2.1 Detach
brake line
from the
front end of
the radiator
Only required for right-hand steering.
3.1 Detach
ignition
cable from
the front end
of the
radiator
Only required on right-hand drive vehicles
with ENGINES 111 /112/113.
4Release coolant overflow from
battery shield
5Disconnect upper coolant hose
from the electric coolant pump Detach hose clamp from the upper
coolant hose.
6Unscrew nuts from expansion
reservoir at firewall
7Remove expansion reservoir from
the firewall and lay aside
8Disconnect coolant delivery/return
hoses for heat exchanger (17) Detach hose clamps from coolant
delivery/ return hoses for heat exchanger.
9Discharge air conditioning system
Installation: Evacuate air
conditioning, refill and check for proper
operation and leaktightness.AR83.30-
P-1760GH
10Unscrew self-locking nut (16) at
the expansion valve (15) Replace self-locking nut.
*BA83.30-
P-1003-01B
11
Detach low-pressure refrigerant
line (13) and high-pressure
refrigerant line (14) from expansion
valve (15)
Installation: Install new sealing rings
and moisten with compressor oil.
12Remove instrument panel carrier
(4) AR68.10-
P-1111GH

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 197 © 2006 Mitchell Repair Information Company, LLC.

Remove/install

Risk of injury to skin and eyes
suffering scalding from contact with
hot coolant spray. Risk of poisoning
from swallowing coolant.
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

Risk of explosion from welding or
soldering work on closed air
conditioning system. Risk of
poisoning. Inhaling overheated
refrigerant vapors may be toxic. Risk
of injury from skin and eye contact
with liquid refrigerant.Do not carry out any welding work on the
closed air conditioning system or in the
surrounding area. No smoking or open
flames. Wear eye protection and protective
gloves. Work only in well ventilated areas.
Carry out repair work on the air
conditioning system circuit only after the
system has been discharged.
AS83.00-Z-
0001-01A
Procedures if air conditioning system
is damaged or leakingAll models
AH83.30-
N-0004-
01A

Protect air conditioning circuit and
components from moisture when
carrying out repair work
All models fitted with air conditioning
AH83.30-
N-0005-
01A
Notes on handling refrigerant R134aAll models fitted with air conditioning
AH83.30-
N-0003-
01A
1Drain coolant J Engine 112, 113.AR20.00-P-
1142HA
Engine 111.AR20.00-P-
1142HG
Engine 612.963.AR20.00-P-
1142M
2Unscrew coolant compensating
reservoir (1) on firewall Lay compensating reservoir to one side.
3Disconnect coolant delivery/return
hoses for heat exchanger (2) Remove hose clamps from coolant hoses.
4Discharge air conditioning system
Installation: Evacuate air conditioning,
refill and check for proper operation and
leaktightness.AR83.30-P-
1760GH
5Remove cover on expansion valve
(4)
6Remove nut (3) on expansion valve
(4) Replace self-locking nut.
*BA83.30-
P-1003-01B
7Disconnect refrigerant lines from
expansion valve Installation: Install new sealing rings
and moisten with compressor oil.

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:19 PMPage 220 © 2006 Mitchell Repair Information Company, LLC.

AR20.20-P-3865HC
Remove/install the radiator
5.6.97

ENGINE
112.942 in MODEL 163.154

ENGINE
112.970 in MODEL 163.157

ENGINE
113.942 in MODEL 163.172

ENGINE
113.965 in MODEL 163.175

ENGINE
113.981 in MODEL 163.174

P20.20-2017-09

Shown on Model 163.154 with Engine 112

1
Viscous fan

2
Plate clamps of fan shroud

3
Fan shroud

4
Coolant line

5
Coolant line to expansion reservoir

6
Coolant line

7
Headlamps
17

Air deflector plate

18
Oil line (return line radiator

!
expansion

reservoir of power steering pump)

19
Oil line (feed line steering gear

!

radiator)

20
Fasteners

21
Damper rubber

8

Radiator crossmember

9
Rubber seal of radiator

10
ATF lines

11
Fan grille

12
Air guides

13
Clamps of air guides

14
Air conditioning system fluid reservoir

15
Radiator

16
Cover strips

Modification notes
23.3.00

Radiator with integral oil cooler for power steering pump
See step 5 and 16


Remove/install


External torx set

*001589760900


6 mm hexagon socket

*WH58.30-Z-1001-06A

7 mm hexagon socket

*WH58.30-Z-1002-06A

1.1
Remove air deflector plate (17)

Engine 113.942 only.

Danger!

Risk of injury
to skin and eyes from scalding

due to 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

2
Drain the coolant at the radiator


To drain the coolant, detach coolant line

at the bottom of the radiator or at the coolant

pump.


Installation:
Replace the hose clamps on

the radiator fitting for the coolant hose, as

they could cause damage to the screw/thread. AR20.00-P-1142HA

Hose clamp

*BA20.20-P-1004-01A

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

3.1
Remove viscous fan (1)

Engine 112.942 /970 and 113.942.

Right-hand thread!

AR20.40-P-5660C

3.2
Remove electric fan

Only Engine 113.965 /981.

AR20.40-P-5000GH
4.1
Pull off plate clamps of fan shroud (2)

Only for Engine 112.942, from 5/98.

5.1
Remove fan shroud (3)

Only for Engine 112.942 /970 und

113.942. Unscrew the bolts at bottom of fan

shroud for this step


Installation:
If installing a new radiator

with integral power steering pump oil cooler, a

new fan shroud is required if a radiator

without integral oil cooler was previously
installed.

6
Remove headlamp (7).

AR82.10-P-4730GH

7
Remove radiator crossmember (8)

AR62.30-P-2300GH

8
Detach coolant line (4, 6) and expansion

reservoir coolant line (5) at the radiator


Installation:
Replace the hose clamps on

the radiator fitting for the coolant hose, as

they could cause damage to the screw/thread.

Hose clamp

*BA20.20-P-1004-01A

9
Remove the rubber seal on radiator (9)

10.1
Remove oil line (return line of radiator
!

power steering pump expansion reservoir)

(18) and oil line (feed line of steering gear

!

radiator) (19)

From 5/98 only, seal off the connections.

Set of plugs

*129589009100

11
Unscrew ATF lines (10) at the radiator

Seal off the connections.


*BA20.20-P-1001-01A


*BA20.20-P-1003-01A

Set of plugs

*129589009100

12.1
Detach the connector from the fan and
remove the fan grille (11)

Only for Engine 112.942 /970 and 113.942.

13
Unscrew the condenser from the radiator
Do not disconnect the lines.

14
Remove fasteners (20) and damper rubber

(21)

The damper rubber (21) is designed to

prevent possible vibrations between the

condenser and radiator (15) during off-road

driving.

15
Remove air conditioning system fluid

reservoir (14) from the radiator

Place aside with the lines connected.

Detach the condenser from the radiator.

16
Remove radiator (15)

When installing, the spigots on the

radiator must be inserted in the rubber

grommets in the bottom crossmember.

Installation:
On Model 163.154 with

Engine 112.942 before VIN end number

043553, when installing a new radiator with

integral power steering pump oil cooler,

additional operations are required, if they

have not already been carried out:

#
v

Retrofit the bracket for the oil cooler line of

the power steering pump

SM46.30-P-0002A

k

Radiator with integral oil cooler for the power

steering pump

BT20.20-P-0001-01A

17
Detach air guides (12)

Replace the clamps on air guides (13).

18
Install in the reverse order

19
Pour in coolant

AR20.00-P-1142HA

20
Check the headlamp setting and correct if

necessary

e

Check and adjust the headlamp setting

AP82.10-P-8260GH

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 the 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

21
Check the oil level in the automatic

transmission and correct if necessary

AR27.00-P-0101A

22
Check the cooling system for leaks

AR20.00-P-1010HA


Radiator, coolant hoses

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

AR20.20-P-3865MM
Remove/install radiator
10.11.99

ENGINE
612.963 in MODEL 163.113

P20.20-2080-09

1
Electric fan

2
Low temperature cooler

3
Bolts (low temperature cooler)
110/2

Charge air cooler

4
Lamp units

5
Cover strips

6
Radiator crossmember

P20.20-2081-09

8
Coolant hose for coolant pump

9
Coolant hose of thermostat housing

10
Coolant hose of coolant expansion tank

11
Seal strip

12
Air ductings
19

Power steering oil line (feed line of
steering gear

!
radiator)

20
Attachment parts

21
Damper rubber

13

Mounting clips

14
Air conditioning fluid reservoir

15
Radiator

16
Bolts

17
Capacitor

18
Power steering oil line

(Return line of radiator

!

Power steering pump supply reservoir)


Removal/installation


Danger!

Risk of injury
to
fingers being jammed or

pinched
when removing, installing or aligning

hoods, doors, trunk lid/tailgate or sliding roof.
When moving components, ensure that no

body parts or limbs are within the operating

range of moving parts.

AS00.00-Z-0011-01A

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

Danger!

Risk of injury
to skin and eyes suffering

scalding from contact with hot coolant spray.
Risk of poisoning
from swallowing coolant.
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 engine hood and raise to vertical position

Have second person secure hood.

AR88.40-P-1000GI

2
Connect no load current retention unit


*WH58.30-Z-1005-09A

3
Disconnect battery ground cable

AR54.10-P-0003A

4
Remove trim panel of cylinder head cover

AR01.20-P-5014-02B


*BA01.20-P-1002-01A


*BA01.20-P-1003-01A

5
Remove bottom part of noise encapsulation

at front

AR94.30-P-5400GH

6
Remove electric fan (1)

Remove toward bottom.

AR20.40-P-5000M

7
Drain coolant

At radiator.

AR20.00-P-1142M


Notes on coolant
All engines

AH20.00-N-2080-01A

8
Remove charge air cooler (110/2)

AR09.41-P-6817MM

9.1
Attach guard plate for radiator/condenser

With automatic air conditioning, code

581a and AC system or Tempmatic USA,

code 580.

Attach additional AC condenser in the

vehicle.

y

Guard plate for radiator/condenser
Engine 606 in model 124,
Engine 606.961 in model 140,

Engine 112, 113, 604, 605, 611.960 in

MODEL 202,

Engine 602.983, 612.966 in MODEL 461,

Engine 628.962, 612.965, 606.964, 112.945,

113.962/ 982 in MODEL 463,

Engine 111, 112, 611.962, 612.962 in model

203,

Engines 112, 113, 611.961, 612.961, 613.961

in MODEL 210,

Engine 112 in model 170,

Engine 112 in MODEL 220,

Engine 113 in MODEL 211, 215, 220,

Engine 112 in MODEL 208,

Engine 112, 612.963, 628.963 in MODEL 163,
Engine 112.923 /943, 113.961 in MODEL 129,

Engine 137, 275 in MODEL 215, 220,

Engine 613.960, 628.960 in MODEL 220,

Engine 113.992 in model 230.474,

Engine 271 in model 209, 203,

Engine 285.950 in model 240.078 /178,

Engine 612.967 in model 209.316,

Engine 648 in model 220

Engine 112.951 in model 639.601/603/

605/701/703/705/801/803/805

Engine 646.983/984 in model 639.601/

603/605/701/703/705/801/803/805

Engine 646.982 in model

639.601/603/605/701/703/705

WF58.50-P-0110-01A

10
Remove seal rail (11)

11
Extract steering oil from reservoir

Hand pump

*210589007100

12.1
Disconnect power steering oil line (return line

radiator

!
power steering pump supply

reservoir) (18)

Seal connections.


Installation:
Install new sealing rings.


*BA46.30-P-1012-01A


Clamp

*000589543700

Set of stop plugs

*129589009100

12.2
Disconnect power steering oil line (feed line of

steering gear

!
radiator) (19)


Clamp

*000589543700

Set of stop plugs

*129589009100

Hexagon socket wrench

*WH58.30-Z-1001-06A

Hexagon socket wrench

*WH58.30-Z-1002-06A

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

13
Disconnect coolant hose to coolant pump (8),

coolant hose from thermostat housing (9) and

coolant hose from coolant expansion tank

(10) at radiator

Hexagon socket wrench

*WH58.30-Z-1001-06A

Hexagon socket wrench

*WH58.30-Z-1002-06A

14
Detach air guides (12)


Installation:
Replace fastening clamps

(13)

15
Unscrew bolts (16) at condenser (17) to

radiator

Avoid deformation of condenser lines.

Do not disconnect lines.

16
Remove attachment parts (20) and rubber

shock absorber (21)


Installation:
Ensure, that the rubber

shock absorbers do not drop when installing

the radiator.

Replace fastening clamps.

17
Take off fluid reservoir of AC (14) at radiator

Place to the side with lines connected.

External torx set

*001589760900

18
Remove bracket of charge air pipe at left

radiator

Installation:
Insert bracket of charge air

pipe into the bracket at the radiator.

19
Remove radiator (15)

Installation:
When installing, the mounting

studs of the radiator must be inserted into the

rubber grommets of the lower crossmember.

20
Install in the reverse order

21
Check headlamp adjustment, correct if

necessary

e

Check and correct headlamp adjustment

AP82.10-P-8260A

22
Inspect cooling system for leaks

AR20.00-P-1010HA

23
Fill power steering pump and bleed


Danger!

Risk of accident
caused by vehicle starting

off by itself 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

24
Run engine and inspect for leaks
Crankcase ventilation, cylinder head cover

Number

Designation
Engine

612.963

BA01.20-P-1002-01A
Bolt, cylinder head cover trim panel to

cylinder head cover
Nm
10

BA01.20-P-1003-01A
Bolt, cover panel to charge air distribution

pipe
Nm
10

Power steering pump

Number

Designation
Model

163.113

BA46.30-P-1012-01A
Banjo bolt, power steering oil line to radiator
Nm
30


Cooling system

Number

Designation
Engine

612.963

BF20.00-P-1001-02E
Cooling system
Total capacity
Liter
Y
11.0

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

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