Mercedes-Benz ML320. 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.

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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

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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.

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