radiator MERCEDES-BENZ ML320 1997 Complete Service Manual

15
Adjust gap dimensions
Gap dimensions

*BE60.00-P-1001-01D

Feeler gage

*129589032100

16
Align engine hood catch upper section (5)

centered in longitudinal and transverse
direction to engine hood catch lower section

and tighten


*BA88.40-P-1004-01C

17
Ensure that engine hood catch catches

properly

For this purpose, close engine hood and

pull upward with a jerk.

18
Release engine hood and ensure that safety

hook catches on radiator crossmember

19
Close engine hood (2)

Test and adjustment values, gap dimensions at hoods, doors and covers

Number

Designation
Model 163

BE60.00-P-1001-01D
Gap

dimension
Engine hood to fender
Dimension "A"
mm
5.0 (
F
0.5)

Engine hood to headlamp
Dimension "R"

mm
5.0 (
F
0.5)

Engine hood to radiator grille

Dimension "O"

mm
5.0 (
F
0.5)

Radiator grill to headlamp
Dimension "N"

mm
-

Fig., see
AR60.00-P-0700-

01GH


Engine hood

Number

Designation
Model 163

BA88.40-P-1001-01C
Bolt, engine hood hinge on engine hood
Nm
10

BA88.40-P-1002-01C
Nut, engine hood hinge to body
Nm
18

BA88.40-P-1004-01C
Bolt, engine hood catch upper section to engine

hood
Nm
12

129 589 03 21 00

Feeler gage

Auxiliary repair materials

Number

Designation
Order number

BR00.45-Z-1004-01A
MB body sealant for sealing seams (suitable for painting)
001 989 63 20

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d by Modification services.
Page 2

15
Adjust gap dimensions
Gap dimensions

*BE60.00-P-1001-01D

Feeler gage

*129589032100

16
Align engine hood catch upper section (5)

centered in longitudinal and transverse
direction to engine hood catch lower section

and tighten


*BA88.40-P-1004-01C

17
Ensure that engine hood catch catches

properly

For this purpose, close engine hood and

pull upward with a jerk.

18
Release engine hood and ensure that safety

hook catches on radiator crossmember

19
Close engine hood (2)

Test and adjustment values, gap dimensions at hoods, doors and covers

Number

Designation
Model 163

BE60.00-P-1001-01D
Gap

dimension
Engine hood to fender
Dimension "A"
mm
5.0 (
F
0.5)

Engine hood to headlamp
Dimension "R"

mm
5.0 (
F
0.5)

Engine hood to radiator grille

Dimension "O"

mm
5.0 (
F
0.5)

Radiator grill to headlamp
Dimension "N"

mm
-

Fig., see
AR60.00-P-0700-

01GH


Engine hood

Number

Designation
Model 163

BA88.40-P-1001-01C
Bolt, engine hood hinge on engine hood
Nm
10

BA88.40-P-1002-01C
Nut, engine hood hinge to body
Nm
18

BA88.40-P-1004-01C
Bolt, engine hood catch upper section to engine

hood
Nm
12

129 589 03 21 00

Feeler gage

Auxiliary repair materials

Number

Designation
Order number

BR00.45-Z-1004-01A
MB body sealant for sealing seams (suitable for painting)
001 989 63 20

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

AR88.40-P-3100GH
Remove/install control cable for engine hood
5.5.00

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

P88.40-2140-06

Illustrated up to VIN A145272, X708318

1
Clips

2
Rubber grommet

3
Engine hood control cable


Removing and installing

1
Open engine hood and raise to vertical position
Up to VIN A145272, X708318.

AR88.40-P-1000GH

As of VIN A145273, X708319.

AR88.40-P-1000GI

2.1
Remove upper frame cross member
Only up to VIN A145272, X708318

AR62.30-P-2300GH
2.2Remove engine hood lock
Only as of VIN A145273, X708319.

AR88.40-P-3200GI

3.1
Unhook engine hood control cable from clip at

bottom of radiator cross member
Only as of VIN A145273, X708319.

4
Remove cover from fuse and relay box

5 screws.

5
Unhook clips (1) from body

6
Remove left cover below instrument panel
Left hand drive vehicle.

AR68.10-P-1500GH

Vehicles with right-hand steering up to

VIN A145272, X708318.

AR68.10-P-1520GH

Vehicles with right-hand steering as of

VIN A145273, X708319.

AR68.10-P-1520GI

7
Remove paneling in left footwell

AR68.30-P-4010GH

8
Unhook engine hood control cable at side at

clip in footwell

9
Remove rubber grommet (2) from fuse and

relay box

10
Pull out engine hood control cable (3) through
firewall on engine side and remove


Installation:
Ensure that engine hood

control cable is routed cleanly along fuse and

relay box.

11
Install in the reverse order

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Page 1

AR88.40-P-3200GI
Remove/install engine hood lock
9.4.99

MODEL
163.136 /154 /172 #A as of 145273,

163.136 /154 /172 #X as of 708319,

163.113 /128 /157 /174 /175

P88.40-2058-06

1
Screws

2
Engine hood lock bottom section

3
Engine hood control cable

4
Electrical connector

5
Screws

6
Engine hood lock top section


Removing and installing

1
Open engine hood and raise to vertical position

AR88.40-P-1000GI

2
Unscrew screws (1) and remove engine hood

lock bottom section (2) upward


*BA88.40-P-1003-01C

3.1
Disconnect electrical connector (4) from

engine hood lock bottom section (2)

Only when equipped with
ATA
.
4
Unhook engine hood control cable (3) from

engine hood lock bottom section (2)

Pull out engine hood control cable slightly.

5
Remove engine hood lock bottom

section (2)


Installation:
Ensure that engine hood

control cable is routed carefully.

6
Unscrew screws (5) and remove engine hood

lock top section (6)

Mark installation position for engine hood

lock top section on engine hood.


*BA88.40-P-1004-01C

7
Install in the reverse order

8
Check alignment of engine hood

If necessary:
#

Adjust engine hood

AR88.40-P-3020GH

9
Lubricate engine hood lock

e

Lubricate hood lock, safety hook and hinges

AP88.40-P-8821GH

10
Perform function check

11
Check function of safety hook

For this purpose, close engine hood,

unlock and check arrest on radiator cross

member.


Engine hood

Number

Designation
Model 163

BA88.40-P-1003-01C
Screw for engine hood lock on radiator cross

member
Nm
12

BA88.40-P-1004-01C
Screw for engine hood lock top section on engine

hood
Nm
12

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1

AR88.40-P-3200GH
Removing and installing engine hood lock
8.4.99

MODEL
163.136 /154 /172 up to 31.8.99

P88.40-2054-06

1
Screw

2
Bottom section of engine hood lock

3
Engine hood control cable mount

4
Screw

5
Upper section of engine hood lock with

safety hook


Removal, installation

1
Open engine hood and position upright
Up to 08.99

AR88.40-P-1000GH

As of 09.99

AR88.40-P-1000GI

2
Unscrew screws (1) and remove upper

section of engine hood lock (2) upward

*BA88.40-P-1003-01C

3
Remove release lever on inside of vehicle

and unhook engine hood cable from lever

4
Unhook engine hood cable from bottom
section of engine hood lock (2)


Pull engine hood cable out slightly. Press

holder (3) on engine hood cable carefully off

engine hood lock.

5
Remove bottom section of engine hood lock (2)


Installation:
Ensure that engine hood

cable is routed carefully.

6
Unscrew screws (4) and remove upper

section of engine hood lock (5)

Mark installation position of upper section

of engine hood lock on engine hood.


*BA88.40-P-1004-01C

7
Install in opposite order

8
Lubricate engine hood lock

e

AP88.40-P-8821GH

9
Check for proper function

10
Check safety hook for proper function

For this purpose, close engine hood,

release and check arrest on radiator cross

member

11
Check engine hood fit
If necessary
#

Adjust engine hood

AR88.40-P-3020GH

Engine hood

Number

Designation
Model 163

BA88.40-P-1003-01C
Screw for engine hook lock on radiator cross

member
Nm
12

BA88.40-P-1004-01C
Screw for engine hood lock upper section on

engine hood
Nm
12

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1

A/C housing. Disconnect control module connector. To install reverse removal procedure. Recode 5-digit radio
security code. Using HHT, check for DTC and erase, and set clock.
A/C PUSH BUTTON CONTROL PANEL
Removal & Installation
1. Obtain 5-digit radio security code from vehicle owner. Disconnect negative battery cable. Using radio
removal plates, remove radio. Disconnect electrical connectors.
2. Remove instrument panel center section. Remove 4 A/C control panel screws and remove control panel.
Release pull cables and disconnect connectors. To install, reverse removal procedure. Recode radio. See
RECODING RADIO
under PROGRAMMING.
BLOWER MOTOR
Removal & Installation
Remove passenger-side instrument panel under cover. Remove blower motor mounting screws from A/C
housing unit. Disconnect blower motor connector and remove blower motor. To install, reverse removal
procedure.
COMPRESSOR
Removal & Installation
1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove accessory
drive belt. Disconnect low pressure refrigerant line from compressor. Discard "O" rings. Plug exposed
openings to protect A/C system from debris and moisture.
2. Disconnect high pressure refrigerant line from compressor. Discard "O" rings. Plug exposed openings to
protect A/C system from debris and moisture. Disconnect electrical connector. Remove compressor
mounting bolts.
3. Raise and support vehicle. Remove compressor from under vehicle without spilling refrigerant oil. To
install, reverse removal procedure. Ensure refrigerant oil quantity in compressor is correct. See
COMPRESSOR REFRIGERANT OIL CHECKING under GENERAL SERVICING. Tighten bolts to
specification. See TORQUE SPECIFICATIONS
.
CONDENSER
Removal & Installation
1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove cooling fans.
See COOLING FANS
. Disconnect refrigerant line from receiver-drier. See Fig. 5 . Discard "O" rings.
2. Plug exposed openings to protect A/C system from debris and moisture. Remove refrigerant line from
condenser. Remove radiator upper rubber seal. See Fig. 6
. Remove condenser upper mounting screws.
Lift condenser upward and remove. NOTE: Each time A/C compressor is removed and installed, receiver-drier must be
replaced.

2001 Mercedes-Benz ML320
2000-01 MANUAL A/C-HEATER SYSTEMS ML 320, ML 430 & ML 55
me
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Fig. 6: Removing Cooling Fans & Condenser
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
COOLING FANS
Removal & Installation
Remove headlight units. Remove upper frame crossmember, release hood release control cable and remove
crossmember. See Fig. 6
. Remove 2 cooling fans frame bolts on radiator. Disconnect cooling fan connector.
Release outside temperature sensor wiring harness. Pull up on cooling fan and remove. To install, reverse
removal procedure. Ensure cooling fan bottom guides are properly seated in lower mounts.
EVAPORATOR
Removal & Installation
Remove A/C housing unit. See A/C HOUSING UNIT . Remove expansion valve. See Fig. 5 . Discard "O"
rings. Disassemble A/C housing unit. Remove evaporator. Remove evaporator temperature sensor. To install,
reverse removal procedure. Use NEW "O" rings lubricated with refrigerant oil. If installing a new or repair
evaporator, add 1.35 ounces of NEW refrigerant oil to evaporator.
EXPANSION VALVE
Removal & Installation
1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Without disconnecting
coolant hoses, remove coolant expansion reservoir and set aside. Remove refrigerant line bracket and
loosen clamps. See Fig. 5
. Pull refrigerant lines out of expansion valve.
2. Remove expansion valve self-locking nut and discard. Remove expansion valve. Discard "O" rings. To
install, reverse removal procedure. Use NEW "O" rings lubricated with refrigerant oil. Tighten NEW self-
locking nut to specification. See TORQUE SPECIFICATIONS
.
INSTRUMENT PANEL & INSTRUMENT PANEL CARRIER
Removal & Installation
1. Secure vehicle against rolling. Set transmission selector to "D" position. Obtain radio security code.
Disconnect negative battery cable. Remove driver-side air bag.
2. Place match marks on steering wheel and steering shaft. Remove steering wheel, upper steering column
covers and combination switch. Remove instrument cluster cover frame. Remove one instrument panel
lower section bolt.
3. Remove screws in footwell from left side of instrument panel bottom section. Remove instrument panel
center section. Remove 4 A/C control panel screws and remove control panel. See Fig. 1
. Release pull
cables and disconnect connectors.
4. Remove screws from center section. Remove glove box. Remove screws in footwell from right side of
instrument panel bottom section. Remove entry courtesy lights. Remove end covers and screws.
5. Release 4 "A" clips between instrument panel bottom section and upper section. See Fig. 7
. Release
parkin
g brake release cable from handle. With assistance, remove instrument panel bottom section.

2001 Mercedes-Benz ML320
2000-01 MANUAL A/C-HEATER SYSTEMS ML 320, ML 430 & ML 55
me
Saturday, October 02, 2010 3:25:10 PMPage 21 © 2006 Mitchell Repair Information Company, LLC.

HEATER CIRCUIT FUNCTION - GF83.20-P-2003GH
MODEL 163
Fig. 33: Identifying Heater Circuit Function

Function
The coolant pump (5) pumps cold coolant through the engine. The coolant absorbs the engine's heat and
becomes heated. The heated coolant is then conducted through the heat exchanger (2). The air blowing by the
heat exchanger (2) is heated and conducted into the vehicle interior.
The coolant is routed over the coolant return (A) and the heating water circulation pump (6) back to the coolant
pump (5).
By far the greater percentage of the coolant does not flow through the heat exchanger (2), but from the engine to
the coolant thermostat (4). Depending on the water temperature, this conducts the water through the radiator (3)
or directly to the coolant pump (5).
HEATER CONTROLS, FUNCTION - GF83.20-P-2004GH
Heater housing position/task/function GF83.20-P-2110GC
Heating system heat exchanger, location/ purpose/function GF83.20-P-2108GC
Heater water circulation pump, location/task/ functionas of 1.09.01GF83.20-P-2109GI

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:15 PMPage 43 © 2006 Mitchell Repair Information Company, LLC.

Fig. 80: Identifying AC Electric Suction Fan With Integrated Control
CONDENSER FUNCTION - GF83.40-P-2120-01GC
Function
The hot, gaseous refrigerant routed into the condenser passes the heat (compression heat) to the coiled pipes and
slats. These then very quickly absorb the refrigerant's heat and transmit the heat to the outside air passing
through. This in turn cools the refrigerant.
By cooling down, the refrigerant is liquefied (condensed). The liquid heat refrigerant is then carried away from
the condenser and flows into the fluid reservoir.
CONDENSER, LOCATION - GF83.40-P-2120-02GH
The condenser (7) is located directly in front of the radiator.

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:16 PMPage 100 © 2006 Mitchell Repair Information Company, LLC.

poisoning from swallowing
coolant.Wear protective gloves, protective
clothing and eye protection.
1Drain coolantEngine 111 in MODEL 163.AR20.00-P-
1142HG
Engines 112 /113 in MODEL 163.AR20.00-
P-1142HA
Engine 628.963 in MODEL 163.128.AR20.00-P-
1142HB
Engine 612.963 in MODEL 163.113.AR20.00-P-
1142M
2.1 Detach
brake line
from the
front end of
the radiator
Only required for right-hand steering.
3.1 Detach
ignition
cable from
the front end
of the
radiator
Only required on right-hand drive vehicles
with ENGINES 111 /112/113.
4Release coolant overflow from
battery shield
5Disconnect upper coolant hose
from the electric coolant pump Detach hose clamp from the upper
coolant hose.
6Unscrew nuts from expansion
reservoir at firewall
7Remove expansion reservoir from
the firewall and lay aside
8Disconnect coolant delivery/return
hoses for heat exchanger (17) Detach hose clamps from coolant
delivery/ return hoses for heat exchanger.
9Discharge air conditioning system
Installation: Evacuate air
conditioning, refill and check for proper
operation and leaktightness.AR83.30-
P-1760GH
10Unscrew self-locking nut (16) at
the expansion valve (15) Replace self-locking nut.
*BA83.30-
P-1003-01B
11
Detach low-pressure refrigerant
line (13) and high-pressure
refrigerant line (14) from expansion
valve (15)
Installation: Install new sealing rings
and moisten with compressor oil.
12Remove instrument panel carrier
(4) AR68.10-
P-1111GH

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 197 © 2006 Mitchell Repair Information Company, LLC.