MERCEDES-BENZ ML430 1997 Complete Repair Manual

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
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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

112 589 01 09 00110 589 01 01 00

Double open-end wrench
Spark plug wrench

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

AR40.10-P-1030A
Replace tire
27.1.95

MODELS
124, 129, 140, 163, 168, 170, 171, 202, 203, 208, 209, 210, 211, 215, 220, 230, 240

MODEL
414

P40.10-0218-01
P40.10-0217-01
P40.10-0219-01 P40.10-0220-01


Detaching


Models 163, 170, 171, 203, 211, 230
: The

spare wheel with collapsible tire is only

available as an assembly component. The

spare wheel with collapsible tire can only be

replaced complete. If the spare wheel is

damaged, remove the collapsible tire and

dispose of it and the rim separately.


Observe notes on tires and rims
Models 124, 129, 140, 163, 168, 170, 171,

201, 202, 203, 208, 209, 210, 211, 215, 220,

230, 240, 414

AH40.10-P-9411-01A

1
Unscrew valve element from valve (43g) and

remove balance weights (43a)

Do
not
unscrew valve element on disk

wheels with tire pressure monitor sensor.


Assembly tool

*124589176300

Removal tool

*129589005900

2.1
Drain tire sealant from tire.

On tires which have been filled with

TIREFIT tire sealing agent:

#

AR40.10-P-1080A

Replace wheel sensor

AR40.15-P-0080A

3
Position pressing-off blade of tire installer on

the tire bead opposite the valve (43g)

Do not position on the tire side wall, but

on the bead flank, otherwise the carcass will

be damaged.

Wheels with wheel sensors:
Do
not


position press-off blades on both sides of the

rim in the area of the valve (43g), otherwise

the wheel sensor will be damaged.

4
Press inside and outside of tire over the

safety bead seat on the rim

5
Clamp the rim on the tire installer. Coat the

rim flange and tire bead with soapy water.

Align mounting head close to disk wheel (X, Y)

Only use soapy water for fitting and

removing tires.

6
Position the disk wheel so that the valve (43g)

is approx. 10 cm in front of the assembly

head, seen in the direction of rotation of the

tire mounting device

7
Lever tire bead with a tire iron over the

mounting lug and pull off the tire

Do not apply compressive force to the

wheel sensor otherwise it will be damaged.

Copyright DaimlerChrysler AG 06.07.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

8.1
Check wheel sensor, valve body and sealing

rubber for damage
Vehicles with tire pressure monitor (code 475)

Do not remove wheel sensor for this.


Do not use compressed air, solvents or

detergents to clean the wheel sensor. Wipe

off dirt with a clean, lint-free cloth only.

Do not retighten the female torx bolt and

union nut.

Replace all valve components of wheel

electronics if:
D
The wheel sensor mounting bolt or union

nut is visibly loose.

Replace the wheel sensor if:

D
The wheel sensor is obviously damaged.

D
Tire sealant was used.

Install new wheel sensors:

#

Replace wheel sensor.

AR40.15-P-0080A

8.2
Install new valve (43g).
Vehicles without tire pressure monitor (code

475)

9
Checking condition of rim

AR40.10-P-1010-01A


Mounting

10
Moisten rim flange and tire beads with soapy

water and align assembly head at a small

distance (X, Y) to the disk wheel

Only use soapy water for fitting and

removing tires.

11
Place tire obliquely on the rim and pull on

over the rim flange using the tire installer


Position wheels with wheel sensors so

that the wheel sensor is approximately 180°

opposite the mounting head.

Do not apply compressive force to the wheel
sensor otherwise it will be damaged.


Observe the running direction on tires with

specified running direction.


Put as little stress as possible on bead

area.

12
Align the match points of the tire and disk

wheel with each other and remove the disk

wheel with tire from the tire mounting device

13
Inflate tires without valve element up to max.

3 bar

Do
not
unscrew valve element on disk

wheels with tire pressure monitor sensor.

The tire must slide evenly over the safety

shoulders of the disk wheel, otherwise coat

the tire beads with soapy water again.

14
Screw the valve element into the valve (43g)

and adjust the tire inflation pressure to the

specified value

Observe the tire pressure information in

the fuel filler flap of the vehicle.

15
Balance wheel

AR40.10-P-1040A

124 589 17 63 00 129 589 00 59 00

Removal tool

Assembly tool

Copyright DaimlerChrysler AG 06.07.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

AZ88.30- P- 0007GH Retrofit fender flares 20.9.01
MODEL 163.113 / 154 #A as of 289565,
163.113 #X as of 754620,
163.128 / 175 except CODE (U49) Styling package
3 Fender flare4 Rear bumper adapter
5 Rocker panel adapter
P88.30- 2205- 06
P88.30- 2206- 01 P88.30- 2207- 01 P88.30- 2208- 01Front fender flare Rear fender flare Rear bumper adapter
Left illustration
Rocker panel adapter, front
Right illustration
Rocker panel adapter, rear
P88.30- 2209- 01 P88.30- 2210- 01
 Install
 If primed parts are ordered, drying temperature
after painting should NOT exceed 75 °C.
 NOT
Do install adapters on rocker panel cover if
vehicle is equipped with running boards, side
bars, or side step bars.
 Each accessory panel is marked for correct
LH Front RH
location: " , ", etc.
1 Clean front surface, outer lip, and inner lip of
fender inside wheelhouse
2 Clean front and rear ends of rocker panel coverand front corners of rear bumper
3 Mark (1) center of attachment clip (2) mounting  Mark outer surface of panels so that mark
points on each fender flare (3), rear bumper is visible when panel is in installed position. Front
adapter (4), and rocker panel adapter (5) not
rocker panel adapters are secured with a
clip.
az8830p0007gh Retrofit fender flares
Page 1 of 3

4 Place fender flare (3) into position on fender
 Align fender flare properly on fender: Flare
should match contours of body.
5 Mark alignment position of fender flare on fender
surface and fender flare
6 Mark attachment clip (2) positions on outer lip of
 Use marks on fender flare for reference.
fender inside wheelhouse
7 Remove adhesive cover from provided anti-
 4 anti- corrosion plates (6) for each fender
corrosion plates (6) and adhere plates to inner lip
flare. Align center of plates to clip position
of fender
marks on outer lip of fender.
8 Peel back 50 mm of cover from adhesive strip
on inside of fender flare (3)
9 Place fender flare (3) into proper position on
 Align fender flare with marks.
fender
10 Peel remaining cover from adhesive strip on

Ensure fender flare remains in proper
inside of fender flare and press fender flare
position.
firmly onto fender
11 Secure fender flare (3) to fender with provided
 4 attachment clips (2). Ensure correct
attachment clips (2)
positioning of clips: align with marks. Ensure
clips attach to pocket on inside of fender flare
and anti- corrosion plate (6) on inner lip of fender.
Clip should NOT touch vehicle paint.
12 Repeat for each fender flare (3)
 Worksteps 3 - 11.
13 Place rear bumper adapter (4) into position on
 Align adapter properly on bumper: Adapter
rear bumper
should match contours of bumper.
14 Mark attachment clip (2) positions on outer lip of
 Use marks on adapter for reference.
rear bumper
15 Remove adhesive cover from provided anti-
 2 anti- corrosion plates (6) for each bumper
corrosion plates (6) and adhere plates to inner lip
adapter. Align center of plates to clip position
of bumper
marks on outer lip of bumper.
16 Peel back 20 mm of cover from adhesive strip
on inside of rear bumper adapter (4)
17 Place rear bumper adapter (4) into proper
position on rear bumper
18 Peel remaining cover from adhesive strip on

Ensure bumper adapter remains in proper
inside of rear bumper adapter (4) and press
position.
adapter firmly onto bumper
19 Secure rear bumper adapter (4) to rear bumper
 2 attachment clips. Ensure clips attach to
with provided attachment clips (2)
pocket on inside of bumper adapter and anti-
corrosion plate (6) on inner lip of bumper.
20 Repeat for other rear bumper adapter (4)
 Worksteps 13 - 19.
21 Place rocker panel adapter (5) into position on
 Align adapter properly on rocker panel
rocker panel cover
cover: Adapter should match contours of cover
and align with bottom edge of fender flare.
22 Mark attachment clip (2) positions on outer lip of
rear
Only for rocker panel adapters. Use
rocker panel cover
marks on adapter for reference.
23 Remove adhesive cover from provided anti-
 Only for rear rocker panel adapters.
corrosion plate (6) and adhere plate to inner lip of
1 anti- corrosion plate (6) for each rocker panel
rocker panel cover
adapter. Align center of plate to clip position
mark on outer lip of rocker panel cover.
24 Peel back 20 mm of cover from each adhesive
strip on inside of rocker panel adapter (5)
25 Place rocker panel adapter (5) into proper
position on rocker panel cover
26 Peel remaining cover from each adhesive strip
 Ensure rocker panel adapter remains in
on inside of rocker panel adapter and press
proper position.
adapter firmly onto rocker panel cover
27 Secure rocker panel adapter (5) to rocker panel
 Only for rear rocker panel adapters. Use
cover with provided attachment clip (2)
mark on adapter for proper placement of
attachment clip in pocket on inside of adapter.
Front rocker panel adapters are NOT secured
with a clip.
28 Repeat for each rocker panel adapter (5)
 Worksteps 21 - 27.
Parts ordering notes
Part no. DesignationQuantity
B6 688 0800 Fender flares, primed1B6 688 0801 Fender flares, black1B6 688 0802 Fender flares, brilliant silver1B6 688 0803 Fender flares, bordeaux red1B6 688 0804 Fender flares, alabaster white1
B6 688 0805 Fender flares, black opal1B6 688 0806 Fender flares, tansanite blue1B6 688 0807 Fender flares, jaspis blue1
B6 688 0808 Fender flares, desert silver1B6 688 0809 Fender flares, andradite green1B6 688 0816 Adapter kit for fender flares, primed1B6 688 0817 Adapter kit for fender flares, black1B6 688 0818 Adapter kit for fender flares, brilliant silver1
az8830p0007ghRetrofit fender flares Page 2 of 3