oil temperature MERCEDES-BENZ ML320 1997 Complete Repair Manual

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

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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

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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

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AR91.40-P-0630GH
Remove/install seat belt with emergency tensioning retractor
26.3.97

MODEL
163.113 /128 /136 /154 /157 /172 /174 /175

P91.40-0374-09

1
Cap

2
Bolt

3
Outer paneling
7

Automatic belt retractor

R12/2
Passenger ETR [GUS] ignition

squib

4

Belt end fitting

5
Screw

6
Screw


Remove/Install

Danger!

Risk of injury
when carrying out test or repair

work on airbag or emergency tensioning

retractor units
Store airbag unit with expulsion area on top,

do not subject to temperatures above 100 °C.

Interrupt power supply when working on such

units.

AS91.00-Z-0001-01A

Danger!

The spring in the inertia reel can pose an

injury hazard
when the tension is released

and it uncoils.
Never disassemble inertia reels

AS91.00-Z-0002-01A


Important instructions for performing repair,

body work and welding on vehicles with

airbags or belt tensioner units
Models 129 as of 1.7.93, 163, 168, 170, 202

as of 1.7.93, 208, 210, 414, 638, 690.6, 901,

902, 903, 904, 905

Model 461 with engine 602.983

Model 463 up to 30.11.00

MODELS WD141, WD241, WD341, WD641,

WD741, XD141, XD241, XD341, XD441,

XD541, XD641, XD741, YD141, YD241,

YD341, YD441, YD541, YD641, YD741

AH91.00-P-0002-01B


Evaluation of airbags and emergency

tensioning retractors on accident vehicles
Model 129 as of 1.7.93, 163, 168, 170, 202 as

of 1.7.93, 203, 208, 209, 210,

211.004/006/016/061/065/070, 215, 220, 230,

240, 414, 463, 638, 901, 902, 903, 904,905

Models WD141, WD241, WD341, WD641,

WD741, XD141, XD241, XD341, XD441,

XD541, XD641, XD741, YD141, YD241,

YD341, YD441, YD541, YD641, YD741

AH91.00-P-0006-01B


Legal regulations concerning the handling

and storage of airbag and emergency

tensioning retractors
Models 124, 129, 140, 163, 168, 170, 202,

203, 208, 209, 210,

211.004/006/016/061/065/070, 215, 220, 230,

240, 314, 316, 318, 414, 461, 463, 638, 668,

670, 690.6, 901, 902, 903, 904, 905, 950,

952, 953, 954, 970, 972, 974, 975, 976

Models WD141, WD241, WD341, WD641,

WD741, XD141, XD241, XD341, XD441,

XD541, XD641, XD741, YD141, YD241,

YD341, YD441, YD541, YD641, YD741

AH91.00-P-0004-01A

o

Notes on disposal of airbags and emergency

tensioning retractors
All models

OS91.00-P-0001-01A


Render emergency tensioning retractors

unusable

AR91.40-P-0611A

1
Move front seat forwards to the full extent, tilt

front seat backrest forwards

See owner's manual.

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AR91.40-P-0681GI
Remove/install rear seat belts
16.4.99

MODEL
163.136 /154 /172 as of 1.9.99,

163.113 /128 /157 /174 /175

1
Bolt

2
Seat belt guide bracket

3
Bolt

4
Automatic belt retractor

5
Belt height adjuster

R12/7
Right rear ETR ignition squib

P91.40-2114-03


Remove/Install

Danger!

Risk of injury
when carrying out test or repair

work on airbag or emergency tensioning

retractor units
Store airbags with exit surface pointing

upward, do not expose to temperatures above

100 °C. Interrupt power supply when working

on such units.

AS91.00-Z-0001-01A

Danger!

The spring in the inertia reel can pose an

injury hazard
when the tension is released

and it uncoils.
Never disassemble inertia reels

AS91.00-Z-0002-01A


Important instructions for performing repair,

body work and welding on vehicles with

airbags or belt tensioner units
Models 129 as of 1.7.93, 163, 168, 170, 202

as of 1.7.93, 208, 210, 414, 638, 690.6, 901,

902, 903, 904, 905

Model 461 with engine 602.983

Model 463 up to 30.11.00

MODELS WD141, WD241, WD341, WD641,

WD741, XD141, XD241, XD341, XD441,

XD541, XD641, XD741, YD141, YD241,

YD341, YD441, YD541, YD641, YD741

AH91.00-P-0002-01B


Evaluation of airbags and emergency

tensioning retractors on accident vehicles
Model 129 as of 1.7.93, 163, 168, 170, 202 as

of 1.7.93, 203, 208, 209, 210,

211.004/006/016/061/065/070, 215, 220, 230,

240, 414, 463, 638, 901, 902, 903, 904, 905

Models WD141, WD241, WD341, WD641,

WD741, XD141, XD241, XD341, XD441,

XD541, XD641, XD741, YD141, YD241,

YD341, YD441, YD541, YD641, YD741

AH91.00-P-0006-01B


Legal regulations concerning the handling

and storage of airbag and emergency

tensioning retractors
Models 124, 129, 140, 163, 168, 170, 202,

203, 208, 209, 210,

211.004/006/016/061/065/070, 215, 220, 230,

240, 314, 316, 318, 414, 461, 463, 638, 668,

670, 690.6, 901, 902, 903, 904, 905, 950,

952, 953, 954, 970, 972, 974, 975, 976

Models WD141, WD241, WD341, WD641,

WD741, XD141, XD241, XD341, XD441,

XD541, XD641, XD741, YD141, YD241,

YD341, YD441, YD541, YD641, YD741

AH91.00-P-0004-01A

o

Notes on disposal of airbags and emergency

tensioning retractors
All models

OS91.00-P-0001-01A


Render emergency tensioning retractors

unusable

AR91.40-P-0611A

1
Withdraw ignition key

2
Remove paneling on C-pillar

AR68.30-P-4490GH

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AD54.30-P-5000-03A
Directly controlled display instruments

troubleshooting chart IC

Directly controlled display instruments or indicator

lamp/warning message:

D
Outside temperature indicator

D
Fuel gauge

D
Oil pressure gauge (models 129 and 140 only)

D
Left turn signal indicator lamp

D
Right turn signal indicator lamp

D
High beam indicator lamp

D
Fuel reserve indicator lamp

D
Airbag SRS indicator lamp/MIL

D
AIRBAG OFF indicator lamp (only model 163 except

I )
D
Low brake fluid level/parking brake indicator lamp (only brake

fluid direct)

(both functions via CAN on model 163)

D
Low windshield washer fluid level indicator lamp (except

models 163 and 168)
D

Low ECL indicator lamp (except models 163 and 168)

D
Generator charge indicator lamp

D
Seat belt reminder lamp

D
Seat belt/backrest lock reminder lamp

D
Exterior lamp failure indicator lamp

D
Hydraulic fluid level indicator lamp (models 202 and 210 only)

D
ADS MIL, suspension

D
Turn signal clicking

D
Seat belt reminder lamp

D
Light reminder lamp

D
Key reminder lamp

D
Soft top reminder lamp (model 170 only)

D
Steering lock warning lamp (

I )

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AD54.30-P-5000-02A
Display instruments controlled via CAN

troubleshooting chart IC

The following display instruments or indicator lamps/ malfunction

indicator lamps receive their information from the traction system

control module (N47) via CAN data buses (an appropriate message

appears in the display on vehicles with multi-function display):

D
Total mileage recorder, trip odometer

D
Electronic speedometer

D
Low brake fluid level/parking brake indicator lamp (except model 163

parking brake indicator lamp only via CAN)

D
Brake pad wear indicator lamp

D
ABS MIL

D
ETS, ASR, ESP indicator lamp

D
ETS, ASR, ESP malfunction indicator lamp

Model 163 only:

The
"Low-Range"
indicator lamp receives its information from the

transfer case control module (N78) via CAN data buses.

The
"Fog lamps"
indicator lamp (only model 163 except

I
) receives

its information from the All-activity module (AAM, N10) via CAN data

buses.

Model 168 only:

The
" Gear indicator "
indicator lamp receives its information from the

gear recognition module (A61) or from automatic clutch control module

(N15/4) via CAN data buses.
The following display instruments or indicator lamps/

malfunction indicator lamps receive their information from the

injection system control module (N3) via CAN data buses (an

appropriate message appears in the display on vehicles with

multi-function display):

D
Tachometer

D
Low engine oil level lamp

D
Engine coolant temperature

D
Preglow indicator lamp (diesel only)

D
Vehicle speed warning

D
Vehicle speed limit warning

D
Severe leak warning (

I
only), the fuel reserve indicator lamp

(A1e4) flashes

D
Active Service System (ASSYST):

D
Oil condition

D
Oil level

D
Oil temperature

D
Mass volumetric efficiency (load moment)

D
Engine speed, engine coolant temperature

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BB00.40-P-0224-01A
Viscosity classes of engine oils (car engines)
Passenger vehicle engines

(BR 100, BR 200, BR 600)

Commercial vehicle engines from the
passenger vehicle sector

(BR 100, BR 200, BR 600)

Industrial engines from the passenger

vehicle sector (BR 100, BR 200, BR 600)

Sheet 224.1

P00.40-0210-11

A precise application of the SAE grades in accordance with ambient

air temperatures would require more frequent engine-oil changes.

The temperature limits for the SAE grades should therefore be

regarded as guidelines, which can be exceeded or undercut for a

short duration.

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