1

Mercedes Benz ML 320 (163.154) V6-3.2L (112.942)

Cooling System: Testing and Inspection
AR20.00-P-1010HA Inspect Cooling System For Leaks
Inspect Cooling System For Leaks

Remove/Install

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 degrees C. Open cap slowly and release the pressure. Do not pour
coolant into beverage bottles.
- Wear protective gloves, protective clothing and eye protection.

1 Open cap with detent (2) or 2-stage cap (2a) expansion reservoir (1) or radiator.

NOTE:
- Cap with detent (2): Rotate cap with detent (2) carefully to first predetent, release pressure, then unscrew cap with detent (2).
- Model 163: Rotate 2-stage cap (2a) or 1-stage cap half a revolution in anti-clockwise direction, release pressure, then unscrew 2-stage
cap (2a) or 1-stage cap.

2 Set heating switches to maximum heating capacity

- All except Model 163

NOTE: Model 163 has no pulsed valves. Coolant is permanently flowing through the heating system heat exchanger.

Inspect

3 Check coolant level, if required adjust correctly.

NOTE: In case of inadequate antifreeze content, Replace coolant against a separate job order.

4 Fit the test cap (3) on the expansion reservoir or radiator

5 Connect tester
6 Apply pressure to cooling system and check leaktightness of cooling system
7 Inspect cooling and heating hoses as well as their connection points for proper condition and loss of coolant, replace coolant hoses, if
necessary.
8 Check condition and seating of hose clamps and retighten or replace if necessary.
9 Install in the reverse order.

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Mercedes Benz ML 320 (163.154) V6-3.2L (112.942)
Cooling System: Testing and Inspection
AP20.00-P-2010GH Inspect Coolant Level Adjust to Correct Level

Engine Cooling System - Inspect Fluid Level Adjust to Correct Level

Inspect Anticorrosion/Antifreeze Protection

Steps 1-3

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Mercedes Benz ML 320 (163.154) V6-3.2L (112.942)
Cooling System: Service and Repair
AN20.30-P-0001S Retrofit Coolant Preheater
AN20.30-P-0001S Retrofitting coolant preheater

Component Identification

Component Identification

Component Identification

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Mercedes Benz ML 320 (163.154) V6-3.2L (112.942)

Steps 1-15

Coolant Preheater

Special Tools

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Mercedes Benz ML 320 (163.154) V6-3.2L (112.942)

Special Tools

Special Tools

Parts Order Notes

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Mercedes Benz ML 320 (163.154) V6-3.2L (112.942)
Cooling System: Service and Repair
AP20.00-P-2010GH Checking/Correcting Cooling System Level

Checking/Correcting Cooling System Level

Coolant level:

To check the coolant level, the vehicle must be parked on level ground and the engine stopped.

Check coolant level only when coolant is cold.

The coolant level should reach the COLD LEVEL mark in the reservoir.

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.

Warning!

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.

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Mercedes Benz ML 320 (163.154) V6-3.2L (112.942)
Coolant: Service and Repair
AR20.00-P-1142HA Drain Coolant, Pour In
Drain Coolant, Pour In

Shown On Model 202

Shown On Model 215 With Engine 137

Lowering

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 degrees C. Open cap slowly and release the pressure.
- Do not pour coolant into beverage bottles.
- Wear protective gloves, protective clothing and eye protection.

1 Open cooling system cap (2) at coolant expansion reservoir (1)

NOTE:
- Cap with detent: Carefully rotate cap to first detent, release overpressure and unscrew cap.
- 2-stage and 1-stage cap: Rotate cap half a revolution in counterclockwise direction, release overpressure, then unscrew cap.

2.1 Remove engine compartment paneling

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Mercedes Benz ML 320 (163.154) V6-3.2L (112.942)
2.2 Remove underride guard
- Model 163, 463

3 Remove air baffle

- Model 163 with Engine 113.942

4 Drain coolant
- Collect coolant

NOTE: Observe regulations for disposal of coolant.

Filling system with coolant

5 Fill with coolant

6 Bleed coolant system

NOTE: Let engine run, put heater on full heat output.

7 Inspect cooling system for leaks.

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Mercedes Benz ML 320 (163.154) V6-3.2L (112.942)
Radiator Cooling Fan Motor: Description and Operation
TASK
Actuating electric suction-type fan.

DESIGN/FUNCTION
The ME-SFI control module actuates the fan steplessly through the electric suction-type fan (engine/AC) control module. The specified speed
of the fan is transmitted by the ME-SFI control module to the electric suction-type fan (engine/AC) control module by means of a pulse width
modulated signal. The ON/OFF ratio is 10-90%, the different ratios meaning e.g.

10% electric suction-type fan OFF

20% electric suction-type fan ON, minimum speed
90% electric suction-type fan ON. maximum speed

The status of the A/C or automatic A/C is transmitted by the instrument cluster through the CAN to the ME-SFI control module. The
specified speed of the fan is dependent on this status.

NOTE:
CAN-compatible instrument cluster required which is programmed accordingly with HHT to with/without A/C or automatic A/C.

Engine 112 at start of production as of 3/97 viscous fan clutch, fan control phased-in.

Shown On Engine 111

A1 Instrument cluster
A9 A/C compressor
B11/4 Coolant temperature sensor
L5 Crankshaft position sensor
M4/3 Electric suction,type fan (engine/AC)
N3/10 ME-SFI control module
N19 A/C push button control module
N22 Automatic A/C push button control module
N76 Electric suction-type fan (engine/AC) control module
CAN Data bus (Controller Area Network)

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Mercedes Benz ML 320 (163.154) V6-3.2L (112.942)
Fan Clutch: Service and Repair
Remove/Install Viscous Fan Clutch

Shown On Engine 112

1 Fit counterholder (1) on bolts of belt pulley (2), counterhold

NOTE: Belt pulley of coolant pump

2 Unscrew union nut at viscous fan (3)

NOTE:
- Right-hand thread.
- Installation: Use torque wrench with open-end wrench bit.

3 Unbolt fan at viscous clutch

NOTE: Installation: The installation position of the fan is preset through cast-on ribs at fan ring.

4 Install in the reverse order.

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Mercedes Benz ML 320 (163.154) V6-3.2L (112.942)
Heater Core: Service and Repair
Remove and Install Heat Exchanger From Heater Housing

1 Remove AC housing
2 Remove bolt (1) from the covering on the air duct (2)

NOTE: The bolt lies under the air duct seal.

3 Remove lever for blend air flap (3)

4 Unscrew bolt (4) at bracket (5)
5 Remove heat exchanger (6) upward
6 Install in the reverse order
7 Inspect cooling system for leaks.

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Mercedes Benz ML 320 (163.154) V6-3.2L (112.942)
Radiator: Service and Repair
Removing And Installing Radiator

Shown On Model 163.154 With Engine 112

1 Remove air guide panel (17)

NOTE: Only 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 degrees C. Open cap slowly and release the pressure. Do not
pour coolant into beverage bottles.
- Wear protective gloves, protective clothing and eye protection.

2 Drain coolant at radiator

NOTE: For draining coolant, remove coolant line (6) at the bottom of radiator or at coolant pump.

3.1 Remove viscous fan (1)

NOTE:
- Engine 112.942/970 and 113.942.
- Right-hand thread!

3.2 Remove electric fan

NOTE: Only Engine 113.965 /981.

4 Pull off plate clamps (2) of fan shroud

NOTE: Only Engine 112.942, as of 5/98.

5 Remove the fan shroud (3).

NOTE:
- Only Engine 112.942 /970 and 113.942.
- For this step unscrew bolts at the bottom of fan shroud.
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Mercedes Benz ML 320 (163.154) V6-3.2L (112.942)
- Installation: When installing a new radiator with integrated oil cooler for the power steering pump, a new fan shroud is necessary, if a
radiator without integrated oil cooler was installed beforehand.

6 Remove lamp unit (7)

7 Remove front end crossmember (8)
8 Take off coolant lines (4, 6) and coolant line expansion reservoir (5) at radiator.
9 Remove rubber seal (9) of radiator
10 Remove oil line (return line of radiator -> expansion tank of power steering pump) (18) and oil line (feed line of steering gear -> radiator)
(19)

NOTE: Only as of 5/98, close connections!

11 Unbolt ATF lines (10) at radiator

NOTE: Seal connections!

12 Separate connector from fan and remove air intake grill (11).

NOTE: Only Engine 112.942/970 and 113.942.

13 Unbolt condenser at radiator

NOTE: Do not disconnect lines.

14 Remove attachment parts (20) and rubber shock absorber (21)

NOTE: The rubber shock absorber (21) is designed to prevent vibrations which may occur between condenser and radiator (15) when
driving off-road.

15 Take off fluid reservoir of AC (14) at radiator

NOTE: Place to the side with lines connected. Detach condenser at radiator.

16 Remove radiator (15)

NOTE: Installation:
- When Installing, the mounting studs of the radiator must be inserted into the rubber grommets of the bottom cross member.
- On Model 163.154 with Engine 112.942 prior to vehicle identification number 043553, additional operations must be carried out, if not
already done so, when installing a new radiator with integrated oil cooler for power steering pump.

17 Detach air ductings (12)

NOTE: Replace clamps of air ductings (13).

18 Install in the reverse order.

19 Pour in coolant
20 Check headlamp adjustment, correct if necessary

DANGER:
- Risk of accident from vehicle starting off by itself when 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 close-fitting work clothes.
- Do not grasp hot or rotating parts.

21 Check oil level in automatic transmission, correct if necessary.

22 Inspect cooling system for leaks.

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Mercedes Benz ML 320 (163.154) V6-3.2L (112.942)
Coolant Level Sensor: Description and Operation

The coolant level indicator electronic switch (S41) is integrated in the coolant reservoir.

Coolant level switch, task

To record the coolant level:
Coolant level In order or below minimum

Coolant level switch, design

The coolant level indicator electronic switch (S41) consists of two electrodes which are permanently cast to the coolant reservoir and a
connector with contacts which have an electrical connection to the electrodes.

Coolant level switch, function

The two electrodes are either immersed or not immersed in the coolant depending on the coolant level. As a result the test current changes via
the coolant level indicator electronic switch (S41). This change is evaluated by the instrument cluster (A1).
An alternating current is used so that the electrodes do not disintegrate.

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Mercedes Benz ML 320 (163.154) V6-3.2L (112.942)
Engine - Coolant Temperature Sensor/Switch: Description and Operation

Task
Detecting the coolant temperature and supplying information to the engine control module

Design
Plastic housing with an NTC resistor, 2-pin, angled plug connection.
Contact assignment at connector:
Contacts 1 and 2 engine control module.
Inserted into hole and sealed with O-ring.
Attached by means of spring clasp.

Function
The NTC resistor integrated in the coolant temperature sensor alters its electrical resistance in line with the coolant temperature. NTC means
Negative Temperature Coefficient, i.e, the electrical resistance becomes less as the temperature rises.

Example:
coolant temperature resistance
20 °C 3100 ohm ± 5%
80 °C 315 ohm ± 5%

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Mercedes Benz ML 320 (163.154) V6-3.2L (112.942)
Engine - Coolant Temperature Sensor/Switch: Service and Repair
Servicing Wiring Harness

Component Identification

NOTE: If a cable break or similar damage exits in the area of the plug connection of the mass air flow sensor (B2) or temperature sensor (B11), it
is possible to repair the wiring harness in order to avoid costly replacement of a wiring harness.

Removing, Installing, Steps 1 - 8

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Mercedes Benz ML 320 (163.154) V6-3.2L (112.942)
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Coolant Temperature Sensor, Location
Coolant Temperature Sensor, Position

B11/4 Coolant temperature sensor

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Mercedes Benz ML 320 (163.154) V6-3.2L (112.942)
Thermostat: Testing and Inspection
Test Coolant Thermostat

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 degrees C. Open cap slowly and release the pressure. Do not pour
coolant into beverage bottles.
- Wear protective gloves, protective clothing and eye protection.

1 Remove coolant thermostat (1)

NOTE: Installation:
- Install new sealing ring.
- The coolant thermostat must not be removed from the housing. Otherwise it will be destroyed. The housing is supplied together with the
coolant thermostat for repair purposes.

Inspection
2 Heat coolant thermostat (1)
- Suspend coolant thermostat (1) from a wire in a vessel filled with water and heat the water.

CAUTION: For heating on no account use a welding torch or soldering torch as the sudden introduction of heat alters the structure
of the metal!

3 Measure temperature of water

NOTE: The heating-up rate should be not more than 1 degrees C to 2 degrees C/min from about 8 degrees C below the start of opening of
the coolant thermostat.

4 Heat water to the fully open temperature of the thermostat (2) and then measure the stroke

NOTE: If the test values are not achieved, install a new coolant thermostat.

5 Install in the reverse order

6 Inspect cooling system for leaks.

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Mercedes Benz ML 320 (163.154) V6-3.2L (112.942)
Thermostat: Service and Repair
Remove/Install Coolant Thermostat

Shown On Engine 112

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 degrees C. Open cap slowly and release the pressure. Do not pour
coolant into beverage bottles.
- Wear protective gloves, protective clothing and eye protection.

1 Drain coolant at radiator

NOTE:
- Model 163: For draining coolant, remove coolant hose at the bottom of radiator or at coolant pump.
- Collect coolant
- Disposal of coolants: observe legal regulations or local wastewater requirements!
- Refer to Environmental Protection Catalog issued by MBVD/PWU for locations in Germany.

2 Unclip cover at face end of engine

- Model 211, 220.

3 Remove engine trim panel or cleaner

- Except Model 211, 230.

NOTE: On Model 463, 220, 210.074/274, 208.370/374/470, 209.361/365/375/376, 202.033/093, 129 the air cleaner is integrated into the
engine cover. Remove engine cover or air cleaner by lifting vertically up and off the cylinder head covers.

4 Detach coolant hose (5)

NOTE: Inspect condition of coolant hose (5) and hose clamp (4), replace if necessary.

5 Unscrew bolts (3), remove coolant thermostat housing (1) with coolant thermostat

CAUTION:The coolant thermostat must not be removed from the housing. If this is done it will be destroyed. Re-installation is not
possible. The housing is supplied together with the coolant thermostat for repair purposes.

NOTE: Installation: Install new sealing ring (2).

6 Install in the reverse order

7 Inspect cooling system for leaks.

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Mercedes Benz ML 320 (163.154) V6-3.2L (112.942)
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Coolant Temperature Sensor, Function
Coolant Temperature Sensor, Function

B11/4 Coolant temperature sensor

The NTC resistor alters its electrical resistance in line with the coolant temperature. It decreases as the temperature increases.
Example:
Coolant temperature Resistor
20°C 3100 ohms ±5 %
80°C 315 ohms ±5 %

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