1997 MERCEDES-BENZ ML430 cooling

1
Open cooling system cap (2) on coolant

expansion reservoir (1)

Cap with detent:

Turn cap carefully as far as the first detent,

release pressure, and then unscrew cap.

2-stage and 1-stage cap: Rotate cap half

a revolution in a counterclockwise direction,

release overpressure, then unscrew cap.

2.1Remove engine compartment paneling
Models 129, 202, 208, 210

AR61.20-P-1105AB

Models 163.172/ 174/ 175

AR61.20-P-1105GH

Models 163.113/ 128

AR94.30-P-5400GH

Model 211

AR61.20-P-1105T

Models 215, 220

AR61.20-P-1105M

Model 230

AR61.20-P-1105R

2.2Remove underride guard
Only on model 463

3.1
Remove air guide
Only on model 163 with engine 113.942

4
Drain coolant

Model 163: For draining coolant, detach

bottom coolant line at radiator or at coolant

pump.

Collect coolant Observe regulations for

disposal of coolant.


Installation:
On model 163 replace
radiator connection of hose clamps to coolant

hose, otherwise this can cause a damage to

the bolt/thread.


Hose clamp

*BA20.20-P-1004-01A

Pouring in

5
Pour in coolant

All except engine 137

*BF20.00-P-1001-02K


Engine 137

*BF20.00-P-1001-02M


Notes on coolant level
Engines 112, 113, 137, 275, 285

AH20.00-P-1142-01V


Notes on coolant level
Model 163 with engines 111, 112, 113

AH20.00-P-1142-01GH

6
Bleed cooling system

Let engine run, put heater on full heat

output.

Except stationary heater, code 228

AR20.00-P-1142-06GA

With stationary heater code 228

7
Inspect cooling system for leaks

AR20.00-P-1010HA


Radiator, coolant hoses

Number

Designation
Engines

112.942/

970,

113.942/

965/981

BA20.20-P-1004-01A
Hose clamp
Nm
3

Designation
Engines

112.910 /920

in model 202,

112.940

in model 208
Engines

112.911/921/941

in model 210
Engines

112.922/944/972

in model 220

BF20.00-P-1001-02K
Cooling system
Total capacity
Liters
Y
9.5
Y
10.0
Y
10.5

Capacity of

anticorrosion/antifreeze agent

down to -37°C

Liters

Y
4.75
Y
5.0
Y
5.0

Capacity of anticorrosion/

antifreeze agent down

to -45°C

Liters

Y
5.25
Y
5.5
Y
5.5

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

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Cooling system

Number

Designation
Engines

112.923/943

in model 129
Engine

112.945 in

models 463.209/

232/233/244/
245/250
Engine 112.942

in models 163,

113.940/980

in models 210,

113.943/984

in model 208,

113.944

in model 202

BF20.00-P-1001-02K
Cooling system
Total capacity
Liters
Y
11.75
Y
11.5
Y
11.0

Capacity of

anticorrosion/antifreeze agent

down to -37°C

Liters

Y
6.0
Y
5.8
Y
5.5

Capacity of anticorrosion/

antifreeze agent down

to -45°C

Liters

Y
6.5
Y
6.4
Y
6.0

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
Engines

112.913/917/
949/954

in model 211
Engines

113.967/969

in model 211
Engine

113.990

BF20.00-P-1001-02K
Cooling system
Total capacity
Liters
Y
9.5
Y
10.75
Y
13.2

Capacity of

anticorrosion/antifreeze agent

down to -37°C

Liters

Y
4.75
Y
5.25

Y
6.6

Capacity of anticorrosion/

antifreeze agent down

to -45°C

Liters

Y
5.25
Y
6.0

Y
7.3

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
Engines

113.941/960

in models 215,

220
Engine

113.961

in model 129
Engine 113.962

in modeld

463.206/

240/241

/247/248 249/254

BF20.00-P-1001-02K
Cooling system
Total capacity
Liters
Y
11.5
Y
12.75
Y
12

Capacity of

anticorrosion/antifreeze agent

down to -37°C

Liters

Y
5.75
Y
6.25
Y6

Capacity of anticorrosion/

antifreeze agent down

to -45°C

Liters

Y
6.25
Y
7.0
Y
6,6

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

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Number
Designation
Engine 113.991

in model 215
Engines

113.960/
986

in model 215
Engine

112.973 in

model 230.467

BF20.00-P-1001-02K
Cooling system
Total capacity
Liters
Y
14.5
Y
11.5
Y
10.8

Capacity of

anticorrosion/antifreeze agent

down to -37°C

Liters

Y
7.3
Y
5.75

Y
5.4

Capacity of anticorrosion/

antifreeze agent down

to -45°C

Liters

Y8Y
6.25

Y6

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-0310-01A


Cooling system

Number

Designation
Engines

112.970

113.965

in model 163
ENgines

113.942/981

in model 163
Engine

113.982
in

models

463.241/243/246

BF20.00-P-1001-02K
Cooling system
Total capacity
Liters
Y
12.0
Y
11.5
Y
11.9

Capacity of

anticorrosion/antifreeze agent

down to -37°C

Liters

Y
6.0
Y
5.75
Y
5.95

Capacity of anticorrosion/

antifreeze agent down

to -45°C

Liters

Y
6.75
Y
6.25
Y
6.55

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
Engines

113.986/991

in model 220
Engines

113.948/966

in model 220
Engine

112.975

in model 220

BF20.00-P-1001-02K
Cooling system
Total capacity
Liters
Y
13.5
Y
11.6
Y
10.4

Capacity of

anticorrosion/antifreeze agent

down to -37°C

Liters

Y
6.8

Y
5.8
Y
5.2

Capacity of anticorrosion/

antifreeze agent down

to -45°C

Liters

Y
7.4

Y
6.4
Y
5.7

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-0310-01A


Cooling system

Number

Designation
Engine

113.968

in models 209,

211;

engine 113.969

in model 211

BF20.00-P-1001-02K
Cooling system
Total capacity
Liters
Y
11.5

Capacity of

anticorrosion/antifreeze agent

down to -37°C

Liters

Y
5.75

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Capacity of anticorrosion/

antifreeze agent down

to -45°C

Liters

Y
6.25

Specifications for Operating

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


Cooling system

Number

Designation
Engine

137.970

BF20.00-P-1001-02M
Cooling system
Total capacity
Liters
Y
12

Capacity of anticorrosion/

antifreeze agent down

to -37°C

Liters

Y6

Capacity of anticorrosion/

antifreeze agent down

to -45°C

Liters

Y
6.6

Specifications for Operating

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

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Page 5

AR20.00-P-1142M
Drain, pour in coolant
8.11.99

ENGINE
612.963 in MODEL 163.113

P20.20-2083-12

1
Front noise encapsulation bottom part

2
Radiator

3
Radiator drain tap

4
Siphon hose

Draining


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


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 assistant secure hood.

AR88.40-P-1000GI

2
Open cap of coolant expansion reservoir

Turn cap half a turn in the anti-clockwise

direction, release pressure, and then unscrew

cap.

3
Remove front noise encapsulation bottom

part (1)

4
Attach siphon hose (4) to drain connection of

radiator

5
Drain coolant at radiator (2) on right

To do this, turn drain tap (3) at radiator (2)

into position "1" (arrow).


Disposal of coolants.

Pay attention to legal provisions or local

wastewater regulations!

Refer to Environmental Protection Catalog

issued by MBVD/PWU for locations in

Germany.

6
Clean cooling and heating system

Clean cooling and heating system in case

of impurities. See

#

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

Pour in


Notes on coolant
All engines

AH20.00-N-2080-01A

7
Turn drain tap (3) at radiator (2) into position

"0" (arrow)

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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

8
Pour in coolant

Warm up engine by running at moderate

revs. Top up coolant constantly at coolant

expansion reservoir. Close coolant expansion

tank once

coolant temperature is 60-70 °C.

*BF20.00-P-1001-02E


Note on coolant level
Model 124, 129, 140, 163.113, 168, 170, 202,

208, 210, 220, 463

AH20.00-P-1142-01A

9
Inspect cooling system for leaks

AR20.00-P-1010HA


Cooling system

Number

Designation
Engine

612.963

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

Filling capacity of anticorrosion/

antifreeze agent down to

-37 °C
Liter
Y
5.5

Filling capacity of anticorrosion/

antifreeze up to -45 °C
Liter
Y
6.25

Specifications for Operating

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

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P01.30-0299-06

20
Bolts cylinder head
!
timing case cover

21
Cylinder head bolts

22
Cylinder head left

23
Cylinder head right

24
Left cylinder head gasket

25
Right cylinder head gasket

26
Dowel sleeves


Remove/Install

Notes on self-locking nuts and bolts
All models

AH00.00-N-0001-01A


External torx set

*001589760900

Torx bit set

*000589011000


Danger!

Risk of explosion
caused by oxyhydrogen

gas.
Risk of poisoning and caustic burns


caused by swallowing battery acid.
Risk of

injury caused by burns to skin and eyes from

battery acid or when handling damaged lead-

acid batteries
No fire, sparks, open flames or smoking.

Wear acid-resistant gloves, clothing and

safety glasses. Pour battery acid only into

suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1
Disconnect battery ground cable


Installation:
After connecting, read out

fault memory, encode radio and normalize

power windows.

Vehicles with stationary heater: Set time on

timer for stationary heater
AR54.10-P-0003A

Notes on battery
All models

AH54.10-P-0001-01A

Danger!

Risk of death

caused by vehicle slipping or

toppling off of the lifting platform.
Align vehicle between the columns of the

hydraulic hoist and position the four support

plates below the hoist support points specified

by the vehicle manufacturer.

AS00.00-Z-0010-01A

2
Place the vehicle on lifting platform

AR00.60-P-1000GH
3.1
Remove air guide (1)


Only with engine 113.942

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

4
Drain coolant

Remove coolant hose at bottom on

radiator.

AR20.00-P-1142HA

5
Remove engine cover

6.1
Remove viscous fan (2)

All except model 163.174 /175 with

engine 113.981 /965.

Right-hand thread!

AR20.40-P-5660C

7.1
Remove the fan shroud (3).

Only model 163.154 /157 /172. Unscrew

bolts (4) from bottom of fan shroud

7.2
Remove electric fan

Only model 163.174/ 175.

AR20.40-P-5000GH

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29
Slacken cylinder head bolts (21) in stages,

unscrew

Loosen cylinder head bolts according to
loosening schematic only after engine has

cooled down to prevent cylinder head from

distorting.

AR01.30-P-5800-09B


Installation:
Observe tightening pattern

and tightening instructions of cylinder head

bolts.
Oil thread and head contact surface of

cylinder head bolts.
AR01.30-P-5800-07B

Screwdriver insert

*000589031000

Screwdriver insert

*000589041000


*BA01.30-P-1001-01D

30
Remove cylinder head


Installation:

On Engine 112/113 observe

porous points in the left and right cylinder

head. If porous points are present, sealant

must be applied to the cylinder head gasket.


Notes on application of sealant to cylinder

head gasket.
Engine 112, 113

AH01.30-P-1000-04VA

The sealant must be applied within

10 minutes.

Loctite 5900 sealant.

*BR00.45-Z-1015-01A

31
Inspect version of cylinder head gasket
Assignment of cylinder head gasket


Information for assigning the cylinder head

gaskets
Engine 112, 113

AH01.30-P-1000-06V

32
Check cylinder head bolts (21)


AR01.30-P-5800-03B

*BE01.30-P-1001-04B

33
Clean sealing surfaces, inspect for cracks,

shrink holes and flatness, clean threaded

holes.

Pay attention to dowel sleeves (26) for

locating the cylinder head.

Sealing surfaces of crankcase and

cylinder head are provided with an 0.8 mm

thick silicone layer during series production.

At the time of repair installation, silicone

sealant is applied to the sealing area only in

case of any shrink holes.

The sealant must be applied within

10 minutes.

Loctite 5900 sealant.

*BR00.45-Z-1015-01A

34
Install in the reverse order

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

35
Run engine and inspect for leaks

36
Inspect cooling system for leaks

Warm up engine to operating temperature

and then inspect cooling system or leaks.

AR20.00-P-1010HA

37
Read out and erase fault memory

Stored faults which can result from cables

being disconnected or from simulation during

removal and installation or test work, have to

be processed and erased in the fault

memories after completing the work:

#

Diagnosis Manual Volume 2 Index 0:

Connecting and using test equipment.

Cylinder head/cylinder head bolts

Number

Designation
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
Engine

113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/965/966/
967/968/969/
980/981/982/
984/986/987/
988/990/991/

992/993

BE01.30-P-1001-04B
Cylinder head bolt
Thread diameter
M
1111

Length (L) when new
mm
141.5141.5

Length (L)
mm
T
144.5
T
144.5

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Page 5