Content .. 780 781 782 783 ..

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

Clutch

Electrical lines circuit 30

Clips

Captive nuts

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

Place the vehicle on lifting platform

AR00.60-P-1000GH

Open engine hood and raise to vertical position

Have second person secure hood.

AR88.40-P-1000GI

Connect quiescent current retention device

*WH58.30-Z-1005-09A

Disconnect ground cable of battery

AR54.10-P-0003A

Detach coupling (1) at electrical connector of
fan

Disconnect electrical lines circuit 30 (2) at
electric fan

Unclip wiring harness from bracket

Remove front part of noise encapsulation

AR94.30-P-5400GH

Detach clamps (3) at bottom side of electric fan

Unscrew screws (5)

Remove captive nuts (4)

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.

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

Electric fan

Low temperature cooler

Bolts (low temperature cooler)

110/2

Charge air cooler

Lamp units

Cover strips

Radiator crossmember

P20.20-2081-09

Coolant hose for coolant pump

Coolant hose of thermostat housing

Coolant hose of coolant expansion tank

Seal strip

Air ductings

Power steering oil line (feed line of
steering gear

radiator)

Attachment parts

Damper rubber

Mounting clips

Air conditioning fluid reservoir

Radiator

Bolts

Capacitor

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

Open engine hood and raise to vertical position

Have second person secure hood.

AR88.40-P-1000GI

Connect no load current retention unit

*WH58.30-Z-1005-09A

Disconnect battery ground cable

AR54.10-P-0003A

Remove trim panel of cylinder head cover

AR01.20-P-5014-02B

*BA01.20-P-1002-01A

*BA01.20-P-1003-01A

Remove bottom part of noise encapsulation
at front

AR94.30-P-5400GH

Remove electric fan (1)

Remove toward bottom.

AR20.40-P-5000M

Drain coolant

At radiator.

AR20.00-P-1142M

Notes on coolant

All engines

AH20.00-N-2080-01A

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.

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

Remove seal rail (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

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

Detach air guides (12)

Installation: Replace fastening clamps

(13)

Unscrew bolts (16) at condenser (17) to
radiator

Avoid deformation of condenser lines.

Do not disconnect lines.

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.

Take off fluid reservoir of AC (14) at radiator

Place to the side with lines connected.

External torx set

*001589760900

Remove bracket of charge air pipe at left
radiator

Installation: Insert bracket of charge air

pipe into the bracket at the radiator.

Remove radiator (15)

Installation:When installing, the mounting

studs of the radiator must be inserted into the
rubber grommets of the lower crossmember.

Install in the reverse order

Check headlamp adjustment, correct if
necessary

Check and correct headlamp adjustment

AP82.10-P-8260A

Inspect cooling system for leaks

AR20.00-P-1010HA

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

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

BA01.20-P-1003-01A

Bolt, cover panel to charge air distribution
pipe

Power steering pump

Number

Designation

Model
163.113

BA46.30-P-1012-01A

Banjo bolt, power steering oil line to radiator

Cooling system

Number

Designation

Engine
612.963

BF20.00-P-1001-02E

Cooling system

Total capacity

Liter

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

Content .. 780 781 782 783 ..