Mercedes-Benz ML320. Manual — part 488

AR07.16-P-1100MM

Remove, install fuel cooler

5.11.99

ENGINE

612.963 in MODELS 163.113

P47.00-2042-12

1

Fuel feed hose

2

Fuel drain hose

3

Coolant feed hose

4

Coolant return flow hose

5

Fuel cooler

7

Bolts of fuel cooler

Operation no. of operation texts or standard texts and flat rates

Category

Op. no.

Operation text

P

075890

REMOVING AND INSTALLING FUEL COOLER

P

075895

REPLACE FUEL COOLER

Remove, Install

Danger!

Risk of injury to fingers being jammed or
squeezed when removing and installing or
aligning hoods, doors, tailgate/tailgate and
sliding roof.

When moving components ensure that no
body parts or limbs are in the area of motion.

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

Danger!

Risk of explosion from fuel igniting, risk of
poisoning from inhaling and swallowing fuel
as well as risk of injury to eyes and skin
from contact with fuel.

No fire, sparks, naked flames or smoking.
Pour fuels only into suitable and appropriately
marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1

Open engine hood and raise to vertical position

Have second person secure hood.

AR88.40-P-1000GI

2

Remove trim panel of cylinder head cover

AR01.20-P-5014-02B

*BA01.20-P-1002-01A

*BA01.20-P-1003-01A

3

Drain coolant

At radiator.

AR20.00-P-1142M

4

Close fuel feed hose (1) at the fuel cooler (5)

Set of plugs

*129589009100

*WH58.30-Z-1001-06A

*WH58.30-Z-1002-06A

5

Detach fuel outlet hose (2)

Clamp

*000589543700

Set of plugs

*129589009100

*WH58.30-Z-1001-06A

*WH58.30-Z-1002-06A

6

Disconnect coolant return flow hose (4) to
thermostat housing

Hose clamp pliers (length 210 mm;

adjustment range 80 mm)

*WH58.30-Z-1026-02A

7

Unscrew bolts (7) at fuel cooler

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8

Disconnect coolant feed hose (3) to fuel cooler

Raise fuel cooler.

Hose clamp pliers (length 210 mm;

adjustment range 80 mm)

*WH58.30-Z-1026-02A

9

Install in the reverse order

Danger!

Risk of accident as vehicle may start off by
itself with the engine running. Risk of injury
as working around the engine during start-up
or while running may result in contusions and
burns

Secure vehicle to prevent it from moving off
by itself.
Wear closed and tight-fitting work clothes.
Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

10

Pour in coolant

*BF20.00-P-1001-02E

Switch heater to maximum and warm up

engine at moderate revs. Top up coolant
constantly at coolant expansion reservoir.
Close coolant expansion reservoir once
coolant temperature is 60-70 °C.

Note on coolant level

Models 124, 129, 140, 168, 170, 202, 208,
210, 220, 463

AH20.00-P-1142-01A

11

Inspect cooling system for leaks

AR20.00-P-1010HA

12

Run engine and inspect fuel system for leaks

Crankcase ventilation, cylinder head cover

Number

Designation

Engine
612.963

BA01.20-P-1002-01A

Screw of trim panel of cylinder head cover
to cylinder head cover

NM

10

BA01.20-P-1003-01A

Screw attaching cover panel to charge air
distribution pipe

NM

10

Cooling system

Number

Designation

Engine
612.963

BF20.00-P-1001-02E

Cooling system

Total capacity

Liter

Y

11,0

Capacity of anticorrosion/
antifreeze agent down to -37 °C

Liter

Y

5,5

Capacity of anticorrosion/
antifreeze agent down to -45 °C

Liter

Y

6,25

Specifications for Service
Products

Sheet

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-02A

129 589 00 91 00

Set of closure plugs

Circuit

000 589 54 37 00

Commercially available tools (see Workshop Equipment Manual)

Number

Designation

Make (e.g.) g.)

Order number

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WH58.30-Z-1001-06A

6 mm socket hexagon on flexible shaft for hose clamps with worm drive

Hazet

Güldenwerther
Bahnhofstrasse 25-28
D-42857 Remscheid

426-6

WH58.30-Z-1002-06A

7 mm hexagon socket wrench to flexible shaft for hose clips with worm
drive

Hazet

Güldenwerther
Bahnhofstrasse 25-28
D-42857 Remscheid

426-7

WH58.30-Z-1026-02A

Hose clamp pliers (length 210 mm; adjustment range 80 mm)

Hazet

Güldenwerther
Bahnhofstrasse 25-28
D-42857 Remscheid

798-12

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AR80.20-P-4004GH

Removing, installing fuel filler flap central locking motor

12.3.97

MODEL

163

P80.20-0478-06

1

Fuel filler flap

2

Outer screws

3

Inner screws

4

Fuel filler fitting

5

Screws

6

Connector

M14/10

Filler flap CL actuating motor

Removal, installation

1

Remove paneling on C-pillar

Remove paneling on left C-pillar

AR68.30-P-4490GH

2

Remove fuel filler flap (1)

3

Unscrew outer screws (2) on fuel filler

When installing: Ensure that rubber seal

is properly seated

4

Unscrew inner screws (3) on fuel filler

5

Unscrew filler flap CL actuating motor (M14/10)

Push filler fitting to right and unscrew

screws from filler flap CL actuating motor

6

Disconnect connector (6)

7

Reinstall in opposite order

8

Check for proper function

Actuate central locking with fuel filler flap

open

Copyright DaimlerChrysler AG 17.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorded by Modification services.

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