radiator cap MERCEDES-BENZ ML320 1997 Complete Repair Manual
[x] Cancel search | Manufacturer: MERCEDES-BENZ, Model Year: 1997, Model line: ML320, Model: MERCEDES-BENZ ML320 1997Pages: 4133, PDF Size: 88.89 MB
Page 285 of 4133
235 Engine compartment
Te ch n ica l
data Instruments
and controlsOperation DrivingInstrument
cluster displayPractical hintsCar care Index Adding coolant
If coolant has to be added, a 50 / 50 mixture of water and
MB anticorrosion / antifreeze should be added.
After adding coolant, close cap until you hear it click a
few times.
The drain plugs for the cooling system are located on
the left and right side of the engine block directly above
the engine mounts and at the bottom of the radiator.
Anticorrosion / antifreeze mixture, see page 297.
Wa r n i n g !
In order to avoid possible serious burns or injury:
• Use extreme caution when opening the hood if
there are any signs of steam or coolant leaking
from the cooling system, or if the coolant
temperature gauge indicates that the coolant is
overheated.
• Do not remove pressure cap on coolant
reservoir if engine temperature is above 194°F
(90°C). Allow engine to cool down before
removing cap. The coolant reservoir contains
hot fluid and is under pressure.• Using a rag, slowly open cap approximately
1/2 turn to relieve excess pressure. If opened
immediately, scalding hot fluid and steam will
be blown out under pressure.• Do not spill antifreeze on hot engine parts.
Antifreeze contains ethylene glycol which may
burn if it comes into contact with hot engine
parts.
Page 702 of 4133
235
Engine compartment
Te ch n ica l
data
Instruments
and controls Operation Driving
Instrument
cluster display Practical hints
Car care Index
Adding coolant
If coolant has to be added, a 50 / 50 mixture of water and
MB anticorrosion / antifreeze should be added.
After adding coolant, close cap until you hear it click a
few times.
The drain plugs for the cooling system are located on
the left and right side of the engine block directly above
the engine mounts and at the bottom of the radiator.
Anticorrosion / antifreeze mixture, see page 297.
Wa r n i n g !
In order to avoid possible serious burns or injury: • Use extreme caution when opening the hood if there are any signs of steam or coolant leaking
from the cooling system, or if the coolant
temperature gauge indicates that the coolant is
overheated.
• Do not remove pressure cap on coolant reservoir if engine temperature is above 194 °F
(90 °C). Allow engine to cool down before
removing cap. The coolant reservoir contains
hot fluid and is under pressure.• Using a rag, slowly open cap approximately 1/2 turn to relieve excess pressure. If opened
immediately, scalding hot fluid and steam will
be blown out under pressure.• Do not spill antifreeze on hot engine parts. Antifreeze contains ethylene glycol which may
burn if it comes into contact with hot engine
parts.
Page 2068 of 4133
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)
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 2070 of 4133
AR20.00-P-1142HA
Draining and pouring in coolant
2.4.93
ENGINE
112 in MODELS 129, 163, 202, 208, 210, 211.061 /065 /261 /265 /080 /280 /082 /282, 220, 230.467
ENGINE
113 in MODELS 129, 163, 202, 208, 210, 211.070 /083 /283, 215, 220
ENGINE
113.962 in MODELS 463.206 /240 /241 /247 /248 /249 /254
ENGINE
112.945 in MODELS 463.209 /232 /233 /244 /245 /250
ENGINE
137 in MODELS 215, 220
ENGINE
113.982 in MODELS 463.241 /243 /246
P20.00-0215-06
Illustrated on model 202
1
Coolant expansion reservoir
2
Cooling system cap
3
Radiator drain plug
3a
Drain hose (inner diameter 12 mm)
4
Crankcase drain plug
4a
Drain hose (inner diameter 14 mm)
P20.00-2045-06
Shown on model 215 with M137
1
coolant expansion reservoir
2
Cooling system cap
3
Radiator drain plug
3a
Drain hose (inner diameter 12 mm)
Draining
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
Notes on coolant
All engines
AH20.00-N-2080-01A
Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1
Page 2071 of 4133
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
Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 2
Page 2075 of 4133
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)
Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1
Page 2086 of 4133
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
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
Page 2094 of 4133
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
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
Page 2409 of 4133
swallowing battery
acid. Risk of injury
caused by burns to
skin and eyes from
battery acid or when
handling damaged
lead-acid batteries
3Disconnect battery
ground cable The battery is located in the right of the
engine compartment.AR54.10-P-
0003A
Notes on batteryAll modelsAH54.10-P-0001-
01A
Installation: After connecting, read out
fault memory, encode radio and normalize
power windows.Vehicles with
stationary heater:
adjust time
display on
stationary heater.
4.1Remove air guide
(23) Engine 113.942 only.
Risk of injury to
skin and eyes caused
by scalding from
contact with hot
coolant spray. Risk
of poisoning caused
by 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 containers.
Wear protective gloves, pr otective clothing and
safety glasses.AS20.00-Z-0001-
01A
5Drain coolant from
radiator Remove coolant pump line --> (16) from
coolant pump.AR20.00-P-
1142HA
6Drain and collect
engine oil *BA01.45-P-
1003-01B
*BF18.00-P-
1001-01H
7.1Remove viscous fan
(1)All except model 163.174 with engine 113.981
and 163.175 with engine 113.965.
Right-hand thread!AR20.40-P-
5660C
8.1Remove fan shroud
(2). Unscrew bolts at bottom of fan shroud
8.2Remove electric fan Only model 163.174 with engine 113.981
and 163.175 with engine 113.965.AR20.40-P-
5000GH
9Attach guard plate
for radiator /
condenser
Guard plate for
radiator / condenserEngine 606 in MODEL 124,
Engine 606.961 in MODEL 140,
Engine 112, 113, 604, 605, 611.960 in MODEL WF58.50-P-0110-
01A
2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:56 PMPage 53 © 2006 Mitchell Repair Information Company, LLC.
Page 2441 of 4133
stationary heater timer.
Notes on batteryAll modelsAH54.10-P-0001-
01A
Risk of death caused
by vehicle slipping
or toppling off of the
lifting platform.Align vehicle between the columns of the
lifting platform and pos ition the four support
plates below the lifti ng platform support points
specified by the vehicle manufacturer.AS00.00-Z-0010-
01A
2Place the vehicle on
lifting platform AR00.60-P-
1000GH
3.1Remove air guide (1) Only for engine 113.942.
Risk of injury to
skin and eyes caused
by 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 containers.
Wear protective gloves, pr otective clothing and
safety glasses.AS20.00-Z-0001-
01A
4Drain coolant Detach coolant hose at bottom of radiator.AR20.00-P-
1142HA
5Remove engine trim
panel
6.1Remove viscous fan
(2) All except model 163.174 /175 with Engine
113.981 /965.
Right-hand thread!AR20.40-P-
5660C
7.1Remove fan shroud
(3) Only model 163.154 /157 /172. unscrew
screws (4) of bottom fan shroud.
7.2Remove electric fan Only models 163.174/ 175.AR20.40-P-
5000GH
8Attach guard plate
for radiator /
condenser
Guard plate for
radiator / condenserEngine 606 in model 124,
Engine 606.961 in model 140,
Engines 112, 113, 604, 605, 611.960 in model
202,
Engines 602.983, 612.966 in model 461,
Engine 628.962, 612.965, 606.964, 112.945,
113.962/982 in model 463,
Engines 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 models 211, 215, 220, WF58.50-P-0110-
01A
2001 Mercedes-Benz ML320
1998-2005 ENGINE Complete engine - 163 Chassis
me
Saturday, October 02, 2010 3:17:57 PMPage 85 © 2006 Mitchell Repair Information Company, LLC.