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Remove/install radiator - AR20.20-P-3865GZ

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ENGINE 113.964 in MODEL 164.175 

Fig 1: Identifying Radiator Components (1 Of 3)
G05257754Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Identifying Radiator Components (2 Of 3)
G05257755Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Radiator Components (3 Of 3)
G05257756Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVINGINSTALLING Remove/install    
DANGER Risk of injury  to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning  caused by 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 containers.
Wear protective gloves, protective clothing and safety glasses.		 AS20.00-Z-0001-01A 
NOTES Notes on coolant All engines AH20.00-N-2080-01A 
DANGER Risk of injury  to skin or eyes caused by hydraulic fluid spraying out under high pressure. Risk of poisoning  caused by swallowing hydraulic fluid. Depressurize the hydraulic system completely before starting any work on the system. Wear protective clothing and safety glasses. AS00.00-Z-0013-01A
DANGER Risk of injury  caused by fingers being pinched or crushed  when removing, installing or aligning hoods, doors, trunk lids, tailgates or sliding roof. Keep body parts and limbs well clear of moving parts. AS00.00-Z-0011-01A
1 Open engine hood   AR88.40-P-1000GZ
DANGER Risk of death  caused by vehicle slipping or toppling off of 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
2 Raise vehicle with lifting platform   AR00.60-P-1000GZ
3 Remove front engine cover   AR01.10-P-2405GZ
4 Remove left and right suction fan duct    
5 Remove upper radiator crossmember   AR62.30-P-2300GZ
6 Remove fan shroud together with electric fan   AR20.40-P-5000GZ 
7 Remove engine compartment paneling IMPORTANTInstallation:  Install engine compartment paneling only after engine test run. AR61.20-P-1105GZ
8 Drain coolant at radiator (1)   AR20.00-P-1142GZ 
    FLUID SPECIFICATION *BF20.00-P-1001-02K 
REFER TO CAPACITIES & SPECIFICATIONS Coolant specifications Sheet 310.1 BB00.40-P-0310-01A
REFER TO CAPACITIES & SPECIFICATIONS Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40-P-0325-00A
9 Remove coolant line (2) from coolant expansion reservoir at engine radiator (1) IMPORTANTInstallation:  Check condition of coolant line and replace if necessary. Replace seal. Ensure coolant line (2) is fitted correctly on radiator (1)  
    SPECIAL TOOL Hose clamp pliers Fig 4
10 Detach coolant lines of coolant pump to connection fitting (10) on radiator (1) and place to one side IMPORTANTInstallation:  Check condition of coolant lines and replace if necessary. Install new seals. Ensure coolant lines are fitted correctly at radiator.  
    SPECIAL TOOL Hose clamp pliers Fig 4
11 Detach automatic transmission oil line (13) on connection (12) from radiator (1) NOTES Seal all connections immediately using stop plugs, otherwise the automatic transmission may be damaged due to contamination.
IMPORTANTInstallation:  Replace sealing rings.
Ensure the oil lines of the automatic transmission are fitted correctly to the radiator.		  
    SPECIAL TOOL Set of stop plugs Fig 5
12 Detach power steering oil line (14) on connection (12) COMMERCIALLY AVAILABLE TOOLS 6 mm socket hexagon on flexible shaft for hose clamps with worm drive *WH58.30-Z-1001-06A 
    COMMERCIALLY AVAILABLE TOOLS 7 mm socket hexagon on flexible shaft for hose clamps with worm drive *WH58.30-Z-1002-06A 
13 Undo bolt (4) on air ducting (3) from radiator (1)   AR88.20-P-2000GZ
14 Remove front section of fender liner in left front fender   AR88.10-P-1310GZ
15 Partially remove left bumper   AR88.20-P-2000GZ
16 Undo bolt (6) for refrigerant line mounting on radiator (1) IMPORTANT To ease access to bolt (6), pull partially removed bumper somewhat to front, see (arrow).  
17 Lift radiator (1) with condenser of air conditioning upwards out of rubber mount (9), slide towards the engine and put down IMPORTANT This improves accessibility to the air ducting (3) bolt (5).  
18 Remove bolt (5) from air ducting (3)    
19 Remove air ducting (3)    
20 Unclip condenser for air conditioning from top mount (7) and pull condenser upwards out of bottom mount (8) IMPORTANT Place air conditioning condenser down in front of radiator (1).  
21 Take out the radiator (1) in the upward direction IMPORTANTInstallation: 
  • Ensure correct seating of rubber mounts (9) in bottom mounts on radiator (1).
  • Ensure air conditioning condenser lower support (8) is correctly seated in radiator (1).
  
22 Install in the reverse order    
23 Check oil level in automatic transmission and correct if necessary   AR27.00-P-0100W
24 Check power steering oil level    
REFER TO MAINTENANCE Check and correct power steering fluid level   AP46.00-P-4611GZ
25 Inspect cooling system for leaks   AR20.00-P-1010GZ 
    SPECIAL TOOL Test cap Fig 6
    SPECIAL TOOL Cooler vacuum filling device Fig 7
26 Read out fault memory and erase if required    
REFER TO SELF-DIAGNOSTIC SYSTEMS Connect STAR DIAGNOSIS and read out fault memory   AD00.00-P-2000-04A
    STAR DIAGNOSIS diagnostic system *WH58.30-Z-1048-13A 
DANGER Risk of accident  caused by vehicle starting off by itself when engine is running. Risk of injury  caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.		 AS00.00-Z-0005-01A
27 Conduct engine test run and check the engine for leaks while it is running NOTES In the event of oil loss determine and eliminate cause, otherwise malfunctions, transmission damage, and serious environmental pollution may occur.  
COOLING SYSTEM

Number Designation Engine 113.964 in model 164
BF20.00-P-1001-02K Cooling system Total filling capacity Liters ≈10.00
Capacity of anticorrosion/antifreeze agent down to -37°C Liters ≈5.00
Filling capacity of anticorrosion/antifreeze down to -45°C Liters ≈5.5
Specifications for Operating Fluids Sheet BB00.40-P-0310-01A
Sheet BB00.40-P-0325-00A
Fig 4: Identifying Hose Clamp Pliers (003 589 03 37 00)
G05257757Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 5: Identifying Set Of Stop Plugs (129 589 00 91 00)
G05257758Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 6: Identifying Test Cap (210 589 00 91 00)
G05257759Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 7: Identifying Vacuum-Type Cooling System Filler (285 589 00 21 00)
G05257760Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
COMMERCIALLY AVAILABLE TOOLS

Number Designation
WH58.30-Z-1001-06A 6 mm socket hexagon on flexible shaft for hose clamps with worm drive
WH58.30-Z-1002-06A 7 mm socket hexagon on flexible shaft for hose clamps with worm drive
WH58.30-Z-1048-13A STAR DIAGNOSIS diagnostic system, Compact Passenger Car 6511 1801 00
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