1997 MERCEDES-BENZ ML430 cooling
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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
Page 3757 of 4133
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
Page 3761 of 4133
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
Page 3762 of 4133
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
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Page 3
Page 3771 of 4133
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
Page 3772 of 4133
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
Page 3773 of 4133
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
Page 3774 of 4133
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
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Page 4