Remove/install radiator - AR20.20-P-3865GZS (ML63 AMG)

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ENGINE 156 in MODEL 164, 251

Fig 1: Identifying Radiator Components (1 Of 4)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Radiator Components (2 Of 4)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Radiator Components (3 Of 4)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Radiator Components (4 Of 4)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Remove/install
	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
	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
	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
	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
1	Open engine hood	Model 164	AR88.40-P-1000GZ
		Model 251	AR88.40-P-1000RT
2	Remove front engine cover	Do not tilt front engine cover, but lift upwards vertically otherwise the retaining lugs can break off.
3	Remove the left and right intake air duct
4	Remove upper radiator crossmember	Model 164	AR62.30-P-2300GZ
		Model 251	AR62.30-P-2300RT
5	Remove electric fan		AR20.40-P-5000GZS
6	Raise vehicle with lifting platform	Model 164	AR00.60-P-1000GZ
		Model 251	AR00.60-P-1000RT
7	Remove engine compartment paneling	Installation: Install engine compartment paneling only after engine test run.
		Model 164	AR61.20-P-1105GZ
		Model 251	AR61.20-P-1105RT
8	Drain coolant at radiator (1)		AR20.00-P-1142GZS
	Notes on coolant	All engines	AH20.00-N-2080-01A
	Notes on coolant level		AH20.00-P-1142-01GZB
		Cooling system	*BF20.00-P-1001-02U
9	Remove coolant line (2) from coolant expansion reservoir at engine radiator (1)	Installation: Check condition of coolant line and replace if necessary. Replace seal. Ensure coolant line (2) is fitted correctly on radiator (1)
		Hose clamp pliers	Fig 5
10	Remove coolant hoses at connection fittings (10) on engine radiator (1) and place to one side	Installation: Check condition of coolant hoses; replace if necessary. Install new seals. Ensure coolant hoses are fitted correctly on radiator.
		Hose clamp pliers	Fig 5
11	Detach automatic transmission oil line (13) on connection (12) from radiator (1)	Seal all connections immediately using stop plugs, otherwise the automatic transmission may be damaged due to contamination.	AR27.10-P-0501-03RT
		Set of stop plugs	Fig 6
12	Remove bumper	Model 164	AR88.20-P-2000GZ
		Model 251	AR88.20-P-2000RT
13	Unclip power steering oil line at the side on engine radiator (1)
14	Undo bolt (4) on air ducting (3) from radiator (1)
15	Undo bolt (6) for refrigerant line mounting on radiator (1)
16	Lift radiator (1) with condenser of air conditioning upwards out of rubber mount (9), slide towards the engine and put down	This improves accessibility to the air ducting (3) bolt (5).
17	Remove bolt (5) from air ducting (3)
18	Loosen bolt on carrier frame (A) for power steering lines	Model 251
19	Unclip carrier frame (A) on cooler (1) and remove	Model 251
20	Unclip condenser for air conditioning from top mount (7) and pull condenser upwards out of bottom mount (8)	Place air conditioning condenser down in front of radiator (1).
21	Take out the radiator (1) in the upward direction	Installation: Ensure correct seating of rubber mounts (9) in bottom mounts of radiator (1). Ensure air conditioning condenser lower supports (8) are 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	Inspect cooling system for leaks		AR20.00-P-1010GZS
		Test cap	Fig 7
		Cooler vacuum filling device	Fig 8
	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
25	Conduct engine test run and check the engine for leaks	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 156 in model 164, 251
BF20.00-P-1001-02U	Cooling system	Total filling capacity	≈Liters	7.5
		Antifreeze/water	Up to -37°C	50/50
		Antifreeze/water	Up to -45°C	55/45
		Specifications for Operating Fluids	Sheet
			Sheet	BB00.40-P-0310-01A
			Sheet
			Sheet	BB00.40-P-0325-00A

Fig 5: Identifying Hose Clamp Pliers (003 589 03 37 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Identifying Set Of Stop Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 7: Identifying Test Cap (210 589 00 91 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 8: Identifying Vacuum-Type Cooling System Filler (285 589 00 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.