1997 MERCEDES-BENZ ML430 coolant temperature

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

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

ENGINE 119.980 /981 /982 /985
ENGINE 137.970
Fig. 1: Identifying Electronic Accelerator Function

The function of the electronic accelerator pedal EFP in the ME control unit determines the opening angle of the
throttle valve over the actuator EFP/TPM/LLR (other designation: throttle valve actuator).
Further functions are:
Idle speed control [ISC]
Cruise control mode
Variable speed limiter
30 km/hour limit
Reduce/increase the engine torque for ASR/ESP operation
short performance limitation, for example for a higher coolant temperature
Emergency electronic accelerator pedal
Safety concept
Actuate indicator lamp EPC (up to 5/96)
Storing faults
Data exchanger via CAN

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY CAB Throttle Control, Speed Control Systems - 163 Chassis
me
Saturday, October 02, 2010 3:36:27 PMPage 2 © 2006 Mitchell Repair Information Company, LLC.

different engine loads, e.g. power steering turned to full lock, engaging drive mode, switching on AC
compressor
different mixture, e.g. from activated charcoal canister if purging activated (depending on activated
charcoal charge)
Function
The actuator EFP/TPM/LLR (additional designation: throttle valve actuator) regulates the idling speed by
changing the throttle valve position. It is actuated by the ME-SFI control unit.
The ME-SFI control unit actuates the throttle valve motor (M16/1 m1) in line with the input signals received at
the ME-SFI control unit (N3/10).
Heating speed of the catalytic converter
In order to warm up the catalytic converter more rapidly to operating temperature, engine speed is increased in
the idle speed range to 1100 up to 1500 rpm for about 20 seconds after each starting procedure at coolant
temperatures of < 40 °C. When a Drive position is engaged, engine speed is immediately controlled to a lower
value.
Automatic transmission
When a drive position is engaged, a lower engine speed is controlled in order to reduce the creeping tendency o
f
the vehicle. The information "Drive position engaged/not engaged" is transmitted by the ETC control unit
(N15/3) over the CAN databus to the ME-SFI control unit.
Ignition angle
To assist the idle speed control, the ignition angle can be retarded by as much as 36° crank angle or advanced by
as much as 20° crank angle from the calculated specified value.

The control in the idle speed range by altering the ignition angle reacts more rapidly than altering the position o
f
the throttle valve.
The idling speed can be influenced with HHT or the STAR DIAGNOSIS.
AC compressor
In order to avoid engine speed dropping in the idle speed range when the AC compressor is engaged, the AC
push-button control unit (N19) or automatic air conditioning push-button control unit (N22) supplies a signal to
the ME-SFI control unit (as of approx. 6/96 over CAN) and the opening cross-section of the throttle valve is
enlarged.
When the air conditionin
g unit is switched on and the external temperature exceeds 35° C the idling speed on

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY CAB Throttle Control, Speed Control Systems - 163 Chassis
me
Saturday, October 02, 2010 3:36:27 PMPage 17 © 2006 Mitchell Repair Information Company, LLC.

vehicles delivered from 6/00 is increased for the driving mode selected by about 100 rpm when the switch-on
threshold of about 900 rpm is exceeded. This increase is cancelled again when the external temperature drops
below 32° C.
Undervoltage
If the engine control unit detects an undervoltage the idling speed is increased until the ignition is switched off
for the driving mode selected by about 100 rpm.
If the control unit SBC reports an undervoltage to the engine control unit over CAN the idling speed for the
driving mode selected is increased to about 750 rpm.
Motor electronics control unit, location/task/
design/function GF07.61-P-
5000F
ME-SFI ignition system function GF15.12-P-
0001F
ECI ignition system functionEngine 137GF15.15-P-
3000L
Pedal value sensor, location/task/design/ function GF30.20-P-
4011L
Coolant temperature sensor, location/task/
design/function
Engine 119, 120GF07.04-P-
5026F
Engine 104, 111GF07.04-P-
5026G
Engine 112, 113, 137GF07.04-P-
5026A
Intake air temperature sensor, location/task/
design/function GF07.04-P-
2100F
ME fuel supply function
Engine 104, 111, 119, 120 in Model 129,
140, 170, 202, 208, 210GF07.61-P-
3004F
Engine 112, 113, 137 (except in Model
203, 209, 211)GF07.61-P-
3004A
Engine 112.91/94/95 203
Engine 112.91/94/95, 113.96 in Model
211
Engine 112.912/955, 113.968 in Model
209
GF07.61-P-
3004P
Crankshaft position sensor, location/task/
design/function GF07.04-P-
4116F
Electronic accelerator/cruise control/idle speed
control actuator location/task/design/function GF30.22-P-
4010F
Electronic accelerator pedal emergency running
mode functionEngine 120.98GF30.20-P-
4026F
Engine 104, 111, 112, 113, 119, 137GF30.20-P-
4026E

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY CAB Throttle Control, Speed Control Systems - 163 Chassis
me
Saturday, October 02, 2010 3:36:27 PMPage 18 © 2006 Mitchell Repair Information Company, LLC.

Fig. 13: Identifying Electronic Accelerator/Cruise Control/Idle Speed Control Actuator Components
Function
The actual value potentiometers for the throttle valve inform the ME control unit about the position of the
throttle valve (idling up to full load) in order to recognize the various loading conditions.
A.Ignition "Off"
In the de-energized state the throttle valve position is determined by the spring capsule (3).
B.Ignition "On"
When the ignition is switched on, the actuator motor in the EA/CC/ISC actuator is operated by the ME
control unit and the return spring is checked. The throttle valve adopts a position which then depends on
the coolant temperature.
C.Idle speed
The actuator motor controls the engine speed in the idle speed range by opening the throttle valve further,
depending on coolant temperature and engine load (increased mixture), or closing it further (reduced
mixture).
In this case, the throttle valve may be closed further by the actuator motor by overcoming the force of the
sprin
g capsule (mechanical end stop).

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY CAB Throttle Control, Speed Control Systems - 163 Chassis
me
Saturday, October 02, 2010 3:36:27 PMPage 21 © 2006 Mitchell Repair Information Company, LLC.