Mercedes-Benz ML320. Service manual — part 782
AR20.40-P-5000M
Remove/install electric fan
24.8.99
ENGINE
612.963 in MODEL 163.113
P20.40-2015-06
Shown on Model 163.113 with
Engine 612.963
1
Clutch
2
Electrical lines circuit 30
3
Clips
4
Captive nuts
5
Bolts
M4/7
Electric suction fan engine and AC
with integrated control
Remove/Install
Danger!
Risk of injury to fingers being jammed or
squeezed when removing and 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 death. Death may result if vehicle
slips or topples from the lifting platform.
Align vehicle between the columns of the
lifting platform and position the four support
plates at the lifting platform support points
specified by the vehicle manufacturer.
AS00.00-Z-0010-01A
1
Place the vehicle on lifting platform
AR00.60-P-1000GH
2
Open engine hood and raise to vertical position
Have second person secure hood.
AR88.40-P-1000GI
3
Connect quiescent current retention device
*WH58.30-Z-1005-09A
4
Disconnect ground cable of battery
AR54.10-P-0003A
5
Detach coupling (1) at electrical connector of
fan
6
Disconnect electrical lines circuit 30 (2) at
electric fan
7
Unclip wiring harness from bracket
8
Remove front part of noise encapsulation
AR94.30-P-5400GH
9
Detach clamps (3) at bottom side of electric fan
10
Unscrew screws (5)
11
Remove captive nuts (4)
12
Unhinge electric suction fan engine and AC
with integrated control (M4/7) at top of
radiator and take out toward bottom
Installation: Insert retaining lugs of
electric fan into the mounts at radiator.
13
Install in the reverse order
Commercially available tools
Number
Designation
Make (e. g.)
Order number
WH58.30-Z-1005-09A
CMP 12.2 quiescent current retention unit
Hans Zeheter
Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services.
Page 1
AR20.20-P-3865MM
Remove/install radiator
10.11.99
ENGINE
612.963 in MODEL 163.113
P20.20-2080-09
1
Electric fan
2
Low temperature cooler
3
Bolts (low temperature cooler)
110/2
Charge air cooler
4
Lamp units
5
Cover strips
6
Radiator crossmember
P20.20-2081-09
8
Coolant hose for coolant pump
9
Coolant hose of thermostat housing
10
Coolant hose of coolant expansion tank
11
Seal strip
12
Air ductings
19
Power steering oil line (feed line of
steering gear
!
radiator)
20
Attachment parts
21
Damper rubber
13
Mounting clips
14
Air conditioning fluid reservoir
15
Radiator
16
Bolts
17
Capacitor
18
Power steering oil line
(Return line of radiator
!
Power steering pump supply reservoir)
Removal/installation
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
Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services.
Page 1
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
Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services.
Page 2
13
Disconnect coolant hose to coolant pump (8),
coolant hose from thermostat housing (9) and
coolant hose from coolant expansion tank
(10) at radiator
Hexagon socket wrench
*WH58.30-Z-1001-06A
Hexagon socket wrench
*WH58.30-Z-1002-06A
14
Detach air guides (12)
Installation: Replace fastening clamps
(13)
15
Unscrew bolts (16) at condenser (17) to
radiator
Avoid deformation of condenser lines.
Do not disconnect lines.
16
Remove attachment parts (20) and rubber
shock absorber (21)
Installation: Ensure, that the rubber
shock absorbers do not drop when installing
the radiator.
Replace fastening clamps.
17
Take off fluid reservoir of AC (14) at radiator
Place to the side with lines connected.
External torx set
*001589760900
18
Remove bracket of charge air pipe at left
radiator
Installation: Insert bracket of charge air
pipe into the bracket at the radiator.
19
Remove radiator (15)
Installation:When installing, the mounting
studs of the radiator must be inserted into the
rubber grommets of the lower crossmember.
20
Install in the reverse order
21
Check headlamp adjustment, correct if
necessary
e
Check and correct headlamp adjustment
AP82.10-P-8260A
22
Inspect cooling system for leaks
AR20.00-P-1010HA
23
Fill power steering pump and bleed
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
24
Run engine and inspect for leaks
Crankcase ventilation, cylinder head cover
Number
Designation
Engine
612.963
BA01.20-P-1002-01A
Bolt, cylinder head cover trim panel to
cylinder head cover
Nm
10
BA01.20-P-1003-01A
Bolt, cover panel to charge air distribution
pipe
Nm
10
Power steering pump
Number
Designation
Model
163.113
BA46.30-P-1012-01A
Banjo bolt, power steering oil line to radiator
Nm
30
Cooling system
Number
Designation
Engine
612.963
BF20.00-P-1001-02E
Cooling system
Total capacity
Liter
Y
11.0
Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services.
Page 3
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