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1998-2004 ENGINE Engine Cooling System - 170 Chassis GENERAL INFORMATION NOTES ON COOLANT - AH20.00-N-2080-01A All engines coolant composition passenger car and commercial vehicle engines 50 water in % by volume and 50 corrosion / antifreeze agent. Tasks of corrosion and frost protection Increase the boiling point so that coolant does not evaporate so rapidly.
1998-2004 ENGINE Engine Cooling System - 170 Chassis GENERAL INFORMATION NOTES ON COOLANT - AH20.00-N-2080-01A All engines coolant composition passenger car and commercial vehicle engines 50 water in % by volume and 50 corrosion / antifreeze agent. Tasks of corrosion and frost protection Increase the boiling point so that coolant does not evaporate so rapidly.
1998-2004 ENGINE Engine Cooling System - 170 Chassis GENERAL INFORMATION NOTES ON COOLANT - AH20.00-N-2080-01A All engines coolant composition passenger car and commercial vehicle engines 50 water in % by volume and 50 corrosion / antifreeze agent. Tasks of corrosion and frost protection Increase the boiling point so that coolant does not evaporate so rapidly.
GENERAL INFORMATION NOTES ON COOLANT - AH20.00-N-2080-01A All engines Coolant composition passenger car and commercial vehicle engines (normally) 50 water in % by volume and 50 corrosion/antifreeze agent in % by volume. Different coolant composition for CV engines, refer to MB Specifications for Operating Fluids Tasks of corrosion and frost protection Corrosion and cavitation protection of all components in cooling system Antifreeze protection (frost protection) Increase the boiling point so that coolant does not evaporate so rapidly. Avoiding ejection of coolant at high coolant temperatures. Antifreeze protection 50 % by volume of anticorrosion/ antifreeze agent offers antifreeze protection down to approx. -37 C . A higher concentration is only necessary if the ambient temperatures are even lower. 55 % by volume of anticorrosion/antifreeze agent offers antifreeze protection down to approx. -45 C A concentration of more than 55 % by volume of anticorrosion/ antifreeze agent should not be used as the maximum antifreeze protection is already reached. An even higher concentration once reduces antifreeze protection and impairs heat dissipation. Reduced heat dissipation can lead to damage to components in the cooling system or damage to the engine. Water Use water which is clean and not too hard. Drinking water often satisfies requirements, but not always the contents of dissolved substances in the water may be of significance for the occurrence of corrosion. If in doubt, analyze the water. For fresh water specifications refer to MB Specifications for Operating Fluids. Period of use
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:09 AM Page 1 2005 Mitchell Repair Information Company, LLC. Microsoft Friday, October 30, 2009 7:30:15 AM Page 1 2005 Mitchell Repair Information Company, LLC. The maximum permissible period of use of the coolant can be taken from the maintenance booklet; from the applicable service/ maintenance sheet or the MB-Specifications for Operating Fluids respectively. For the period of use for a varying coolant composition for CV engines, refer to MB Specifications for Operating Fluids Before pouring in fresh coolant, flush the used coolant out of the cooling system. In the event of high pollution or oil fouling levels, clean the cooling system, otherwise damage can occur to the components of the cooling system. Disposing of coolants Pay attention to legal provisions and local wastewater regulations. For workshops located in the Federal Republic of Germany refer to: "Environmental Protection Manual for Automotive Repair Workshops" Publisher: Association of Automotive Industry e.V. (VDA) 60625 Frankfurt am Main, Westendstrab 61 GENERAL INFORMATION ON THE COOLANT PREHEATER - AH20.00-P-1001-01A General information An electric coolant preheater can be retrofitted in the motor water circuit to keep the engine coolant warm or to warm it up in order to prevent the engine cooling out completely at low ambient temperatures. The electrical coolant preheater can be built into the water circuit of the engine subsequently or can be retrofitted. The engine coolant preheater can be connected to the local mains supply using the plug provided on the device. It has a power consumption of 500 W at a voltage of 230 V or 115 V. For retrofitting: The spare parts are listed in Group 20 of the ET documentation for the corresponding engine. NOTES ON COOLANT LEVEL - AH20.00-P-1142-01P The coolant level must reach on a cold engine up to the marking (arrow) on the coolant expansion reservoir. When coolant is warm: approx. 1 cm above this scribe mark. Shown on model 203 with engine 112
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:09 AM Page 2 2005 Mitchell Repair Information Company, LLC. Fig. 1: Locating Coolant Expansion Reservoir Marking GENERAL NOTES: PASSENGER CARS: ENGINE COOLING SYSTEM - AH20.00-Z-9999AZ MODEL all
Notes on coolant level ENGINE 271, 272, 646 in MODEL 204 AH20.00-P-1142-01CW
Notes on coolant level ENGINE 266.9, 640.9 in MODEL 169.0/3, 245.2 AH20.00-P-1142-01AK
Notes on coolant level ENGINE 113, 156, 272, 629, 642 in MODEL 164 ENGINE 113, 156, 272, 642 in MODEL 251 AH20.00-P-1142-01GZB
Notes on coolant level ENGINE 272, 642 in MODEL 203 ENGINE 156, 272, 273, 642 in MODEL 209 AH20.00-P-1142-01PI
Notes on coolant ENGINE all AH20.00-N-2080-01A
General information on the coolant preheater ENGINE 111, 112, 113, 119, 166, 271, 602, 603, 604, 605, 606, 611, 612, 613, 668 ... AH20.00-P-1001-01A
Notes on coolant level MODEL 124, 129, 140, 163, 168, 170, 202, 208, 210, 211, 219, 220 ... AH20.00-P-1142-01A
Notes on engine coolant level ENGINE 111, 112, 113 in MODEL 163 AH20.00-P-1142-01GH
Notes on coolant level ENGINE 642.940 in MODEL 164.120/122 AH20.00-P-1142-01GZD
Notes on application of sealant to coolant pump housing ENGINE 113... AH20.10-P-0001-02RVK
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:09 AM Page 4 2005 Mitchell Repair Information Company, LLC. ENGINE 605.960 in MODEL 202 ENGINE 606.912/962 in MODEL 210 ENGINE 112 in MODEL 129, 170, 202, 203, 208, 210, 220 ENGINE 113 in MODEL 129, 202, 208, 209, 210, 220 ENGINE 111.951 in MODEL 203.035 /235 /735 ENGINE 111.955 in MODEL 203.045 /245 /745 ENGINE 112.912 in MODEL 203.061/261 ENGINE 112.946 in MODEL 203.064/264 ENGINE 611.962 in MODELS 203.004 /006 /204 /206 /706 ENGINE 112.961 in MODEL 203.065 /265 ENGINE 611.960 ENGINE 611.961 ENGINE 612.961 ENGINE 612.965 ENGINE 612.963 ENGINE 613.960 ENGINE 613.961 ENGINE 612.966 ENGINE 113.968 in MODEL 209.375 /475 ENGINE 112.912 in MODEL 209.361 ENGINE 112.955 in MODEL 209.365 ENGINE 271.940 in MODEL 203.042 /242 /742, 209.342 ENGINE 271.946 in MODEL 203.046 /246 /746
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:09 AM Page 5 2005 Mitchell Repair Information Company, LLC. ENGINE 271.948 in MODEL 203.040 /740 ENGINE 612.962 ENGINE 612.967 in MODEL 209.316 ENGINE 271.941 in MODEL 211.042 /242 ENGINE 271.942 in MODEL 203.043 /243 /743, 209.343 /443 ENGINE 112.947 in MODEL 170.465 ENGINE 112.960 in MODEL 170.466 ENGINE 113.987 in MODEL 209.376 ENGINE 112.916 in MODEL 203.081/281 ENGINE 112.953 in MODEL 203.084 /284 ENGINE 612.990 in MODEL 203.018 /218 /718 ENGINE 646.962 in MODEL 203.007 /207 /707 ENGINE 646.963 in MODEL 203.008 /208 /708 Fig. 3: Identifying Reservoir Cap, Location/Design/Function Cap location The cap (2) is screwed onto
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:09 AM Page 6 2005 Mitchell Repair Information Company, LLC. Reservoir cap, function - GF20.30-P-1000-01A Fig. 4: Identifying Reservoir Cap, Function The cap (2) has two opening pressures. 1st stage If the pressure in the cooling system exceeds the first compression stage, the valve opens and allows the pressure to escape into the upper part of the cap (2) 2nd stage If the pressure continues to rise, the pressure relief valve of the 2nd stage (4) opens and allows the pressure to escape through several ventilation bores (a) mounted at the cap of the expansion reservoir (1), along the annular the expansion reservoir in the engine compartment. Cap task During the engine off heating phase (after switching off the engine) the pressure in the cooling system may rise. So that no coolant escapes, the cap (2) is additionally built-in with a compression stage.
Cap function Reservoir cap, function - GF20.30-P-1000-01A
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:09 AM Page 7 2005 Mitchell Repair Information Company, LLC. port (b) into the outlet nipple (c) and a hose extension to atmosphere. The 2nd stage cap (2) eliminates the need for the overflow tank. SAFETY PRECAUTIONS RISK OF INJURY - AS20.00-Z-0001-01A 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. Possible hazards Risk of injury When the engine is warm, the cooling system is pressurized. If the cooling system is opened suddenly, there is a risk of scalding from hot coolant which splashes out. Danger of poisoning If coolant is swallowed, this can result in manifestations of poisoning such as headaches, dizziness, stomach pain, respiratory paralysis, unconsciousness, vomiting and cramps. Safety precautions/instructions Allow cooling system to cool down to a coolant temperature of less than 90 C. Open cap of cooling system slowly; turn a conventional coolant cap as far as the first detent and turn a screwed coolant cap approx. 1/2 turn and release the pressure. Wear protective gloves, protective clothing and eye protection. Do not pour coolant into beverage bottles. First aid measures Rinse affected skin with large quantities of cold water and cover with sterile bandages. Allow the person affected to drink plenty of water with the addition of medicinal charcoal. If the person has suffered severe burns or has swallowed coolant, contact a doctor. SAFETY INFORMATION: ENGINE COOLING SYSTEM - AS20.00-Z-9999ZZ MODEL all
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:09 AM Page 8 2005 Mitchell Repair Information Company, LLC. TROUBLE DIAGNOSIS COOLANT HOSE DAMAGED - AF20.20-P-2002A ENGINE 112 in MODEL 129, 163, 170, 202, 203, 208, 210 ENGINE 113 in MODEL 129, 163, 202, 208, 210 MODIFICATION NOTES PARTS ORDERING NOTES ENGINE OVERHEATED - AF20.20-P-6100A MODEL 124, 126, 129, 140, 163, 168, 170, 201, 202, 208, 210, 220, 461, 463 MODIFICATION NOTES
Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant. ENGINE all AS20.00-Z-0001-01A 15.11.00 Supersedes STIP 20.20-008 dated 09.11.2000
Damage code Cause Remedy 20 023 04 Hose fixture Coolant hose damaged/chafed at top by engine cover 1 Install hose bracket. The safety lug should catch audibly in the retaining hole on the oil filter.
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. AS20.00-Z-0001-01A Wear protective gloves, protective clothing and eye protection.
2 Remove/install/replace chafed coolant hose.
Part no. Designation Quantity 210 501 00 20 Hose fixture As required
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:09 AM Page 9 2005 Mitchell Repair Information Company, LLC. 29.9.99 Supersedes SI20/50 from 08.03.94 Remove SI 20/50 from your binder.
Damage code Cause Remedy 50 001 F7 Radiator clogged with corrosion products Convert cooling system to KFM type 30 ?
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 safety glasses. 1 Drain coolant from engine block and radiator. Flush residual corrosion products out of cooling/heating system so that new radiator cannot be clogged Do not flush cooling/heating system with citric acid, only with clear water. AS20.00-Z-0001-01A 2 Disconnect hot water hose from engine to heater feed line
3 Carefully blow out or flush heat exchanger Do not work with full air pressure available Ensure that the coolant is completely drained from the heater.
4 Remove/install/replace radiator
5 Mix antifreeze, type 30, with water outside of cooling system and fill into cooling system.
Mixing ratio 50 : 50.
Coolant specifications BB00.40-P-0310-01A 6 Remove sticker from 5 l container and apply to
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 10 2005 Mitchell Repair Information Company, LLC. PARTS ORDERING NOTES TESTING & REPAIR INSPECT COOLING SYSTEM FOR LEAKS - AR20.00-P-1010 Inspect cooling system for leaks - AR20.00-P-1010HA ENGINE 111 ENGINE 112 (except 112.961 /946 /953 /947 /960 /916 /955 /912) ENGINE 112.945 ENGINE 113.962 ENGINE 113 (except 113.992 /987 /988 /968 /991 /990 /963 /995) ENGINE 120 ENGINE 137 ENGINE 601 ENGINE 602 ENGINE 602.931 ENGINE 603 ENGINE 603.931 ENGINE 603.972 expansion reservoir
Service Information on coolant SI20.00-P-0001A 7 Dispose of drained coolant properly Pay attention to legal provisions and local wastewater regulations.
Notes on coolant All engines AH20.00-N-2080-01A Part no. Designation Quantity 000 989 16 25 11 Antifreeze, type 30 (5 l container) 1
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 12 2005 Mitchell Repair Information Company, LLC. Fig. 5: Inspecting Cooling System For Leaks -- Engines 111 & 112 (Except 112.961 /946 /953 /947 /960 /916 /955 /912) Remove/install
1 Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant. Open cap with detent (2) or 2-stage cap (2a) at expansion reservoir (1) or radiator. Do not open cooling system unless coolant temperature is below 90C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses. When closing cover with detent (2): rotate closing cover with detent carefully up to first detent, release pressure relief, then unscrew closing cover with detent (2). For model 163 with 2-stage cap (2a) or 1-stage cap: Rotate cap half a revolution in anticlockwise direction, release pressure, then unscrew 2-stage cap (2a) or 1-stage cap. AS20.00-Z-0001-01A 2 Set heating switches to maximum heating capacity All model except model 163. Model 163 does not have any pulsed valve; the heater heat exchanger has coolant permanently flowing through it.
Checking 3 Check coolant level, if Replace coolant against a
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 13 2005 Mitchell Repair Information Company, LLC. required adjust correctly. separate order if the antifreeze protection is insufficient: 4 Fit test cap (3) on expansion reservoir or radiator Model 124, 126, 129, 140, 170, 201, 202, 210, Model 463.209 /232 /233 with engine 112.945, Model 463.304 /324 /325 with engine 602.931 Model 463.307 /327 /328 with engine 603.931 Model 463.300 /320 /321 with engine 603.972 Model 463.308 /330 /331 with engine 606.964 Fig. 7 Model 170, 202, 203, 208, 209, 210, 211 Model 215, Model 220 with engine 137, 275, 628, Model 230 with engine 112, 113, 275, Model 240 with engine 285 Model 461.302 /331 /332 /342 /345 with engine 612.966, Model 463.243 /246 with engine 113.982, Model 463.244 /245 /250 with engine 112.945, Model 463.247 /248 /249 /254 with engine 113.962, Model 463.322 /323 with engine 612.965, Model 463.309/ 332/ 333 with engine 628.962 Fig. 9 Model 163 with engine 111, 112, 113, 612, 628 Fig. 8 5 Connect pressure pump (4).
Fig. 6 6 Apply pressure to cooling system and check leaktightness of cooling system *BE20.30-P-1005-01A 7 Inspect cooling and heating hoses as well as their connection points
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 14 2005 Mitchell Repair Information Company, LLC. Radiator or expansion reservoir cap Fig. 6: Identifying Pressure Pump (124 589 24 21 00) Fig. 7: Identifying Test Cap (124 589 00 91 00) for proper condition and loss of coolant; replace coolant hoses, if necessary 8 Check hose clamps for condition and seating If necessary, retighten hose clamps and replace if required.
*WH58.30-Z-1001- 06A
*WH58.30-Z-1002- 06A
*WH58.30-Z-1019- 02A 9 Install in the reverse order
Number Designation Cap 2-stage cap BE20.30-P-1005-01A Test pressure for pressure-testing cooling system bar gage 1.4 1.4
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 15 2005 Mitchell Repair Information Company, LLC. Fig. 8: Identifying Test Cap (163 589 01 91 00) Fig. 9: Identifying Test Cap (210 589 00 91 00) Commercially available tools Inspect cooling system for leaks - AR20.00-P-1010P ENGINE 111, 112, 113, 271, 611, 612, 646 in MODEL 203 ENGINE 112 in MODEL 170 ENGINE 112, 113, 271, 612, 646 in MODEL 209 ENGINE 271 in MODEL 211 ENGINE 113.989 in MODEL 171.473 ENGINE 646.8 in MODEL 211 Illustrated on model 203.035 Number Designation WH58.30-Z-1019-02A Hose clamp pliers (length 210 mm, clamping range 80 mm) 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
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 16 2005 Mitchell Repair Information Company, LLC. Fig. 10: Inspecting Cooling System For Leaks -- Illustrated On Model 203.035 Checking
Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant. Do not open cooling system unless coolant temperature is below 90C. 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
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 Model 170 AR88.40-P-1000G Model 171.4 AR88.40-P-1000V Model 203 AR88.40-P-1000P Model 209 AR88.40-P-1000Q Model 211 AR88.40-P-1000T 2 Open cap on expansion reservoir (2) 2-stage cap: Rotate cap half a revolution in a counterclockwise direction, release overpressure, then unscrew cap.
3 Set heating switches to maximum heating capacity
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 17 2005 Mitchell Repair Information Company, LLC. 4 Check coolant level If the antifreeze share of the coolant is too small, either antifreeze must be added or the coolant must be replaced: ?
Model 170 with Engine 112 Drain, fill system with coolant. AR20.00-P-1142SV Model 203 with engine 111, 271
Model 209 with engine 271 Drain, fill system with coolant. AR20.00-P-1142PR Model 171.473 with engine 113.989
Model 203 with engine 112, 113
Model 209 with Engine 112, 113
Drain, fill system with coolant. AR20.00-P-1142PV Model 203 with engine 611, 612, 646
Model 209 with engine 612, 646
Model 211 with engine 646.8
Drain, fill system with coolant. AR20.00-P-1142HB Model 211 with engine 271 Drain, fill system with coolant. AR20.00-P-1142T
Notes on coolant AH20.00-N-2080-01A
Notes on coolant level AH20.00-P-1142-01P 5 Mount test cap (1) at expansion reservoir (2) Test cap Fig. 9 6 Connect pressure pump (3). Pressure pump Fig. 6 7 Pressurize cooling system The test pressure must not be greater than 1.4 bar to avoid damage.
If new cylinder head gasket fitted, first warm up
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 18 2005 Mitchell Repair Information Company, LLC. CAP FOR RADIATOR OR EXPANSION RESERVOIR Fig. 11: Identifying Test Cap (210 589 00 91 00) engine to operating temperature before testing cooling system for leaks. Test pressure for pressure- testing cooling system *BE20.30-P-1005-01A 8 Check hose clamps for condition and seating If hose clamps are loose, tighten them or replace them.
9 Check coolant hoses and heater hoses and their connecting points for condition and coolant loss Replace damaged parts in order to prevent leaks.
10 Remove test cap (1) on expansion reservoir (2) Test cap Fig. 9 11 Detach pressure pump (3) Pressure pump Fig. 6 12 Move heater switch to starting position
13 Close cap on expansion reservoir (2)
Number Designation 2-stage cap BE20.30-P-1005-01A Test pressure for pressure- testing cooling system bar gage 1.4
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 19 2005 Mitchell Repair Information Company, LLC. Fig. 12: Identifying Pressure Pump (124 589 24 21 00) Inspect cooling system for leaks - AR20.00-P-1010RVK ENGINE 113.992 in MODEL 230.474 ENGINE 113.990 in MODELS 211.076 /276 ENGINE 113.991 in MODEL 215.374 ENGINE 113.991 in MODELS 220.074 /174 ENGINE 113.963 in MODEL 230.475 ENGINE 112.960 in MODEL 170.466 ENGINE 112.961 in MODELS 203.065 /265 ENGINE 113.993 in MODELS 463.270 /271 ENGINE 113.995 in MODEL 230.472 Shown on model 220 Fig. 13: Inspecting Cooling System For Leaks (Shown On Model 220)
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 20 2005 Mitchell Repair Information Company, LLC. Remove/install
Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant. Do not open cooling system unless coolant temperature is below 90C. 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 2-stage cap (2) Rotate 2-stage cap (2) half a revolution in counterclockwise direction, release overpressure, then unscrew 2-stage cap (2).
2 Set heater control to maximum heat output
Checking 3 Check coolant level, if required adjust correctly. If antifreeze protection is insufficient, replace as a separate repair order: ? Drain/fill in coolant
Engine 113.992 in model 230.474 Engine 113.995 in model 230.472 Engine 113.990 in models 211.076/276 Engine 113.991 in model 215.374 Engine 113.991 in models 220.074/174 Engine 113.963 in model 230.475 Engine 112.960 in model 170.466 Engine 112.961 in models 203.065/265 AR20.00-P-1142RVK Engine 113.993 in models 463.270/271 AR20.00-P-1142GX
Notes on coolant AH20.00-N-2080-01A
Notes on coolant level Engine 113.992 in model 230.474 Engine 113.995 in model 230.472 AH20.00-P-1142-01V
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 21 2005 Mitchell Repair Information Company, LLC. Fig. 14: Identifying Pressure Pump (124 589 24 21 00) Engine 113.990 in models 211.076 /276 Engine 113.991 in model 215.374 Engine 113.991 in models 220.074/ 174 Engine 113.963 in model 230.475 Engine 113.993 in models 463.270/ 271
Notes on coolant level Engine 112.960 in model 170.466 Engine 112.961 in models 203.065/ 265 AH20.00-P-1142-01P 4 Mount test cap (3) on expansion reservoir (1) Test cap Fig. 9 5 Connect tester (4) Discharge cooling system with a test pressure of approx. 1,4 bar.
Pressure pump Fig. 6 6 Check tightness of cooling system. Check cooling and heating hoses as well as their connection points for proper condition and loss of coolant; replace cooling and heating hoses if necessary
7 Inspect condition and installation at hose clamps; retighten or replace if necessary 6 mm socket hexagon *WH58.30-Z-1001-06A
7 mm socket hexagon *WH58.30-Z-1002-06A
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 22 2005 Mitchell Repair Information Company, LLC. Fig. 15: Identifying Test Cap (210 589 00 91 00) COMMERCIALLY AVAILABLE TOOLS DRAIN/FILL IN COOLANT - AR20.00-P-1142 Drain coolant, pour in - AR20.00-P-1142HG ENGINE 111 in MODEL 124, 163, 170, 202, 208, 210 Shown on model 202 Fig. 16: Draining Coolant - Shown On Model 202 MODIFICATION NOTES 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 13.10.04 Fill coolant using vacuum Step 13
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 23 2005 Mitchell Repair Information Company, LLC. method Draining
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
Notes on coolant AH20.00-N-2080-01A 1 Open cooling system cap (2) at coolant expansion reservoir (1) Pay attention to the different versions. Cooling system cap with detent (2): rotate cooling system cap with detent (2) carefully up to first detent, release pressure relief, then unscrew cooling system cap with detent (2).
2-step and 1-step cooling system cap (2): Turn cooling system cap (2) half a turn in an anti- clockwise direction, release overpressure and undo cooling system cap (2).
Risk of death cased by vehicle slipping or toppling off of the lifting platform. Align vehicle between the columns of the hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A 2 Raise vehicle. 3.1 Remove lower engine compartment paneling Model 170, 202 AR61.20-P-1105A Model 208, 210 AR61.20-P-1105AB
Model 124: undo bolts
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 24 2005 Mitchell Repair Information Company, LLC. and remove engine compartment paneling from below. Drain coolant from radiator 4.1 Push siphon hose (3a) onto radiator drain plug (3) Model 124, 170, 202, 208, 210
5.1 Open the radiator drain plug (3) and drain the coolant Model 124, 170, 202, 208, 210
Catch coolant with suitable vessel.
6.1 Close radiator drain plug (3) and pull out siphon hose (3a) Model 124, 170, 202, 208, 210
7.1 Dismantle bottom coolant hose at radiator or at coolant pump and drain off coolant Model 163
Catch coolant with suitable vessel.
8.1 Fit bottom coolant hose to radiator or to coolant pump Model 163
Replace hose clamp.
*BA20.20-P-1004-01A Drain coolant at crankcase 9 Slide the drain hose (4a) on to the crankcase drain plug (4)
10 Open the crankcase drain plug (4) and drain the coolant Catch coolant with suitable vessel.
11 Screw tight crankcase drain plug (4) and pull out siphon hose (4)
*BA01.40-P-1003-01B 12 Lower vehicle Pouring in 13 Pour in coolant and bleed cooling system Reuse the clean coolant. AR20.00-P-1142-04A
Notes on coolant level Model 124, 170, 202, 208, 210 AH20.00-P-1142-01A Model 163 AH20.00-P-1142-01GH 14 Inspect cooling system for AR20.00-P-1010HA
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 25 2005 Mitchell Repair Information Company, LLC. CRANKCASE, TIMING CASE COVER, END COVER RADIATOR, COOLANT HOSES COOLING SYSTEM leaks 15 Install bottom engine compartment covering
Model 170, 202 AR61.20-P-1105A Model 208, 210 AR61.20-P-1105AB
Model 124: insert bolts at bottom of engine compartment paneling and tighten.
Number Designation Engine 111 BA01.40-P-1003-01B Outlet connection of crankcase Nm30 Number Designation Engine 111.977 BA20.20-P-1004-01A Hose clamp Nm3 Number Designation Engines 111.920/921/941/944/ 945/961/974/975 in model 202, 111.940/960 in model 124, 111.942/947/970 in model 210, 111.944/945/975 in model 208, 111.946 in model 170 Engine 111.943/958/ 973/983 in model 170 BF20.00-P- 1001-02F Cooling system Total capacity without AC Liters8.0 8.5 with AC Liters8.5 9.0 Capacity of anticorrosion/antifreeze agent down to -37 C without AC Liters4.0 4.25 with AC Liters4.25 4.5 Capacity of anticorrosion/antifreeze agent down to -45 C without AC Liters4.5 4.7 with AC Liters4.75 5.0 Specifications for Operating Fluids SheetBB00.40-P-0310- 01A BB00.40-P- 0310-01A SheetBB00.40-P-0325- 00A BB00.40-P- 0325-00A
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 26 2005 Mitchell Repair Information Company, LLC. COOLING SYSTEM Fig. 17: Identifying Test Cap (210 589 00 91 00) Fig. 18: Identifying Vacuum-Type Cooling System Filler (285 589 00 21 00) Pour in coolant and bleed cooling system - AR20.00-P-1142-04A Number Designation Engine 111.977 in model 163 BF20.00-P- 1001-02F Cooling systemTotal capacity without AC Litersapprox. 10,5 with AC Litersapprox. 10,5 Capacity of anticorrosion/antifreeze agent down to -37 C without AC Litersapprox. 5,25 with AC Litersapprox. 5,25 Capacity of anticorrosion/antifreeze agent down to -45 C without AC Litersapprox. 5,75 with AC Litersapprox. 5,75 Specifications for Operating Fluids SheetBB00.40-P- 0310-01A SheetBB00.40-P- 0325-00A
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 27 2005 Mitchell Repair Information Company, LLC. Fig. 19: Identifying Tester Cap (169 589 00 91 00) Fig. 20: Identifying Test Cap (210 589 00 91 00) Fig. 21: Identifying Vacuum-Type Cooling System Filler (285 589 00 21 00) test cap: Test cap 169 589 00 91 00 for model 168 Test cap 210 589 00 91 00 for all except model 168 Only vent cooling system for a cold engine 1. Unscrew cooling system closure cap (10) and screw on test cap (2) at coolant expansion reservoir (1). 2. Attach the control unit (3) to the test cap (2) . 3. Attach the venturi nozzle (9) to the control unit (3). 4. Close the drain valve (8) and the feed valve (7).
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 28 2005 Mitchell Repair Information Company, LLC. Shown on model 171 with engine 272 Fig. 22: Identifying Cooling System Bleeding Procedure - Shown On Model 171 With Engine 272 5. Attach feed hose (4) of the coolant to coolant reservoir (4a) To avoid suctioning in of air put at least 2 l more coolant in the coolant reservoir (4a) than the maximum filling capacity of the cooling system. 6. Guide waste air hose (5) into an empty container (5a) 7. Connect compressed-air hose (6) to venturi nozzle (9) and apply pressure. 8. Open the drain valve (8). A vacuum is created in the cooling system. 9. Open feed valve (7) until feed hose (4) has filled with coolant. 10. Close drain valve (8) if display of the control unit (3) is in the green area. 11. Detach compressed air hose (6) from the venturi nozzle (9) and monitor whether vacuum remains stable for 30 seconds. If this is not the case, check hoses and connections and if necessary, repair and create a new vacuum. 12. Open feed valve (7).
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 29 2005 Mitchell Repair Information Company, LLC. The cooling system is filled. 13. Open the drain valve (8) if coolant is no longer suctioned. 14. Remove control unit (3) along with all connections and test cap (2) 15. Fill coolant up to bottom edge of filler neck of coolant expansion reservoir (1). 16. Screw cooling system closure cap (10) onto coolant expansion reservoir (1). Drain/fill in coolant - AR20.00-P-1142RVK ENGINE 113.992 in MODEL 230.474 ENGINE 113.990 in MODELS 211.076 /276 ENGINE 113.991 in MODELS 215.374, 220.074 /174 ENGINE 113.963 in MODEL 230.475 ENGINE 112.960 in MODEL 170.466 ENGINE 112.961 in MODELS 203.065 /265 ENGINE 113.995 in MODEL 230.472 Shown on model 220 Fig. 23: Identifying Coolant Drain/Fill Components (Shown On Model 220) MODIFICATION NOTES 14.10.04 Fill coolant using vacuum Step 10
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 30 2005 Mitchell Repair Information Company, LLC. method added Drain
Risk of injury to skin and eyes caused by 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 pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses. AS20.00-Z-0001-01A
Notes on coolant AH20.00-N-2080-01A 1 Open engine hood Model 170 AR88.40-P-1000G Model 203 AR88.40-P-1000P Model 215, 220 AR88.40-P-1000M Model 211 AR88.40-P-1000T Model 230 AR88.40-P-1000R 2.1 Detach ground line(s) at battery(ies) Only when draining coolant at crankcase, on the right, in models 170, 203, 215, 220, 230. Do not connect quiescent current retention device.
Model 170 AR54.10-P-0003A Model 203 AR54.10-P-0003P Model 215, 220 AR54.10-P-0003I Model 230 AR54.10-P-0003R 3 Open cooling system cap (1) at coolant expansion reservoir (2) Pay attention to different versions. Cooling system cap (1) with notch: Turn cooling system cap (1) carefully to first predetent, release pressure, then unscrew cooling system cap (1). 1-stage and 2-stage cooling system cap (1): turn cooling system cap (1) 1/2 revolution anticlockwise, release pressure and then
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 31 2005 Mitchell Repair Information Company, LLC. unscrew cooling system cap (1). 4 Remove lower engine compartment paneling Model 170 AR61.20-P-1105A Model 203 AR61.20-P-1105P Model 211 AR61.20-P-1105T Model 215, 220 AR61.20-P-1105M Model 230 AR61.20-P-1105R Drain coolant from radiator 5 Push drain hose (3a) onto engine radiator (3) drain plug (arrow), engine radiator (3) open drain plug and drain coolant Catch coolant with suitable vessel.
6 Close engine radiator (3) drain plug and detach coolant (3a) drain hose at fitting (arrow)
Drain coolant at crankcase 7.1 Slide drain hose onto crankcase drain plug (4), open crankcase drain plug (4) and drain coolant Models 170, 203, 215, 220, 230 Catch coolant with suitable vessel.
8.1 Detach drain hose on crankcase drain plug (4) and screw crankcase drain plug (4) tight Model 170, 203, 215, 220, 230
*BA20.00-P-1001-02B 9 Lower vehicle Filling 10 Pour in coolant and bleed cooling system Reuse clean coolant. AR20.00-P-1142-04A
Notes on coolant level Model 211, 215, 220, 230 with engine 113 AH20.00-P-1142-01V
Notes on coolant level Models 170, 203 with engine 112 AH20.00-P-1142-01P 11 Inspect cooling system for leaks AR20.00-P-1010RVK 12 Install lower engine compartment paneling Model 170 AR61.20-P-1105A Model 203 AR61.20-P-1105P
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 32 2005 Mitchell Repair Information Company, LLC. ENGINE COOLING, GENERAL COOLING SYSTEM Model 211 AR61.20-P-1105T Model 215, 220 AR61.20-P-1105M Model 230 AR61.20-P-1105R 13.1 Connect up ground line(s) at battery(ies) Only when coolant has been drained at crankcase on the right.
Model 170 AR54.10-P-0003A Model 203 AR54.10-P-0003P Model 215, 220 AR54.10-P-0003I Model 230 AR54.10-P-0003R 14.1 Perform basic programming Only if ground line(s) on battery(ies) were disconnected.
Model 170 AR00.19-P-0200B Model 203 AR00.19-P-0200P Model 215, 220 AR00.19-P-0200M Model 230 AR00.19-P-0200R 15.1 Connect up STAR DIAGNOSIS, read and erase diagnostic trouble code memory Only if ground line(s) on battery(ies) were disconnected.
Connect up STAR DIAGNOSIS and read out fault memory AD00.00-P-2000-04A 16 Close engine hood Model 170 AR88.40-P-1000G Model 203 AR88.40-P-1000P Model 215, 220 AR88.40-P-1000M Model 211 AR88.40-P-1000T Model 230 AR88.40-P-1000R Number Designation Engines 112, 113.940/941/942/943/944/945/946/948/960/961/963/964/965/966/967/968/971/980/981 BA20.00- P-1001- 02B Coolant drain plug on crankcase Nm12 Number Designation Engine 113.990 Engine 113.991 in model 215 Engine 113.992/995 in model 230 BF20.00-P- 1001-02K Cooling system Total filling capacity Litersapprox. 13.2 approx. 14.5 approx. 13.0 Capacity of Litersapprox. 6.6 approx. 7.3 approx. 6.5
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 33 2005 Mitchell Repair Information Company, LLC. COOLING SYSTEM COOLING SYSTEM Drain/fill in coolant - AR20.00-P-1142SV anticorrosion/antifreeze agent down to -37C Filling capacity of anticorrosion/antifreeze down to -45C Litersapprox. 7.3 approx. 8 approx. 7.3 Specifications for Operating Fluids SheetBB00.40-P- 0310-01A BB00.40-P- 0310-01A BB00.40-P- 0310-01A SheetBB00.40-P- 0325-00A BB00.40-P- 0325-00A BB00.40-P- 0325-00A Number Designation Engine 113.963 in model 230.475 Engine 112.961 in model 203.065/265 AMG Engine 112 in model 170 BF20.00-P- 1001-02K Cooling system Total filling capacity Litersapprox. 11.5 approx. 10.5 approx. 8 Capacity of anticorrosion/antifreeze agent down to -37C Litersapprox. 5.8 - approx. 4 Filling capacity of anticorrosion/antifreeze down to -45C Litersapprox. 6.5 - approx. 4.5 Specifications for Operating Fluids SheetBB00.40-P- 0310-01A - BB00.40-P- 0310-01A SheetBB00.40-P- 0325-00A - BB00.40-P- 0325-00A Number Designation Engine 113.986/991 in Model 220 BF20.00-P-1001- 02K Cooling system Total filling capacity Litersapprox. 13.5 Capacity of anticorrosion/antifreeze agent down to -37C Litersapprox. 6.8 Filling capacity of anticorrosion/antifreeze down to -45C Litersapprox. 7.4 Specifications for Operating Fluids SheetBB00.40-P-0310- 01A SheetBB00.40-P-0325- 00A
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 34 2005 Mitchell Repair Information Company, LLC. ENGINE 112.947 in MODEL 170.465 ENGINE 112.960 in MODEL 170.466 Fig. 24: Identifying Coolant Drain/Fill Components - Engine 112.947/960 Shown on model 170.465 MODIFICATION NOTES 14.10.04 Fill coolant using vacuum method added Step 11 Drain
Risk of injury to skin and eyes caused by 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 containers. Wear protective gloves, protective clothing and safety glasses. AS20.00-Z-0001-01A
Notes on coolant AH20.00-N-2080-01A 1 Open engine hood AR88.40-P-1000G 2.1 Disconnect battery ground cable Only when draining coolant at crankcase, right. Do not connect quiescent current retention device. AR54.10-P-0003A 3 Open cooling system cap (1) at coolant expansion reservoir (2) Turn cooling system cap(1) 1/2 one revolution anti-clockwise, release
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 35 2005 Mitchell Repair Information Company, LLC. pressure, then unscrew cooling system cap (1). 4 Remove lower engine compartment paneling AR61.20-P-1105A Drain coolant from radiator 5 Slide siphon hose onto fitting on radiator (3), open radiator drain plug (4) and drain coolant Catch coolant with suitable vessel.
6 Turn down radiator drain plug (4) and detach collector siphon hose from fitting at radiator (3).
Drain coolant at crankcase 7 Loosen crankcase drain plug (5) and push collector siphon hose onto crankcase drain plug (5).
8 Open the crankcase drain plug (5) and drain the coolant Catch coolant with suitable vessel.
9 Pull collector siphon hose off crankcase drain plug (5) and tighten crankcase drain plug (5).
*BA20.00-P-1001-02B 10 Lower vehicle Filling 11 Pour in coolant and bleed cooling system Reuse the clean coolant. AR20.00-P-1142-04A
Notes on coolant level AH20.00-P-1142-01P 12 Inspect cooling system for leaks AR20.00-P-1010P 13 Install lower engine compartment paneling AR61.20-P-1105A 14.1 Connect ground cable to battery Only when the coolant has been drained at the crankcase, right. AR54.10-P-0003A 15.1 Perform basic programming Only if the ground line of AR00.19-P-0200B
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 36 2005 Mitchell Repair Information Company, LLC. ENGINE COOLING, GENERAL COOLING SYSTEM the battery has been disconnected. 16.1 Connect up STAR DIAGNOSIS, read and erase diagnostic trouble code memory Only if the ground line of the battery has been disconnected.
Connect up STAR DIAGNOSIS and read out fault memory AD00.00-P-2000-04A STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A 17 Close engine hood AR88.40-P-1000G Number Designation Engines 112, 113.940/941/ 942/943/944/ 945/946/948/ 960/961/963/ 964/965/966/ 967/968/971/ 980/981/984/ 986/987/988/ 990/991/992/ 955 BA20.00-P-1001-02B Coolant drain plug to crankcase Nm12 Number Designation Engine 112 in model 170 BF20.00-P-1001- 02K Cooling system Total filling capacity Litersapprox. 8 Capacity of anticorrosion/antifreeze agent down to -37C Litersapprox. 4 Filling capacity of anticorrosion/antifreeze down to -45C Litersapprox. 4.5 Specifications for Operating Fluids SheetBB00.40-P-0310- 01A SheetBB00.40-P-0325- 00A
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 37 2005 Mitchell Repair Information Company, LLC. Fig. 25: Identifying Test Cap (210 589 00 91 00) Fig. 26: Identifying Vacuum-Type Cooling System Filler (285 589 00 21 00) COMMERCIALLY AVAILABLE TOOLS VENTING AIR FROM THE LOW TEMPERATURE CIRCUIT - AR20.00-P-1145RVK ENGINE 113.992 in MODEL 230.474 ENGINE 113.990 in MODELS 211.076 /276 ENGINE 113.991 in MODEL 215.374 ENGINE 113.991 in MODELS 220.074 /174 ENGINE 113.963 in MODEL 230.475 ENGINE 112.960 in MODEL 170.466 ENGINE 112.961 in MODELS 203.065 /265 ENGINE 113.995 in MODEL 230.472 Number Designation WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 38 2005 Mitchell Repair Information Company, LLC. Fig. 27: Identifying Venting Air From Low Temperature Circuit Remove/install
Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant. Do not open cooling system unless coolant temperature is below 90C. Open cap slowly and release pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses. AS20.00-Z-0001-01A 1 Open cap at coolant expansion reservoir (2) Cap with detent: Carefully turn cap as far as first detent, release pressure, and then unscrew cap. 2-stage and 1-stage cap: Rotate cap half a revolution counterclockwise, release pressure relief and then unscrew cap.
Notes on coolant All engines AH20.00-N-2080-01A 2 Pour in coolant Fill coolant up to prescribed marking in coolant expansion reservoir (2). AR20.00-P-1142RVK
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 39 2005 Mitchell Repair Information Company, LLC. COMMERCIALLY AVAILABLE TOOLS REMOVE/INSTALL COOLANT PUMP - AR20.10-P-1271 Remove/install coolant pump - AR20.10-P-1271A ENGINE 111 3 Close coolant drain line (4) with pliers
4 Detach coolant line from fitting (3)
5 Attach additional ventilation hose to fitting (3) Route vent hose to coolant expansion tank (2).
Risk of injury caused by moving parts that can pinch, crush or , in extreme cases even sever extremities. No parts of the body or limbs should be within the operating range of the mechanism when components are in motion. AS00.00-Z-0009-01A 6 Venting air from the low temperature circuit The electric fan runs up to 50% during the ventilation procedure. Purging: Actuate charge air cooler circulation pump (M44) using STAR DIAGNOSIS. Let charge air cooler circulation pump (M44) run until coolant flows out of fitting (3) free of bubbles.
STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A 7 Install in the reverse order 8 Inspect cooling system for leaks AR20.00-P-1010RVK Number Designation WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 40 2005 Mitchell Repair Information Company, LLC. Fig. 28: Identifying Coolant Pump Removal/Install Components Remove/install 1 Remove viscous fan clutch (1) Engines with viscous fan clutch Left-hand thread AR20.40-P-5660A 2 Drain coolant At radiator and crankcase AR20.00-P-1142HG 3 Disconnect coolant hoses (11, 12 and 32)
*WH58.30-Z-1002-06A
Inspect condition of coolant hoses and hose clamps, replace if necessary.
4 Loosen combination screws (33a) at belt pulley (33)
*BA20.10-P-1002-01B 5 Remove poly V-belt (2) AR13.22-P-1202A 6 Unscrew and remove coolant pump belt pulley (33)
7 Unscrew and remove coolant pump (34) The coolant pump for engines 111.943/ 944/973/975 with compressor is 29.5 mm longer. *BR00.45-Z-1012-01A
Installation: Clean the sealing surfaces. Coolant pumps that were originally coated with liquid sealant
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 41 2005 Mitchell Repair Information Company, LLC. COOLANT PUMP, COOLANT THERMOSTAT REPAIR MATERIALS COMMERCIALLY AVAILABLE TOOLS Remove/install coolant pump - AR20.10-P-1271B ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250 ENGINE 112 in MODELS 129, 163, 170, 202, 203, 208, 209, 210, 220 ENGINE 113.962 in MODELS 463.206 /240 /241 /247 /248 /249 /254 ENGINE 113 in MODELS 129, 163, 202, 203, 208, 209, 210, 220 ENGINE 113.982 in MODELS 463.243 /246 ENGINE 113.989 in MODEL 171.473 Shown on engine 112 can be sealed with liquid sealant or paper sealant (35) in the event of a repair.
*BA20.10-P-1001-01B 8 Install in the reverse order 9 Inspect cooling system for leaks AR20.00-P-1010HA Number Designation Engine 111 BA20.10-P-1001- 01B Bolt connecting coolant pump to crankcase M6 Nm10 M8 Nm25 BA20.10-P-1002- 01B Bolt connecting pulley to coolant pump Nm10 Number Designation Order number BR00.45-Z-1012-01A Sealant A 002 989 47 20 10 Number Designation WH58.30-Z-1002-06A 7 mm socket hexagon on flexible shaft for hose clamps with worm drive
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 42 2005 Mitchell Repair Information Company, LLC. Fig. 29: Identifying Coolant Pump Remove/Install Components - Shown On Engine 112 Modification notes 16.12.03 Value changed from 10 Nm to 9 Nm Value in BA20.10-P-1002-01M modified on engine 112.910/911/912/913/914/915/916/ 917/920/921 /922/923/940/941 /942/ 943/944/945/946/947/949/953/954/ 955/960/961 /970/972/973/975 *BA20.10-P-1002- 01M Remove/install
Risk of death caused by vehicle slipping or toppling off the lifting platform. Align vehicle between the columns of the and position the four support plates below the lifting platform support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A 1 Lift/jack up vehicle Models 129, 170, 202, 208, 210, 220
Model 163 AR00.60-P-1000GH Model 171 AR00.60-P-1000V Models 203, 209 AR00.60-P-1000P Model 463 AR00.60-P-1000G
Risk of injury caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/ rear-end door or sliding When moving components, ensure that no body parts or limbs are within the operating range of moving parts. AS00.00-Z-0011-01A
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 43 2005 Mitchell Repair Information Company, LLC. roof. 2 Open engine hood Model 129 Model 163.154/172 up to VINA145272 AR88.40-P-1000GH Model 163.154/172 up to VINX708318154/172
Model 163.154/172 from VINA145273 AR88.40-P-1000GI Model 163.154/172 from VINX708319
Models 163.157/174/175 Model 170 AR88.40-P-1000G Model 171.4 AR88.40-P-1000V Model 202 AR88.40-P-1000E Model 203 AR88.40-P-1000P Models 208/210 AR88.40-P-1000F Model 209 AR88.40-P-1000Q Model 220 AR88.40-P-1000M Model 463 AR88.40-P-1000GG 3.1 Unclip cover on front side of engine Only model 220.
4.1 Remove engine cover or air filter All except models 170.466, 171.473, 203.065 /265, 203.076 /276, 209.376 /476 from 24.4.04.
5.1 Partially remove air filter housing Engine 112.960 in model 170.466 AR09.10-P-1150SVK Engine 112.961 in models 203.065/ 265
Engine 113.987 in models 209.376 /476 as of 24.4.04 AR09.10-P-1150AC ENGINE 113.988 in Models 203.076/276
Engine 113.989 in model 171.473 6.1 Remove viscous fan (1) All except models 163.174/175, 170, 171.473, 203, 208.365 /465, 209, 220 Right-hand thread! AR20.40-P-5660C 7.1 Remove fan shroud (3) On vehicles fitted with suction fan, separate the plug connection of the suction fan before removing the fan shroud.
Model 171.473 with engine 113.989 AR20.40-P-6800VT Model 463 with engines 112.945, AR20.40-P-6800V
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 44 2005 Mitchell Repair Information Company, LLC. 113.962/982 Model 220 with engines 112, 113 AR20.40-P-6800AB 8.1 Remove electric fan Model 163 with engines 113.965/981 AR20.40-P-5000GH Model 170 with engines 112.947/ 960 AR20.40-P-5000SV Model 171.473 with engine 113.989 AR20.40-P-5000V Model 203.076/ 276 AR20.40-P-5000AC Model 203 with engines 112.912/916/ 946/953/961 AR20.40-P-5000PV Model 209 with engines 112.912 /955, 113.968 /987.
Models 208.365/ 465
Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant. Do not open cooling system unless coolant temperature is below 90C. 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 9 Drain coolant from radiator Model 163: For draining coolant, detach bottom coolant line at radiator or at coolant pump.
Installation: On model 163 replace radiator connection of hose clamps to coolant hose, otherwise this can cause a damage to the bolt/ thread.
Hose clamp *BA20.20-P-1004- 01A 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. Models 129, 163, 202, 208, 210, 220 with engine 112 AR20.00-P-1142HA Models 220, 210, 208, 202, 163, 129 with engine 113 Model 463.206 /240 /241 /247 /248 / 249 /254 with engine 113.962. Model
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 45 2005 Mitchell Repair Information Company, LLC. 463.209 /232 /233 /244 /245 /250 with engine 112.945. Models 463.243 /246 with Engine 113.982 Model 170.465 with engine 112.947 AR20.00-P-1142SV Model 170.466 with engine 112.960 Model 171.473 with engine 113.989 AR20.00-P-1142PV Models 203.061 /261 with Engine 112.912 Models 203.064 /264 /764 with Engine 112.946 Models 203.065 /265 with Engine 112.961 Models 203.076 /276 with Engine 113.988 Models 203.081 /281 with Engine 112.916 Models 203.084 /284 with Engine 112.953 Models 209.361 /461 with Engine 112.912 Models 209.365 /465 with Engine 112.955 Models 209.375 /475 with Engine 113.968 Models 209.376 /476 with Engine 113.987 10 Remove poly-V-belt (2) Lock tensioning pulley with drift or pin (diameter 5 mm).
Model 463.209 /232 /233 /244 /245 /250 with engine 112.945. AR13.22-P-1202B Model 463.206 /240 /241 /247 /248 / 249 /254 with engine 113.962. Models 463.243 /246 with Engine 113.982 Models 129, 163 with engine 112 Models 129, 202, 208.370 /470, 210 with engine 113 Model 163 with engine 113 except 113.965/981
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 46 2005 Mitchell Repair Information Company, LLC. Models 202, 208, 210, 220 with engine 112 AR13.22-P-1202BA Model 220 with engine 113 except 220.074/174 Model 163.174 with engine 113.981 Model 163.175 with engine 113.965 MODELS 208.374 /474 with Engine 113 Models 220.074/174 AR13.22-P-1202R Model 170.465 with engine 112.947 AR13.22-P-1202SV Model 170.466 with engine 112.960 AR13.22-P-1202SVK MODELS 203.065 /265 with ENGINE 112.961
Model 171.473 with engine 113.989 AR13.22-P-1202PV Models 203.061 /261 with Engine 112.912 Models 203.064 /264 /764 with Engine 112.946 Models 203.076 /276 with Engine 113.988 Models 203.081 /281 with Engine 112.916 Models 203.084 /284 with Engine 112.953 Models 209.361 /461 with Engine 112.912 Models 209.365 /465 with Engine 112.955 Models 209.375 /475 with Engine 113.968 Models 209.376 /476 with Engine 113.987 11.1 Remove shock absorber (10) Models 210, 203, 209, 202, 170, 129 with manual transmission
12 Remove poly-V-belt tensioning device Model 463.209 /232 /233 /244 /245 /250 with engine 112.945. AR13.25-P-3200B Model 463.206 /240 /241 /247 /248 / 249 /254 with engine 113.962.
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 47 2005 Mitchell Repair Information Company, LLC. Models 463.243 /246 with Engine 113.982 Models 129, 163 with engine 112 Models 129, 202, 208, 210 with engine 113 Model 163 with engine 113 except 113.965/981 Model 163.174 with engine113.981 AR13.25-P-3200BA Model 163.175 with engine 113.965 Models 170, 202, 203, 208, 209, 210, 220 with engine 112 Model 171.473 with engine 113.989 Models 203, 209, 220 with engine 113 13 Disconnect coolant hose (4, 5) Check condition of coolant hoses and hose clamps, replace if necessary.
14.1 Disconnect coolant hose (6) at oil-water heat exchanger All except model 171.473. Check condition of coolant hose and hose clamp, replace if necessary.
15.1 Remove bolts from oil lines on oil filter Only model 171.473.
Bolt of oil line to oil filter housing *BA18.20-P-1003- 01D 16.1 Remove bolts from oil lines brackets and lay oil lines with brackets to one side Only model 171.473. Bolt, oil line bracket *BA18.20-P-1004- 01D 17.1 Remove bracket with switchover valve and pressure sensor and place to one side Only model 171.473
18 Take off belt pulley of coolant pump (7) Engine 112: ?
Belt pulley to coolant pump *BA20.10-P-1002- 01M Engine 113, except 113.987 /988 / 989 /991: ?
Belt pulley to coolant pump *BA20.10-P-1002- 01C Engines
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 48 2005 Mitchell Repair Information Company, LLC. Alternator Oil filter 113.987 /988/989 /991: ? Belt pulley to coolant pump *BA20.10-P-1002- 01L Engine 113.989: ?
Engine 112: ? Self-tapping screw, coolant pump to timing case *BA20.10-P-1001- 01M Engine 113 except 113.987 /988 / 989 /991: ? Self-tapping screw, coolant pump to timing case *BA20.10-P-1001- 01C Engines 113.987 /988/989 /991: ?
Bolt, coolant pump to timing case *BA20.10-P-1001- 01L Engine 112, 113: ?
Alternator screw *BA15.40-P-1003- 01A External Torx set Fig. 30 20 Install in the reverse order
21 Inspect cooling system for leaks All except models 170, 171.473, 203, 209, 220.074/174 AR20.00-P-1010HA Models 170, 171.473, 203, 209 AR20.00-P-1010P Models 220.074/174 AR20.00-P- 1010RVK Number Designation Engines 112.91/92/94/ 953/954/955/ 96/97, 113.94/96/98 Engine 113.991 in models 215, 220 BA15.40-P-1003- 01A Bolt for alternator Nm42 - Number Designation Engine 113.989 BA18.20-P-1003-01D Bolt, oil line to oil filter housing Nm9 BA18.20-P-1004-01D Bolt for oil line bracket Nm-
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 49 2005 Mitchell Repair Information Company, LLC. Coolant pump, coolant thermostat Coolant pump, coolant thermostat Number Designation Engines 112.910/911/91 2/913/914/915/ 916/917/920/ 921/922/923/ 940/941/942/ 943/944/945/ 946/947/949/ 953/954/955/ 960/961/970/ 972/973/975 BA20.10-P-1001- 01M Self-tapping screw, coolant pump to timing case Thread not pre- tapped M6 Nm14 Thread not pre- tapped M8 Nm35 Thread pre- tapped M6 Nm10 Thread pre- tapped M8 Nm25 BA20.10-P-1002- 01M Belt pulley to coolant pump Nm9 Number Designation Engines 113.940/941/ 942/943/944/ 945/946/948/ 960/961/962/ 963/965/966/ 967/968/969/ 980/981/982/ 984/986/992 993/995 BA20.10-P-1001- 01C Self-tapping screw, coolant pump to timing case Thread not pre- tapped M6 Nm14 Thread not pre- tapped M8 Nm35 Thread pre- tapped M6 Nm10 Thread pre- tapped M8 Nm25 BA20.10-P-1002- 01C Belt pulley to coolant pump Nm10
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 50 2005 Mitchell Repair Information Company, LLC. Coolant pump, coolant thermostat Radiator, coolant hoses Fig. 30: Identifying External Torx Set (001 589 76 09 00) Fig. 31: Identifying Counterholder (113 589 00 40 00) Remove/install coolant pump - AR20.10-P-1271GS ENGINE 111.958 in MODEL 170.444 ENGINE 111.983 in MODEL 170.449 Number Designation Engine 113.987/988/ 990/991 Engine 113.989 BA20.10-P-1001- 01L Bolt, coolant pump to timing case M6 Nm14 14 M8 Nm20 20 BA20.10-P-1002- 01L Belt pulley to coolant pump Nm9 9 Number Designation Engines 112.942/ 970, 113.942/ 965/981 BA20.20-P-1004-01A Hose clamp Nm3
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 51 2005 Mitchell Repair Information Company, LLC. Fig. 32: Identifying Coolant Pump Remove/Install Components - Engine 111.983
Remove/install
Risk of injury to skin and eyes caused by 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 containers. Wear protective gloves, protective clothing and safety glasses. AS20.00-Z-0001-01A 1 Drain coolant from radiator AR20.00-P-1142HA 2 Remove fan shroud AR20.40-P-6800GS 3 Detach coolant lines (4, 5 and 12) Check the condition of the hose clamps and the coolant lines, replace if required.
*WH58.30-Z-1002-06A 4 Unscrew combination screws (6) at belt pulley (7)
*BA20.10-P-1002-01B 5 Remove poly-V-belt (3) AR13.22-P-1202GS 6 Unscrew and remove belt pulley (7) at coolant pump (8)
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 52 2005 Mitchell Repair Information Company, LLC. Coolant pump, coolant thermostat Repair materials Commercially available tools SEALING COOLANT PUMP - AR20.10-P-2250A ENGINE 111 7 Unscrew and remove coolant pump (8) Installation: Clean the sealing surfaces. Coolant pumps that were originally coated with liquid sealant can be sealed with liquid sealant or paper sealant (11) in the event of a repair. *BR00.45-Z-1012-01A
*BA20.10-P-1001-01B 8 Install in the reverse order 9 Inspect cooling system for leaks AR20.00-P-1010HA Number Designation Engine 111 BA20.10-P-1001- 01B Bolt, coolant pump to crankcase M6 Nm10 M8 Nm25 BA20.10-P-1002- 01B Bolt, pulley to coolant pump Nm10 Number Designation Order number BR00.45-Z-1012-01A Sealant A 002 989 47 20 10 Number Designation WH58.30-Z-1002-06A 7 mm socket hexagon on flexible shaft for hose clamps with worm drive
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 53 2005 Mitchell Repair Information Company, LLC. Fig. 33: Sealing Coolant Pump Removal, installation 1 Remove coolant pump AR20.10-P-1271A 2 Place puller (14) against impeller (5), tension
Tension claws of puller (14) with sleeve, inner 40 mm (shop-made) or suitable hose strap Fig. 34 3 Pull off impeller (5) If impeller (5) is tight, apply slight pressure to puller (14) when pulling off.
4 Pull off mating ring (3) With pliers 5 Press out cassette-type seal (4) Position screwdriver against circumference of cassette-type seal (4) to pinch out of coolant pump (1). Do not damage coolant pump (1); use clean rag as a base.
6 Install cassette-type seal (4) AR20.10-P-2250-01A 7 Install in the reverse order 8 Check cooling system for leaks AR20.00-P-1010HA
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 54 2005 Mitchell Repair Information Company, LLC. Fig. 34: Identifying Puller (000 589 94 33 00) Installing cassette-type seal - AR20.10-P-2250-01A 1. Clean mounting hole for cassette-type seal (4). Sealant is applied to the circumference of the cassette-type seal. 2. Use a sleeve 40 mm to press new cassette-type seal (4) into the mounting hole in the coolant pump housing as far as a stop. 3. Push mating ring (3) onto pump shaft with ground face toward the slide ring (4a). 4. Heat impeller (5) to about 100 C. 5. Press on impeller (5) to dimension (a) 0.2 - 0.8 mm. Fig. 35: Identifying Cassette-Type Seal, Mating Ring, Impeller & Slide Ring TESTING COOLANT THERMOSTAT - AR20.10-P-2455AV
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 55 2005 Mitchell Repair Information Company, LLC. ENGINE 112 ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250 ENGINE 113.962 in MODELS 463.206 /240 /241 /247 /248 /249 /254 ENGINE 113.982 in MODELS 463.243 /246 ENGINE 113 (except 113.995) in MODELS 129, 163, 202, 203, 208, 209, 210, 211, 215, 220, 230 Fig. 36: Testing Coolant Thermostat Remove/install
Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant. Do not open cooling system unless coolant temperature is below 90C. Open cap slowly and release pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses. AS20.00-Z-0001- 01A 1 Remove coolant thermostat (1) Installation: Install new sealing ring. The coolant thermostat (1) must not be removed from housing. Otherwise it will be destroyed. The housing is supplied together with a coolant thermostat (1) for repair purposes.
Engine 112 in models 170, 203, 211.080/280 /082/282/261/265, Engine 113 in models 211.083/283/270, 215.373/375 Engine 112 in models 211.061/065, 220, 129, 209.361/461, 163, 202, 208, 209.365/465, 210, Engine 112.945 in models AR20.10-P-2460B
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 56 2005 Mitchell Repair Information Company, LLC. 463.245/233/209 /250/244/232, Engine 113 in models 209, 210, 129, 208, 211.070, 220, 230.475, 163, 202, Engine 113.962 in models 463.254/206/248 /240/247/241/249, Engine 113.982 in models 463.246/243 Engine 113.990 in models 211.076/276, Engine 113.991 in models 215.374, 220.074, Engine 113.992 in model 230.474 AR20.10-P- 2460RVK Engine 112.973 in model 230.467 AR20.10-P-2460R
Checking 2 Heat coolant thermostat (1) Suspend coolant thermostat (1) from a wire in a vessel filled with water and heat water. For heating up under no circumstance use a welding torch or a soldering torch, otherwise sudden heat penetration modifies the metal structure!
3 Measure temperature of water The heating-up rate should be not more than 1C to 2C/minute from about 8C below start of opening of coolant thermostat (1).
*WH58.30-Z-1002- 08A 4 Warm up water to full opening temperature of valve (2) and then measure hub of valve (2) If the check values are not achieved, replace coolant thermostat (1). Check values for engine 113.969:
Start of opening *BE20.10-P-1001- 02A Minimum stroke *BE20.10-P-1002- 02A 5 Install in the reverse order
6 Inspect cooling system for leaks
Engine 112.946 in model 209.764 Engine 112 (except 112.961/946/953/947 /960/916/955/912), Engine 113 (except 113.992/987/968/991 /990/963) AR20.00-P-1010HA Engine 113.963/990/991/992 AR20.00-P-
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 57 2005 Mitchell Repair Information Company, LLC. Coolant thermostat Commercially available tools REMOVING AND ENGINE INSTALLING COOLANT THERMOSTAT - AR20.10-P-2460 Removing and engine installing coolant thermostat - AR20.10-P-2460A ENGINE 111 1010RVK Engine 112.912/916/947/953/955/960/961, Engine 112.946 except in model 209.764, Engine 113.968/987 AR20.00-P-1010P Number Designation Engine 112, engines 113.940/941/ 942/943/944/ 945/946/948/ 960/961/962/ 963/964/965/ 966/967/968/ 971/980/981/ 982/984/986/ 987/988/990/ 991/992/993/ 995 BE20.10-P-1001-02A Start of opening C85 to 89 BE20.10-P-1002-02A Minimum stroke C102 mm8 BE20.10-P-1003-02A Thermostat bypass valve dia. mm- Number Designation WH58.30-Z-1002-08A Digital temperature measuring instrument (measuring range -20 to +70
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 58 2005 Mitchell Repair Information Company, LLC. Fig. 37: Identifying Coolant Thermostat Remove/Install Components - Engine 111
Removing, installing 1 Drain coolant at radiator AR20.00-P-1142HG 2 Remove upper front cover 3.1 Unscrew charge air pipe bracket from cover (27) Engine 111.944/975 with aluminum intake manifold
4 Disconnect coolant hoses (2 and 4)
Check condition of coolant hoses and coolant clamps and replace if necessary. *WH58.30-Z-1002-06A 5 Unscrew and remove cover (27) of coolant thermostat housing (30) with coolant thermostat (27a) The coolant thermostat (27a) must not be removed from the cover (27). It will be damaged beyond repair. It cannot be re-installed. In the event of a repair being necessary the cover (27) is included in the supply of the coolant thermostat (27a). Installation: Replace O-ring (29).
6 Install in reverse order
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 59 2005 Mitchell Repair Information Company, LLC. Commercially available tools Removing and engine installing coolant thermostat - AR20.10-P-2460GS ENGINE 111.958 in MODEL 170.444 ENGINE 111.983 in MODEL 170.449 Fig. 38: Identifying Coolant Thermostat Remove/Install Components - Engine 111.983 7 Check cooling system for leaks AR20.00-P-1010HA Number Designation WH58.30-Z-1002-06A 7 mm socket hexagon on flexible shaft for hose clamps with worm drive
Removing, installing
Risk of injury to skin and eyes from scalding from hot coolant which splashes out. Risk of poisoning from swallowing coolant. Do not open the cooling system unless the coolant temperature is below 90 C. Open cap slowly and allow the pressure to release. Do not pour coolant into containers for drinks. Wear protective gloves, AS20.00-Z-0001-01A
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 60 2005 Mitchell Repair Information Company, LLC. Commercially available tools REMOVING AND INSTALLING ENGINE COOLANT THERMOSTAT HOUSING - AR20.10-P-2710 Removing and installing engine coolant thermostat housing - AR20.10-P-2710A ENGINE 111 protective clothes, and eye protection. 1 Drain coolant at radiator AR20.00-P-1142HA 2 Remove front cover at top, unclip
3 Detach coolant hoses (2 and 4) Inspect condition of coolant hoses and hose clamps, replace if necessary.
*WH58.30-Z-1002-06A 4 Unscrew cover (27) of coolant thermostat housing (30) together with coolant thermostat (27a), take off The coolant thermostat (27a) must not be taken out of the cover (27) otherwise it will be destroyed. Re-installation is not possible. The cover (27) is supplied for repair purposes together with the coolant thermostat (27a). Installation: replace O- ring (29).
6 Install in the reverse order 7 Inspect cooling system for leaks AR20.00-P-1010HA Number Designation WH58.30-Z-1002-06A 7 mm socket hexagon on flexible shaft for hose clamps with worm drive
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 61 2005 Mitchell Repair Information Company, LLC. Fig. 39: Identifying Engine Coolant Thermostat Housing Remove/Install Components - Engine 111
Removing, installing 1 Remove viscous fan clutch (1) Engines with viscous fan clutch Left-handed thread AR20.40-P-5660A 2 Drain coolant at radiator AR20.00-P-1142HG 3 Remove cover (16) 4 Disconnect coolant hoses (2, 3 and 4)
Check condition of coolant hoses and hose clamps and replace if necessary. *WH58.30-Z-1002-06A 5 Disconnect electrical connectors and vacuum pipes on temperature sensor in coolant thermostat housing (30)
6 Unscrew suspension lug (6)
7 Unscrew coolant thermostat housing (30)
Unscrew bolts (7, 8 and 9). Installation: Clean sealing surfaces and replace O-ring (31). If the coolant thermostat housing (30) is replaced, observe location of *BA20.10-P-1003-01B
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 62 2005 Mitchell Repair Information Company, LLC. Engine coolant pump, coolant thermostat Commercially available tools Location of coolant temperature sensor - AR20.10-P-2710-01A 1. Re-install temperature sensors and thermal valves at the same point. Fig. 40: Identifying Coolant Temperature Sensor Components Location (1 Of 2) 1. Re-install temperature sensor and thermostatic valves at the same point. temperature sensor ? Location of temperature sensor, coolant thermostat housing AR20.10-P-2710-01A 8 Install in reverse order 9 Check cooling system for leaks. AR20.00-P-1010HA Number Designation Engine 111 BA20.10-P-1003- 01B Bolt, coolant thermostat housing M6 Nm10 M8 Nm25 Number Designation WH58.30-Z-1002-06A 7 mm socket hexagon on flexible shaft for hose clamps with worm drive
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 63 2005 Mitchell Repair Information Company, LLC. Fig. 41: Identifying Coolant Temperature Sensor Components Location (2 Of 2) Removing and installing engine coolant thermostat housing - AR20.10-P-2710GS ENGINE 111.958 in MODEL 170.444 ENGINE 111.983 in MODEL 170.449 Fig. 42: Identifying Engine Coolant Thermostat Housing Remove/Install Components - Engine 111.983
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 64 2005 Mitchell Repair Information Company, LLC. Coolant pump, coolant thermostat Commercially available tools
Removing, installing
Risk of injury to skin and eyes from scalding from hot coolant which splashes out. Risk of poisoning from swallowing coolant. Do not open the cooling system unless the coolant temperature is below 90 C. Open cap slowly and allow the pressure to release. Do not pour coolant into containers for drinks. Wear protective gloves, protective clothes, and eye protection. AS20.00-Z-0001-01A 1 Drain coolant at radiator AR20.00-P-1142HG 2 Remove fan shroud AR20.40-P-6800GS 3 Remove cover (16) 4 Detach coolant hoses (2, 3 and 4) Inspect condition of coolant hoses and hose clamps, replace if necessary.
*WH58.30-Z-1002-06A 5 Unplug electrical connection of temperature sensor (B11/4)
*BA20.10-P-1003-01B 8 Install in the reverse order 9 Inspect cooling system for leaks AR20.00-P-1010HA Number Designation Engine 111 BA20.10-P-1003- 01B Bolt of coolant thermostat housing M6 Nm10 M8 Nm25 Number Designation WH58.30-Z-1002-06A 7 mm socket hexagon on flexible shaft for hose clamps with worm drive
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 65 2005 Mitchell Repair Information Company, LLC. REMOVE/INSTALL THE RADIATOR - AR20.20-P-3865 Remove/install the radiator - AR20.20-P-3865A ENGINE 111 in MODELS 124, 170, 202, 208, 210 Shown on Model 210 Fig. 43: Identifying Radiator Removal/Install Components - Shown On Model 210 Picture item, etc. Work instructions Coolant drain at the radiator AR20.00-P-1142HG 2, 3 Viscous fan clutch, fan shroud remove Engines with viscous fan clutch AR20.40-P-5660A 7, 6 Transmission oil lines unscrew *BA20.20-P-1001-01A
on automatic transmission
connect transmission oil lines with a connecting pipe (01).
Installation: Check oil level, and adjust if necessary
Transmission 722.6 AR27.00-P-0101A
Connecting pipe (01) for automatic transmission oil lines WF58.50-P-2020-01A
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 66 2005 Mitchell Repair Information Company, LLC. RADIATOR, COOLANT HOSES COMMERCIALLY AVAILABLE TOOLS Remove/install the radiator - AR20.20-P-3865GS ENGINE 111.958 in MODEL 170.444 ENGINE 111.983 in MODEL 170.449 2, 20, 22a, 23 Radiator crossmember, blower protective grille, air guide components remove 24 Condenser at radiator unscrew and leave in the vehicle with the connected lines. Model 170, 202, 208, 210 with air conditioning system
Installation: Insert the spigots in the grommets (19) in the lower crossmember. *WH58.30-Z-1002-06A Check the cooling system for leaks AR20.00-P-1010HA Number Designation Engine 111 except 111.977 Engine 111.977 BA20.20-P-1001- 01A Union nut of automatic transmission ATF line to radiator Nm20 20 Number Designation WH58.30-Z-1002-06A 7 mm socket hexagon on flexible shaft for hose clamps with worm drive
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 67 2005 Mitchell Repair Information Company, LLC. Fig. 44: Identifying Radiator Remove/Install Components - Engine 111.983
Remove/Install
Risk of injury to skin and eyes from scalding due to contact with hot coolant spray. Risk of poisoning if coolant is swallowed. 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 Drain the coolant Drain plug (10) on radiator AR20.00-P-1142HG 2 Remove fan shroud (2) AR20.40-P-6800GS 3 Unscrew transmission oil lines (11, 12) For automatic transmission. Connect the transmission oil lines with a connecting pipe (01). Installation: Check the oil level and adjust if necessary
Transmission 722.6 AR27.00-P-0101A
*BA20.20-P-1001-01A
Connecting pipes (01) for WF58.50-P-2020-01A
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 68 2005 Mitchell Repair Information Company, LLC. Radiator, coolant hoses Commercially available tools Remove, install radiator - AR20.20-P-3865SV ENGINE 112.947 in MODEL 170.465 with TRANSMISSION 716.6, 722.6 ENGINE 112.960 in MODEL 170.466 with TRANSMISSION 722.6 ATF lines 4 Remove air guide parts (3) 7 Unscrew the air conditioning system condenser at radiator (6) Leave in the vehicle with the lines connected.
8 Unscrew the conditioning system line to the condenser from the bracket (arrowed) at radiator (6)
9 Disconnect coolant hoses (7, 8, 9) at radiator (6) Replace the hose clamps
10 Detach the radiator (6) and remove Installation: Insert the spigots in the grommets (5) on the lower crossmember.
*WH58.30-Z-1002-06A 11 Install in the reverse order 12 Check the cooling system for leaks AR20.00-P-1010HA Number Designation Engine 111 except 111.977 BA20.20-P-1001-01A Automatic transmission ATF line at radiator (union nut) Nm20 Number Designation WH58.30-Z-1002-06A 7 mm socket hexagon on flexible shaft for hose clamps with worm drive
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 69 2005 Mitchell Repair Information Company, LLC. Fig. 45: Identifying Radiator Remove/Install Components - Engine 112.947/960 (1 Of 2) Fig. 46: Identifying Radiator Remove/Install Components - Engine 112.947/960 (2 Of 2)
Removing, installing 1 Remove the two air inlet pipes (1) of the air cleaner housing (2)
2 Remove electric fan AR20.40-P-5000SV
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 70 2005 Mitchell Repair Information Company, LLC.
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 3 Drain coolant at radiator AR20.00-P-1142SV 4 Detach connection hoses (3) at the ATF lines (4) and fit together with connector (5) Only transmission 722.6. Seal connections!
Set of plugs Fig. 47
Connection fitting for automatic oil pipes WF58.50-P-2020-01A 5 Detach coolant line (6) at radiator Installation: Inspect hose clamp and coolant line, replace if necessary.
*WH58.30-Z-1001-06A
*WH58.30-Z-1002-06A 6 Detach coolant line (7) at radiator Installation: Inspect hose clamp and coolant line, replace if necessary.
*WH58.30-Z-1001-06A
*WH58.30-Z-1002-06A 7 Detach coolant line (8) at radiator Installation: Inspect hose clamp and coolant line, replace if necessary.
*WH58.30-Z-1001-06A
*WH58.30-Z-1002-06A 8 Take off clamps (9) 9 Pull radiator toward engine and detach coolant line (10) Installation: Inspect hose clamp and coolant line, replace if necessary.
*WH58.30-Z-1001-06A
*WH58.30-Z-1002-06A 10 Unscrew bolts (11)
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:10 AM Page 71 2005 Mitchell Repair Information Company, LLC. 11 Lift radiator (12) up and out Installation: When installing, ensure: That the retaining studs (13) of the radiator on bottom right and left are located in the rubber mounts (14). That the two retaining studs (13) are lightly moistened with lubricant. That the rubber strip (15) and the retaining rubber 816) are correctly located. That the spacer sleeves (17) and the rubber shock absorber (18) and the four-point nuts (19) are correctly located.
12 Install in the reverse order 13 Pour in coolant AR20.00-P-1142SV 14 Inspect cooling system for leaks AR20.00-P-1010P
Risk of accident from vehicle starting off by itself when engine running. Risk of injury from contusions and burns if you insert your hands into the engine when it is started or when it is running Secure vehicle to prevent it moving off. Wear closed and close- fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A 15 Check oil level in automatic transmission and correct if necessary Only transmission 722.6. AR27.00-P-0101A 16 Run engine and inspect for leaks
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 72 2005 Mitchell Repair Information Company, LLC. Fig. 47: Identifying Set Of Plugs (129 589 00 91 00) Commercially available tools TEST COOLING SYSTEM CAP - AR20.30-P-4300 Test cooling system cap - AR20.30-P-4300FV ENGINES 112,113 ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250 ENGINE 113.962 in MODELS 463.206 /240 /241 /247 /248 /249 /254 ENGINE 113.982 in MODELS 463.243 /246 ENGINE 113.993 in MODELS 463.270 /271 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
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 73 2005 Mitchell Repair Information Company, LLC. Fig. 48: Testing Cooling System Cap - Engine 112 Remove
Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant. Do not open cooling system unless coolant temperature is below 90C. 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 1.1 Fit cap with detent (5) For model 463.206/209/232/233/ 240/241 with cap with notch (5).
Carefully rotate cap up to the first detent, release overpressure, then unscrew cap (5). If corrosion present at cap with detent (5), the cap must be replaced.
1.2 Remove 1 or 2-stage cap (5a) A 1-stage cap (5a) is installed in model 163. In models 140, 170, 199, 202, 203, 208, 209, 210, 211, 215, 220, 230, 463.243/244/245/ 246/247/248/249/250/254/270/271 there are 2-stage caps (5a) installed.
Turn 1 or 2-stage cap (5a) half a turn in an anti-clockwise direction, release pressure and then unscrew cap.
Check cap with detent
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 74 2005 Mitchell Repair Information Company, LLC. 2.1.1 Attach test cap (3) and adapter (4) to tester (2) Only on model 463.206/209/232/233/240/ 241 with cap with notch (5).
Tester Fig. 6
Test cap Fig. 7
Adapter Fig. 49 2.1.2 Screw cap (5) with detent onto the adapter (4)
2.1.3 Inspect pressure relief valve (6) Only on model 463.206/209/232/233/240/ 241 with cap with notch (5).
The pressure relief valve (6) must be resting against the rubber seal (arrow), it must be possible to lift it easily and it must spring back after being released.
Determine the opening pressure of the cap with notch (5) by pump and replace cap with notch (5) if necessary.
Cap code number *BE20.30-P-1001- 01A Pressure relief valve opens *BE20.30-P-1002- 01A Pressure relief valve opens (Reference value) *BE20.30-P-1003- 01A Test pressure *BE20.30-P-1005- 01A
Test the 1 or 2-stage cap
2.2.1 Attach adapter (3a) to tester (2) Only on models 163, 140, 170, 199, 202, 203, 208, 209, 210, 211, 215, 220, 230, 463.243/244/245/246/247/248/249/250/ 254/270/271.
Test cap Fig. 52 2.2.2 Screw 1 and 2-stage cap (5a) onto adapter Only on models 163, 140, 170, 199, 202, 203, 208, 209, 210, 211, 215, 220,
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 75 2005 Mitchell Repair Information Company, LLC. Cap of radiator or expansion reservoir (3a) 230, 463.243/244/245/246/247/248/249/250/ 254/270/271. 2.2.3 Inspect pressure relief valve Only on models 163, 140, 170, 199, 202, 203, 208, 209, 210, 211, 215, 220, 230, 463.243/244/245/246/247/248/249/250/ 254/270/271.
Determine opening pressure of the cap (5a) by pumping and replace cap (5) if necessary.
Cap code number *BE20.30-P-1001- 01A Pressure relief valve opens *BE20.30-P-1002- 01A Vacuum valve opens (reference value) *BE20.30-P-1003- 01A Pressure relief valve opens *BE20.30-P-1004- 01A Test pressure *BE20.30-P-1005- 01A
Installing 3.1 Fit cap with detent (5) For model 463.206/209/232/233/240/241 with cap with notch (5).
3.2 Install Remove 1 or 2-stage cap (5a) For models 140, 163, 170, 199, 202, 203, 208, 209, 210, 211, 215, 220, 230, 463.243/244/245/246/247/248/249/250/ 254/270/271 with 1 or 2-stage cap (5a).
Number Designation Cap 2-stage cap 1-stage cap model 163 BE20.30-P- 1001-01A Cap code number 140 140/200 - BE20.30-P- 1002-01A Pressure relief valve opens New bar gage 1.4 (+0.1) - 1.4 (+0.1) Used bar gage 1.4 (-0.1) - 1.4 (+0.1) BE20.30-P- 1003-01A Vacuum valve opens (reference value) bar vacuum 0.1 0.1 0.5 BE20.30-P- 1004-01A Pressure relief valve opens 1st stage bar gage - 1.4 ( 1) - Coolant temp. - >or =130/134- 2nd stage bar gage - 2.0 (1) - Coolant temp. - >or =137/143- BE20.30-P- Test pressure for pressure- bar gage 1.4 1.4 -
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 76 2005 Mitchell Repair Information Company, LLC. Cap of radiator or expansion reservoir Fig. 49: Identifying Adapter (000 589 77 63 00) Fig. 50: Identifying Test Cap (124 589 00 91 00) 1005-01A testing cooling system Number Designation 2-stage cap engine 113.968 in model 209 2-stage closing cover on model 211 BE20.30-P-1001- 01A Cap code number 140/200 - BE20.30-P-1002- 01A Pressure relief valve opens New bar gage - 1.5 (-0.2) Used bar gage - 1.5 (-0.2) BE20.30-P-1003- 01A Vacuum valve opens (reference value) bar vacuum 0.1 0.1 BE20.30-P-1004- 01A Pressure relief valve opens 1 st stage bar gage 1.4 (1) 1.5 (-0.2) Coolant temp. >or =130/134 135 (+5) 2nd stage bar gage 2.0 (1) 1.5 (-0.2) Coolant temp. >or =137/143 145 (+5) BE20.30-P-1005- 01A Test pressure for pressure-testing cooling system bar gage 1.4 1.4
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 77 2005 Mitchell Repair Information Company, LLC. Fig. 51: Identifying Pressure Pump (124 589 24 21 00) Fig. 52: Identifying Test Cap (163 589 02 91 00) Fig. 53: Identifying Adapter (210 589 03 63 00) Test cooling system cap - AR20.30-P-4300HA Engines 111, 120, 601, 602, 603, 604, 605, 606 /
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 78 2005 Mitchell Repair Information Company, LLC. Fig. 54: Testing Cooling System Cap - Engine 111
Removing/installing
The cap in model 163 cannot be checked; it must simply be replaced.
1 Open cooling system cap (5, 5a) Cap (5, 5a) Cap with detent: Carefully rotate cap up to the first detent, release overpressure, then unscrew cap. 2-stage cap: Turn cap half a turn in anti-clockwise direction, release overpressure, then unscrew cap.
Test cap with detent 2.1 Check cap (5) for corrosion Replace in case of corrosion
3.1 Attach test cap (3) and double union (4) to tester (2) Tester (2) Fig. 6
Test cap (3) Fig. 7
Double fitting (4) Fig. 49 4.1 Screw cap (5) with detent onto the double union (4)
5.1 Inspect pressure relief valve Determine the opening pressure of cap (5) by *BE20.30-P-1001-01A
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 79 2005 Mitchell Repair Information Company, LLC. Cap of radiator or expansion reservoir pumping; replace cap (5) if necessary. From 02/1986 the opening pressure of the cap was increased from the previous 1.2 bar to 1.4; this means that the permissible coolant temperature has been raised from 125 to 129C for standard antifreeze protection down to -30C 6.1 Test vacuum valve (6) For a cap (5): The vacuum valve (6) must be resting against the rubber seal (arrow); it must be easy to raise it and must spring back when released. *BE20.30-P-1003-01A
Check 2-stage cap 7.1 Attach test cap (3a) to tester (2) Tester (2) Fig. 6
Test cap (3a) Fig. 9 8.1 Screw 2-stage cap (5a) onto test cap (3a)
9.1 Inspect pressure relief valve Determine the opening pressure of cap (5) by pumping, replace cap (5) if necessary. Function see ? *BE20.30-P-1004-01A Function of 2-stage cap GF20.30-P-1000A 10 Install in reverse order Number Designation Cap 2-stage cap BE20.30-P-1001- 01A Cap code number 140 140/200 BE20.30-P-1002- 01A Pressure relief valve opens New bar gage 1.4 (+0.1) - Used bar gage 1.4 (-0.1) - BE20.30-P-1003- 01A Vacuum valve opens (reference value) bar vacuum 0.1 0.1 BE20.30-P-1004- 01A Pressure relief valve opens 1st stage bar gage - 1.4 (1) Coolant temp. - >or =130/134 2nd stage bar gage - 2.0 (1) Coolant temp. - >or =137/143
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 80 2005 Mitchell Repair Information Company, LLC. Fig. 55: Identifying Tester (124 589 24 21 00) Fig. 56: Identifying Test Cap (124 589 00 91 00) Fig. 57: Identifying Test Cap (210 589 00 91 00) Fig. 58: Identifying Adapter (210 589 03 63 00) BE20.30-P-1005- 01A Test pressure for pressure-testing cooling system bar gage 1.4 1.4
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 81 2005 Mitchell Repair Information Company, LLC. Fig. 59: Identifying Adapter (000 589 77 63 00) TEST COOLANT GAGE - AR20.30-P-4460A ENGINE 111 in MODELS 170, 202, 208, 210 ENGINE 112 in MODELS 129, 202, 208, 209, 210 ENGINE 113 in MODELS 129, 171, 202, 203, 208, 209, 210 ENGINE 156 in MODEL 209 Fig. 60: Testing Coolant Gage
Removing 1 Remove coolant level indicator switch (S41) The coolant level indicator switch (S41) is not directly enveloped directly with coolant and can be removed from the expansion reservoir or radiator without draining the coolant.
Model 209 with engine 156 AR20.30-P-4392PI
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 82 2005 Mitchell Repair Information Company, LLC. Except model 209 with engine 156
Checking 2 Connect multimeter (DMM-5) at coolant level indicator switch (S41) Electrical connection set Fig. 61
Multimeter *WH58.30-Z-1001-09A 3 Test switching point of 'maximum' coolant level Use float with ring magnet from expansion reservoir of models 129, 140, 202, 203, 208, 209, 210. Check without using the ring magnet (1)! If the resistance indicated by the multimeter (DMM-5) =infinity (infinite) ? Replace coolant level indicator switch (S41).
4 Test switching point of 'minimum' coolant level Guide the ring magnet (1) along the coolant level indicator switch (S41) to do this until the contact switches in the coolant level indicator switch (S41). Specified resistance approx. 5 ohms!
If the contact is not switched or if the resistance indicated is too high: ?
Replace coolant level indicator switch (S41).
Install 5 Fit coolant level indicator switch (S41) Model 209 with engine 156 Except model 209 with engine 156 AR20.30-P-4392PI
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 83 2005 Mitchell Repair Information Company, LLC. Fig. 61: Identifying Electrical Connection Kit (220 589 00 99 00) Commercially available tools REMOVING, INSTALLING ELECTRIC FAN - AR20.40-P-5000SV ENGINE 112.947 in MODEL 170.465 ENGINE 112.960 in MODEL 170.466 Fig. 62: Identifying Electric Fan Removal/Install Components - Engine 112.947/960 Number Designation WH58.30-Z-1001-09A Multimeter Removing, installing 1 Separate connector (1) of electric fan (M4/7)
2 Press coolant line (2) out of bracket (3)
3 Take off clamps (4)
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 84 2005 Mitchell Repair Information Company, LLC. REMOVING AND INSTALLING VISCOUS FAN CLUTCH - AR20.40-P-5660A ENGINE 111 in MODEL 124 ENGINE 111 in MODEL 170 with automatic heater ENGINE 111 in MODEL 202 with automatic heater ENGINE 111 in MODEL 202 up to 31.8.96 with CODE (580) Air conditioning or for USA Tempmatic with CODE (581a) Automatic air conditioning ENGINE 111 in MODEL 210 with automatic heater ENGINE 111 in MODEL 210 up to 31.8.96 with CODE (580) Air conditioning or for USA Tempmatic with CODE (581a) Automatic air conditioning ENGINE 111 in MODEL 208 ENGINE 111 in MODEL 163 4 Lift electric fan (M4/7) up and out Installation: The two retaining studs (5) of the electric fan must be located at the bottom in the rubber mounts (6). Moisten the two retaining studs lightly with lubricant.
5 Install in the reverse order
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 85 2005 Mitchell Repair Information Company, LLC. Fig. 63: Identifying Viscous Fan Clutch Removal/Install Components - Engine 111 FAN, FAN CLUTCH Fig. item, etc. Work instructions 26a Viscous fan clutch with fan (25)
*BA20.40-P-1002-01A Unscrew union nut (26a), left-hand thread!
Fig. 64 Use torque wrench (2) with open-end wrench insert (5)
Fig. 65 26 Fan (25) to viscous fan clutch
*BA20.40-P-1001-01A
Installation: installation position of fan (25) is fixed by cast rib on fan ring.
33 Coolant pump belt pulley 1st version: place counterholder (3) against retaining plate (33a) of belt pulley (33) and counter- hold. Fig. 66
2nd version: place counterholder (3a) against hexagon socket bolts of belt pulley (33) and counter-hold. Fig. 67 Number Designation Engine 111 BA20.40-P-1001-01A Bolt of fan to viscous clutch Nm10 BA20.40-P-1002-01A Tightening bolt of viscous fan clutch to bearing body with approved special tool Nm40
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 86 2005 Mitchell Repair Information Company, LLC. Fig. 64: Identifying Torque Wrench (001 589 72 21 00) Fig. 65: Identifying Open-End Wrench Insert (111 589 02 01 00) Fig. 66: Identifying Open-End Wrench (120 589 02 01 00) Fig. 67: Identifying Counterholder (119 589 02 40 00) REMOVING AND INSTALLING FAN SHROUD - AR20.40-P-6800 Removing and installing fan shroud - AR20.40-P-6800GS ENGINE 111.958 in MODEL 170.444 ENGINE 111.983 in MODEL 170.449
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 87 2005 Mitchell Repair Information Company, LLC. Fig. 68: Identifying Fan Shroud Remove/Install Components - Engine 111.983 Removing, installing fan shroud - AR20.40-P-6800HA ENGINE 111, 605, 606 in MODEL 124 ENGINE 606 in MODEL 140 ENGINE 111 in MODEL 170 ENGINE 111, 604, 605 in MODEL 202
Removing, installing 1 Unbolt coolant expansion reservoir (1) at front end crossmember Place to the side with lines connected.
2 Unplug connector (arrow) at suction fan
3 Unclip coolant line (2) at top and bottom at fan shroud
4 Pull out clamps (3) 5 Pull fan shroud (4) out of fixture at bottom of radiator (5)
6 Remove fan shroud (4) 7 Install in the reverse order
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 88 2005 Mitchell Repair Information Company, LLC. ENGINE 111 in MODEL 208 ENGINE 111, 602.982, 604, 605, 606 in MODEL 210 ENGINE 111 in MODEL 163 Fig. 69: Identifying Fan Shroud Remove/Install Components - Engine 111
Removal, installation 1.1 Remove charge air pipe (110) Engine 605.960 in model 202, engine 602.982, 605.962 in model 210 AR09.41-P-1311H 2.1 Release fan shroud ring (7a) from the locking studs by turning at the fan shroud, remove Engine 606 in model 124, 140 Installation: when installing, ensure that fan shroud ring is properly located in the locking studs of the fan shroud.
3 Remove viscous fan coupling (1) Engine 604 and 605 in model 124, 202 Engine 111 in model 163, 170, 208 Engine 111, 604, 605, 606 in model 210 ?
Engine 111 AR20.40-P-5660A Engine 604 AR20.40-P-5660HA Engine 605, 606 in model 124 AR20.40-P-5660HB
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 89 2005 Mitchell Repair Information Company, LLC. TEST & ADJUSTMENT VALUES TEST AND ADJUSTMENT VALUES: PASSENGER CARS: ENGINE COOLING SYSTEM - BE20.00- Z-9999AZ MODEL all Engine 606.961 in model 140 Engine 605 in model 202 Engine 602.982, 605, 606.912 in model 210 4.1 Detach coolant expansion reservoir Model 170 5 Remove fan shroud (7), take out upwards on engine 604/605 in models 124, 202 together with viscous fan coupling Model 163: remove screws of flat springs and take off flat springs. Installation: insert retaining lugs (arrows) of the fan shroud into the mounts at the radiator. Align fan shroud to the fan.
6 Install in the reverse order Coolant thermostat ENGINE 103, 104, 111, 112, 113, 119, 120, 155, 271... BE20.10-P-1000-02A Coolant thermostat ENGINE 601, 602.91 /96, 603.91 /96 /97, 604, 605 BE20.10-P-1000-02B Coolant thermostat ENGINE 272, 273 BE20.10-P-1000-02C Coolant thermostat ENGINE 156 BE20.10-P-1000-02D Fan/fan shroud ENGINE 111, 604, 605, 606 BE20.20-P-1000-01A Fan/fan shroud ENGINE 103, 104, 119 BE20.20-P-1000-01B Fan/fan shroud ENGINE 104, 119, 120, 603 BE20.20-P-1000-01C Test values for cooling system cap ENGINE all BE20.30-P-1000-01A Fan, fan clutch ENGINE 120 BE20.40-P-1000-01A
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 90 2005 Mitchell Repair Information Company, LLC. COOLANT THERMOSTAT - BE20.10-P-1000-02A Engine 103, 104, 111, 112, 113, 119, 120, 155 COOLANT THERMOSTAT COOLANT THERMOSTAT TEST VALUES FOR COOLING SYSTEM CAP - BE20.30-P-1000-01A All engines CAP OF RADIATOR OR EXPANSION RESERVOIR Number Designation Engine 103, 104, 111, 120 Engine 112, Engine 113.940/941/942/943/944/945/946/948/960/961/962/963/964/965/966/967/96 BE20.10- P-1001- 02A Start of opening C85...89 85...89 BE20.10- P-1002- 02A Minimum stroke C102 102 mm8 8 BE20.10- P-1003- 02A Thermostat bypass valve dia. mm43 - Number Designation Engine 119 Engine 155 Engine 271 BE20.10-P-1001- 02A Start of opening C82...86 85...89 88...92 BE20.10-P-1002- 02A Minimum stroke C- 102 105 mm- 8 8 BE20.10-P-1003- 02A Thermostat bypass valve dia. mm29 - - Number Designation Cap 2-stage cap 1-stage cap on model 163 BE20.30-P- 1001-01A Cap code number 140 140/200 - BE20.30-P- 1002-01A Pressure relief valve opens New bar overpressure1.4 (+0.1) - 1.4 (+0.1) Used bar overpressure1.4 (-0.1) - 1.4 (+0.1) BE20.30-P- 1003-01A Vacuum valve opens (reference value) bar vacuum0.1 0.1 0.5 BE20.30-P- Pressure relief Stage 1 bar overpressure- 1.4 (1) -
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 91 2005 Mitchell Repair Information Company, LLC. CAP FOR RADIATOR OR EXPANSION RESERVOIR CAP FOR RADIATOR OR EXPANSION RESERVOIR 1004-01A valve opens Coolant temp.- >or = 130/134 - Stage 2 bar overpressure- 2.0 (1) - Coolant temp.- >or = 137/143 - BE20.30-P- 1005-01A Test pressure for pressure- testing cooling system bar overpressure1.4 1.4 - Number Designation 2-stage cap for engine 113.968 in model 209 2-stage closing cover on model 211 Engines 160.921 / 923 in model 452.3/4 BE20.30-P- 1001-01A Cap code number 140/200 - 160 BE20.30-P- 1002-01A Pressure relief valve opens New bar overpressure- 1.5 (-0.2) 1.6 Used bar overpressure- 1.5 (-0.2) - BE20.30-P- 1003-01A Vacuum valve opens (reference value) bar vacuum0.1 0.1 0.1 BE20.30-P- 1004-01A Pressure relief valve opens Stage 1 bar overpressure1.4 (1) 1.5 (-0.2) - Coolant temp.>or = 130/134 135 (+5) - Stage 2 bar overpressure2.0 (1) 1.5 (-0.2) - Coolant temp.>or = 137/143 145 (+5) - BE20.30-P- 1005-01A Test pressure for pressure- testing cooling system bar overpressure1.4 1.4 1.6 Number Designation Engine 160.922 in model 452.3/4 Engine 160.910 in model 450.3/4 Engine 160.920 in model 450.3/4 BE20.30-P- 1001-01A Cap code number 160 160 160 BE20.30-P- 1002-01A Pressure relief valve opens New bar overpressure1.6 1.6 1.6 Used bar overpressure- - - BE20.30-P- 1003-01A Vacuum valve opens (reference value) bar vacuum0.1 0.1 0.1 BE20.30-P- 1004-01A Pressure relief valve opens Stage 1 bar overpressure- - - Coolant temp.- - - Stage 2 bar overpressure- - - Coolant temp.- - -
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 92 2005 Mitchell Repair Information Company, LLC. MAINTENANCE ENGINE COOLING SYSTEM - CHECK FLUID LEVEL, ADJUST TO CORRECT LEVEL. INSPECT ANTICORROSION/ANTIFREEZE PROTECTION, ADJUST TO CORRECT CONCENTRATION - AP20.00-P-2010Z MODEL 203.004 /006 /016 /018 /020 /035 /040 /042 /043 /045 /046 /061 /064 /065 /076 /081 /084 /204 /206 /216 /218 /22 MODEL 211.004 /006 /007 /008 /016 /020 /022 /023 /026 /028 /029 /041 /042 /052 /054 /056 /061 /065 /070 /072 /076 /07 MODEL 414 MODEL 209.308 /316 /320 /341 /342 /343 /354 /356 /361 /365 /375 /376 /420 /441 /442 /454 /456 /461 /465 /475 /476 MODEL 215 (except 215.376/379) MODEL 220 (except 220.176 /179) MODEL 230 with ENGINES 112, 113 MODEL 124, 129, 140, 168, 170, 202, 208, 210 MODEL 209 with ENGINE 156.9 BE20.30-P- 1005-01A Test pressure for pressure- testing cooling system bar overpressure1.6 1.6 1.6
Check
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 90C. 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 on coolant AH20.00-N-2080-01A 1 Remove screw cap of coolant expansion reservoir
2 Check coolant level Coolant cold: Engine coolant level up to marking "Cold water level".
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 93 2005 Mitchell Repair Information Company, LLC. Coolant warm: Engine coolant level approx. 1 cm above marking "Cold water level". 3 Inspect cooling system for leaks If loss of fluid is not due to normal consumption (against separate order)
Inspect cooling system for leaks Engine 111 in model 203 Engine 112 except 112.912/916/946/947/953/955/960/961, Engine 113 except 113.963/968/987/988/990/991/992/995 AR20.00-P-1010HA Engine 120, 137, 601, 602, 603, 604, 605, 606, 613, 628, 646 except 646.8, 647, 648, Engine 611 except in model 203 Engine 612 except in model 203,
Engine 156 in model 209, 211 AR20.00-P-1010TMG
Engine 272, 273 in model 211 AR20.00-P-1010TS
Engine 642 in model 211 AR20.00-P-1010TI
Engine 629 in model 211 AR20.00-P-1010TJ
Engine 113.963/990/991/992/995 Engine 112.960 in model 170.466 Engine 112.961 in model 203.065/265 AR20.00-P-1010RVK
Engine 111, 112, 113, 271, 611, 612, 646 in model 203 Engines 271, 646.8 in model 211 Engine 112 in Model 170 Engine 112, 113, 271, 612 in MODEL 209 AR20.00-P-1010P
Engine 642 in model 209 AR20.00-P-1010PI
Engine 272 in model 209 AR20.00-P-1010QB
Engine 166, 668 in model 168 AR20.00-P-1010GF
Engine 166, 668 in model 414 AR20.00-L-1010VA 4 Inspect anticorrosion and antifreeze agent in coolant and coolant composition Use only approved anticorrosion and antifreeze agents. If the coolant composition is incorrect: Correct the coolant composition (subject to separate repair order).
5 Mount screw cap for coolant expansion reservoir
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 94 2005 Mitchell Repair Information Company, LLC. REPLACE COOLANT - AP20.00-P-2080A ENGINE 103 ENGINE 104 ENGINE 111 ENGINE 112 in MODEL 210, 208, 202, 203, 209, 129 ENGINE 113 in MODEL 210, 208, 209, 202, 129, 203 ENGINE 119 ENGINE 120 ENGINE 166 ENGINE 271 in MODEL 203, 209 Modification notes 10.3.05 Cooling system Engine 271 *BF20.00-P-1001-02P
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
Notes on coolant All engines AH20.00-N-2080-01A 1 Drain/fill with coolant
Notes on coolant level Model 124, 129, 140, 163.113/128, 168, 170, 202, 208, 210, 211, 220 AH20.00-P-1142-01A
Notes on coolant level Model 203 with engine 111, 112, 113, 611, 612, 271, 646 AH20.00-P-1142-01P Model 170 with engine 112 Model 209 with engine 112, 113, 271, 612.967 Model 211.042 /242 with Engine 271.941
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 95 2005 Mitchell Repair Information Company, LLC. As a separate repair order:? Engine 103 ra20001030100x Engine 104 ra20001040100x
Engine 111 in Model 124, 163, 170, 202, 208, 210 AR20.00-P-1142HG Engine 112 in Model 129, 163, 202, 208, 210, 220 AR20.00-P-1142HA Engine 113 in Model 129, 163, 202, 208, 210, 215, 220
Engine 112.912 in Model 203.061/261, 209.361/461 Engine 112.946 in Model 203.064/264 Engine 112.955 in Model 209.365/465 Engine 112.961 in Model 203. Engine 113.968 in Model 209.375/475 Engine 113.987 in Model 209.376/476 Engine 113.988 in Model 203.076/276 AR20.00-P-1142PV Engine 111.951 /955 /981 in model 203 Engine 271 in Model 203, 209 AR20.00-P-1142PR Engine 119 ra20001190100x Engine 120 ra20001200100x Engine 166 Only use approved anticorrosion/antifreeze agents. AR20.00-P-1142GF
Engine 104 *BF20.00-P-1001-02A
Engine 111 *BF20.00-P-1001-02F
Engines 112, 113 *BF20.00-P-1001-02K
Engine 119 *BF20.00-P-1001-02B
Engine 120 *BF20.00-P-1001-02C
Engine 271 *BF20.00-P-1001-02P
Engine 166.940 /960 Without separate coolant expansion reservoir. *BF20.00-P-1001-02L
Engine 166.940 /960 With trailer hitch, automatic transmission, air conditioning without separate coolant expansion reservoir. *BF20.00-P-1002-02L
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 96 2005 Mitchell Repair Information Company, LLC. Cooling system
Engine 166.940/ 960/990/ 995 With separate coolant expansion reservoir. *BF20.00-P-1003-02L
Engine 166.940/ 960/ 990/ 995 With trailer hitch, automatic transmission, air conditioning without separate coolant expansion reservoir. In case fluid loss not due to normal consumption As a separate repair order: ? Check radiator system for leaks *BF20.00-P-1004-02L Engine 103 ra20001020017x Engine 119 ra20001190170x Engine 104
Engine 111 Engine 112 (except 112.912 /946/ 947/960/961) Engine 113 (except 113.968/987/988/990/991/992) Engine 120 AR20.00-P-1010HA Engine 111.951 in Model 203.035/ 235 /735 Engine 111.955 in Models 203.045 / 245 /745 Engine 111.981 in model 203.747 Engine 112.912 in Model 203.061/261, 209.361 Engine 112.946 in Model 203.064/264, 209.365 Engine 112.947 in Model 170.465 Engine 112.960 in Model 170.466 Engine 112.961 in Model 203. Engine 113 in Model 209 Engine 113 in Model 203 AR20.00-P-1010P Engine 166 AR20.00-P-1010GF Number Designation Engine 104.941 in Model 202 Engine 104.942/980/992 in Model 124 BF20.00-P- 1001-02A Cooling system Total capacity without AC Liters10.0 9.0
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 97 2005 Mitchell Repair Information Company, LLC. Cooling system Cooling system with AC Liters10.5 9.5 Capacity of anticorrosion/antifreeze down to -37 C without AC Liters5.0 4.5 with AC Liters5.25 4.75 Capacity of anticorrosion/antifreeze agent down to -45 C without AC Liters5.5 5.0 with AC Liters5.75 5.25 Specifications for Operating Fluids SheetBB00.40-P- 0310-01A BB00.40-P-0310- 01A SheetBB00.40-P- 0325-00A BB00.40-P-0325- 00A Number Designation Engine 104.943/981/991 in model 129 Engine 104.944/990/994 in model 140 BF20.00-P- 1001-02A Cooling system Total capacity without AC Liters11.5 14.5 with AC Liters11.5 14.5 Capacity of anticorrosion/antifreeze down to -37 C without AC Liters5.75 7.25 with AC Liters5.75 7.25 Capacity of anticorrosion/antifreeze agent down to -45 C without AC Liters6.25 8.0 with AC Liters6.25 8.0 Specifications for Operating Fluids SheetBB00.40-P-0310- 01A BB00.40-P-0310- 01A SheetBB00.40-P-0325- 00A BB00.40-P-0325- 00A Number Designation Engine 104.945/995 in Model 210 BF20.00-P- 1001-02A Cooling system Total capacity without AC Liters8.0 with AC Liters8.0 Capacity of anticorrosion/antifreeze down to -37 C without AC Liters4.0 with AC Liters4.0 Capacity of anticorrosion/antifreeze agent down to -45 C without AC Liters4.5 with AC Liters4.5 Specifications for Operating Fluids SheetBB00.40-P-0310- 01A
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 98 2005 Mitchell Repair Information Company, LLC. Cooling system Cooling system SheetBB00.40-P-0325- 00A Number Designation Engine 111.920/921/941/944/945/961/974/975 in model 202, 111.940/960 in model 124, 111.942/947/970 in model 210, 111.944/945/975 in model 208, 111.946 in model 170 Engine 111.943/958/97 in model 170 BF20.00- P-1001- 02F Cooling system Total capacity without AC Liters8.0 8.5 with AC Liters8.5 9.0 Capacity of anticorrosion/antifreeze down to -37 C without AC Liters4.0 4.25 with AC Liters4.25 4.5 Capacity of anticorrosion/antifreeze agent down to -45C without AC Liters4.5 4.7 with AC Liters4.75 5.0 Specifications for Operating Fluids SheetBB00.40-P-0310-01A BB00.40-P-031 01A SheetBB00.40-P-0325-00A BB00.40-P-032 00A Number Designation Engine 111.977 in model 163 Engine 111.951/955/981 in Model 203 BF20.00-P- 1001-02F Cooling system Total capacity without AC Litersapprox. 10, 5approx. 8, 5 with AC Litersapprox. 10, 5approx. 8, 5 Capacity of anticorrosion/antifreeze down to -37 C without AC Litersapprox. 5, 25approx. 4, 25 with AC Litersapprox. 5, 25approx. 4, 25 Capacity of anticorrosion/antifreeze agent down to -45 C without AC Litersapprox. 5, 75approx. 4, 75 with AC Litersapprox. 5, 75approx. 4, 75 Specifications for Operating Fluids SheetBB00.40-P- 0310-01A BB00.40-P-0310- 01A SheetBB00.40-P- 0325-00A BB00.40-P-0325- 00A
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 99 2005 Mitchell Repair Information Company, LLC. Cooling system Cooling system Cooling system Number Designation Engine 112.910/920 in Model 202, 112.940 in Model 208 Engines 112.911/921/941 in Model 210 Engine 112.923/943 in Model 129 BF20.00-P- 1001-02K Cooling system Total capacity Litersapprox. 9, 5 approx. 10, 0 approx. 11, 75 Full capacity of anticorrosion/antifreeze agent down to -37 C Litersapprox. 4, 75 approx. 5, 0 approx. 6, 0 Full capacity of anticorrosion/antifreeze agent down to -45 C Litersapprox. 5, 25 approx. 5, 5 approx. 6, 5 Specifications for Operating Fluids SheetBB00.40-P- 0310-01A BB00.40-P-0310- 01A BB00.40-P- 0310-01A SheetBB00.40-P- 0325-00A BB00.40-P-0325- 00A BB00.40-P- 0325-00A Number Designation Engine 112.912/946 in Model 203 Engine 112.942 in Model 163, 113.940/980 in Model 210, 113.943/984 in Model 208, 113.944 in Model 202 Engine 113.961 in model 129 BF20.00-P- 1001-02K Cooling system Total capacity Litersapprox. 10, 5 approx. 11, 0 approx. 12, 75 Full capacity of anticorrosion/antifreeze agent down to -37 C Litersapprox. 5, 25 approx. 5, 5 approx. 6, 25 Full capacity of anticorrosion/antifreeze agent down to -45 C Litersapprox. 5, 75 approx. 6, 0 approx. 7, 0 Specifications for Operating Fluids SheetBB00.40-P- 0310-01A BB00.40-P- 0310-01A BB00.40-P- 0310-01A SheetBB00.40-P- 0325-00A BB00.40-P- 0325-00A BB00.40-P- 0325-00A Number Designation Engine 112.912/946/955 in model 209 Engine 112.916/953 Engine 113.968 in Model 209,
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 100 2005 Mitchell Repair Information Company, LLC. Cooling system Cooling system 211 Engine 113.969 in Model 211 BF20.00-P- 1001-02K Cooling system Total capacity Litersapprox. 10, 5 approx. 10, 0 approx. 11, 5 Full capacity of anticorrosion/antifreeze agent down to -37C Litersapprox. 5, 25 approx. 5, 0 approx. 5, 75 Full capacity of anticorrosion/antifreeze agent down to -45 C Litersapprox. 5, 75 approx. 5, 5 approx. 6, 25 Specifications for Operating Fluids SheetBB00.40-P-0310- 01A BB00.40-P- 0310-01A BB00.40-P- 0310-01A SheetBB00.40-P-0325- 00A BB00.40-P- 0325-00A BB00.40-P- 0325-00A Number Designation Engine 113.987/988 BF20.00-P-1001- 02K Cooling system Total capacity Litersapprox. 11, 5 Full capacity of anticorrosion/antifreeze agent down to -37C Litersapprox. 5, 8 Full capacity of anticorrosion/antifreeze agent down to -45 C Litersapprox. 6, 3 Specifications for Operating Fluids SheetBB00.40-P-0310- 01A SheetBB00.40-P-0325- 00A Number Designation Engine 119.960/972/982 in model 129 Engine 119.970/971/980/981 in model 140 BF20.00- P-1001- 02B Cooling system Total capacity without AC Liters15 16.5 with AC Liters15.5 16.5 Capacity of anticorrosion/antifreeze down to -37 C without AC Liters7.5 8.25 with AC Liters7.75 8.25 Capacity of anticorrosion/antifreeze agent down to -45 C without AC Liters8.25 9.0 with AC Liters8.5 9.0 Specifications for Operating SheetBB00.40-P- BB00.40-P-0310-
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 101 2005 Mitchell Repair Information Company, LLC. Cooling system Cooling system Cooling system Fluids 0310-01A 01A SheetBB00.40-P- 0325-00A BB00.40-P-0325- 00A Number Designation Engine 119.974/975 in Model 124 Engine 119.980/985 in Model 210 BF20.00-P- 1001-02B Cooling system Total capacity without AC Liters15.5 11 Capacity of anticorrosion/antifreeze down to -37 C with AC Liters15.5 11 Capacity of anticorrosion/antifreeze agent down to -45 C without AC Liters7.75 5.5 Specifications for Operating Fluids with AC Liters7.75 5.5 without AC Liters8.5 6.0 with AC Liters8.5 6.0 SheetBB00.40-P- 0310-01A BB00.40-P- 0310-01A SheetBB00.40-P- 0325-00A BB00.40-P- 0325-00A Number Designation Engine 120.980/982 in model 140 Engine 120.981/983 in model 129 BF20.00-P- 1001-02C Cooling system Total capacity Liters18.5 19 Capacity of anticorrosion/antifreeze agent down to -37 C Liters9, 25 8, 5 Filling capacity of anticorrosion/antifreeze up to -45 C Liters10, 25 9, 5 Specifications for Operating Fluids SheetBB00.40-P- 0310-01A BB00.40-P- 0310-01A SheetBB00.40-P- 0325-00A BB00.40-P- 0325-00A Number Designation Engines 166.940/960 Engine 166.990/995 BF20.00-P- Cooling system Total capacity Litersapprox. 4, 9 -
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 102 2005 Mitchell Repair Information Company, LLC. 1001-02L without separate coolant expansion reservoir Capacity of anticorrosion/antifreeze agent down to -37 C literapprox. 2, 5 - Capacity of anticorrosion/antifreeze agent down to -45 C literapprox. 2, 7 - Specifications for Operating Fluids SheetBB00.40-P- 0310-01A - SheetBB00.40-P- 0325-00A - BF20.00-P- 1002-02L Cooling system with trailer hitch or automatic transmission or air conditioning without separate coolant expansion reservoir Total capacity Litersapprox. 5, 1 - Capacity of anticorrosion/antifreeze agent down to -37C literapprox. 2, 55 - Capacity of anticorrosion/antifreeze agent down to -45C literapprox. 2, 8 - Specifications for Operating Fluids SheetBB00.40-P- 0310-01A - SheetBB00.40-P- 0325-02A - BF20.00-P- 1003-02L Cooling system with separate coolant expansion reservoir Total capacity Litersapprox. 5, 5 approx. 5, 7 Capacity of anticorrosion/antifreeze agent down to -37 C literapprox. 2, 75 approx. 2, 85 Capacity of anticorrosion/antifreeze agent down to -45C literapprox. 3, 05 approx. 3, 15 Specifications for Operating Fluids SheetBB00.40-P- 0310-01A BB00.40-P- 0310-01A SheetBB00.40-P- 0325-02A BB00.40-P- 0325-02A BF20.00-P- 1004-02L Cooling system with trailer hitch or automatic transmission or air conditioning without separate coolant expansion reservoir Total capacity Litersapprox. 5, 7 - Capacity of anticorrosion/antifreeze agent down to -37 C literapprox. 2, 85 - Capacity of anticorrosion/antifreeze agent down to -45 C literapprox. 3, 15 - Specifications for Operating Fluids SheetBB00.40-P- 0310-01A - SheetBB00.40-P- 0325-00A -
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 103 2005 Mitchell Repair Information Company, LLC. Cooling system RETROFITTING & CONVERSION RETROFITTING COOLANT PREHEATER - AN20.30-P-0001 Retrofitting coolant preheater - AN20.30-P-0001A MODEL 170 with ENGINE 111 Installation sequence Fig. 70: Retrofitting Coolant Preheater Components - Engine 111 (1 Of 4) Number Designation Engine 271 BF20.00-P-1001- 02P Cooling system Total filling capacity (first filling capacity) literapprox. 8 Total filling capacity (workshop change capacity) literapprox. 5, 6 Capacity of anticorrosion/antifreeze agent down to -37C literapprox. 2, 8 Filling capacity of anticorrosion/antifreeze up to -45C literapprox. 3, 3 Specifications for Operating Fluids SheetBB00.40-P-0310- 01A SheetBB00.40-P-0325- 00A
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 104 2005 Mitchell Repair Information Company, LLC. Fig. 71: Retrofitting Coolant Preheater Components - Engine 111 (2 Of 4) Fig. 72: Retrofitting Coolant Preheater Components - Engine 111 (3 Of 4) Fig. 73: Retrofitting Coolant Preheater Components - Engine 111 (4 Of 4)
Removing
Risk of injury to skin and eyes from scalding from hot coolant which splashes out. Risk of poisoning from swallowing coolant. Do not open the cooling system unless the coolant temperature is below 90 C. Open cap slowly and allow the pressure to release. Do not pour coolant into containers for drinks. Wear protective gloves, protective clothes, and eye protection. AS20.00-Z-0001-01A 1 Drain coolant At radiator and crankcase AR20.00-P-1142HA
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 105 2005 Mitchell Repair Information Company, LLC. Coolant preheater 2 Unscrew plug (1) at left of engine block
Press wrench socket firmly onto the hexagon Fig. 74
Installing
General notes on coolant preheater Engine 111 in model 170 Engine 119 in model 210 AH20.00-P-1001-01A 3 Screw coolant preheater (20) into the engine block
Use new O-ring *BA20.00-P-1001-01A
Fig. 75 4 Attach electric cable with the two hose fixtures (2) to the engine breather pipe (2a) Connect both hose fixtures part no. 115 995 03 65 and 000 995 23 65 to each other before installing
5 Attach further routing along the cable rail at the intake manifold with the cable strap (3) Cable strap part no. 005 995 10 90
6 Attach at the fluid reservoir of the power steering with the hose fixtures (4) Connect both hose fixtures part no. 000 995 36 65 and 000 995 63 65 to each other before installing
7 Attach electric cable at the cable harness at the wheelhousing with 3 hose strap fixtures (5)
8 Screw together retaining spring (a) with cap (b) and bracket (6)
9 Install completed bracket (6) below the fixture for the cooling pipes of the power steering Unscrew securing bolt (7) for bracket for this step
10 Attach connector (8) of electric cable into retaining spring, fit on cap (b)
11 Pour in coolant AR20.00-P-1142HA 12 Inspect cooling system for leaks AR20.00-P-1010HA Number Designation Engine 111 BA20.00-P-1001-01A Coolant preheater in Nm70
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 106 2005 Mitchell Repair Information Company, LLC. Fig. 74: Identifying Wrench Socket (119 589 00 09 00) Fig. 75: Identifying Ring Wrench Socket (119 589 00 03 00) Fig. 76: Identifying Tester (124 589 15 21 00) Fig. 77: Identifying Test Cap (124 589 00 91 00) Retrofit coolant preheater - AN20.30-P-0001U ENGINE 112 in MODEL 170 engine block
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 107 2005 Mitchell Repair Information Company, LLC. Fig. 78: Retrofitting Coolant Preheater Components - Engine 112 (1 Of 4) Fasten carefully wiring harness with rubber clamps (15) to the oil pan. Fig. 79: Retrofitting Coolant Preheater Components - Engine 112 (2 Of 4) Fig. 80: Retrofitting Coolant Preheater Components - Engine 112 (3 Of 4)
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 108 2005 Mitchell Repair Information Company, LLC. Fig. 81: Retrofitting Coolant Preheater Components - Engine 112 (4 Of 4)
Remove
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 Drain coolant at radiator and crankcase
3 Remove lower coolant hose from Is replaced by a new coolant hose.
Install
Notes on coolant preheater AH20.00-P-1001-01A 4 Screw coolant preheater (20) into housing (10)
Clamp housing in vise and adjust distance with sleeves or nuts. Use new O-ring. *BA20.00-P-1001-01A
Fig. 75 5 Connect housing (10) to coolant pump with hose (11)
6 Screw housing (10) onto timing case cover with self-tapping screws (13) Take special care when screwing in the self- tapping screws.
7 Fasten hose (11) with clamps (12)
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 109 2005 Mitchell Repair Information Company, LLC. Oil pan Coolant preheater 8 Insert and tighten new lower coolant hose (14) between housing (10) and radiator
9 Fasten electric cable of coolant preheater (20) to oil pan using two rubberized clamps (15)
*BA01.45-P-1001-01B 10 Further routing to left of wheelhouse Set cable with tie strap (5) to existing cables
11 Fasten electric cable to wiring harness on wheelhouse with 3 hose strap brackets (5)
12 Screw together retaining spring (a) with cover cap (b) and bracket (6)
13 Mount complete bracket (6) under bracket of the transmission for the power steering Unscrew mounting screw (7) of bracket
14 Hang plug (8) of electric cable in retaining spring, attach cap (b)
15 Inspect cooling system for leaks
AR20.00-P-1010HA
Fig. 76
Fig. 7 Number Designation Engine 112.910/911/ 912/913/914/ 915/917/920/ 921/922/923/ 940/941/942/ 943/944/945/ 946/947/949/ 951/954/955/ 960/961/970/ 972/973/976 BA01.45-P-1001- 01B Bolt, oil pan to crankcase M6 Nm9 M8 Nm20
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 110 2005 Mitchell Repair Information Company, LLC. Fig. 82: Identifying Wrench Socket (119 589 00 09 00) Fig. 83: Identifying Ring Wrench Socket (119 589 00 03 00) Fig. 84: Identifying Tester (124 589 15 21 00) Fig. 85: Identifying Test Cap (124 589 00 91 00) Number Designation Engines 112, 113 BA20.00-P-1001-01A Coolant preheater in engine block Nm35
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 111 2005 Mitchell Repair Information Company, LLC. Parts ordering notes CAPACITIES & SPECIFICATIONS COOLING SYSTEM - BF20.00-P-1000 Cooling system - BF20.00-P-1000-02F Engine 111 COOLING SYSTEM COOLING SYSTEM Part no. Designation Quantity KG20 (see EPC) Preheater parts kit 1 KG20 (see EPC) Clip 1 KG200 (see EPC) Housing 1 KG20 (see EPC) Coolant hose 1 KG20 (see EPC) Self-tapping screw M6 (mounted to housing) 2 Number Designation Engine 111.920/921/941/944/945/961/974/975 in model 202, 111.940/960 in model 124, 111.942/947/970 in model 210, 111.944/945/975 in model 208, 111.946 in model 170 Engine 111.943/958/97 in model 170 BF20.00- P-1001- 02F Cooling system Total capacity without AC Liter8,0 8,5 with AC Liter8,5 9,0 Capacity of anticorrosion/antifreeze agent down to -37C without AC Liter4,0 4,25 with AC Liter4,25 4,5 Capacity of anticorrosion/antifreeze agent down to -45C without AC Liter4,5 4,7 with AC Liter4,75 5,0 Specifications for Service Products SheetBB00.40-P-0310-01A BB00.40-P-031 01A SheetBB00.40-P-0325-00A BB00.40-P-032 00A Number Designation Engine 111.951/955/981 Engine 111.977 in
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 112 2005 Mitchell Repair Information Company, LLC. Cooling system - BF20.00-P-1000-02K Engines 112, 113 COOLING SYSTEM COOLING SYSTEM in model 203 model 163 BF20.00-P- 1001-02F Cooling system Total capacity without AC Literapprox. 8,5 approx. 1 0,5 with AC Literapprox. 8,5 approx. 10,5 Capacity of anticorrosion/antifreeze agent down to -37C without AC Literapprox. 4,25 approx. 5,25 with AC Literapprox. 4,25 approx. 5,25 Capacity of anticorrosion/antifreeze agent down to -45C without AC Literapprox. 4,75 approx. 5,75 with AC Literapprox. 4,75 approx. 5,75 Specifications for Service Products SheetBB00.40-P-0310- 01A BB00.40-P- 0310-01A SheetBB00.40-P-0325- 00A BB00.40-P- 0325-00A Number Designation Engine 112 in model 170 Engines 112.910/920 in models 202, 112.940 in model 208 Engines 112.911/921/941 in model 210 BF20.00-P- 1001-02K Cooling system Total filling capacity Litersapprox. 8 approx. 9.5 approx. 10.0 Capacity of anticorrosion/antifreeze agent down to -37C Litersapprox. 4 approx. 4.75 approx. 5.0 Filling capacity of anticorrosion/antifreeze down to -45C Litersapprox. 4.5 approx. 5.25 approx. 5.5 Specifications for Operating Fluids SheetBB00.40-P- 0310-01A BB00.40-P- 0310-01A BB00.40-P-0310- 01A SheetBB00.40-P- 0325-00A BB00.40-P- 0325-00A BB00.40-P-0325- 00A Number Designation Engines 112.912/946 in model 203 Engines 112.912/946/955 in model 209 Engines 112.913/917/949/954 in model 211 BF20.00- P-1001- 02K Cooling system Total filling capacity Liters10.5 10.5 9.5 Capacity of anticorrosion/antifreeze Litersapprox. 5.25 approx. 5.25 approx. 4.75
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 113 2005 Mitchell Repair Information Company, LLC. COOLING SYSTEM COOLING SYSTEM agent down to -37C Filling capacity of anticorrosion/antifreeze down to -45C Litersapprox. 5.75 approx. 5.75 approx. 5.25 Specifications for Operating Fluids SheetBB00.40-P- 0310-01A BB00.40-P- 0310-01A BB00.40-P-0310- 01A SheetBB00.40-P- 0325-00A BB00.40-P- 0325-00A BB00.40-P-0325- 00A Number Designation Engines 112.916/953 Engines 112.922/944/972 in model 220 Engines 112.923/943 in model 129 BF20.00-P- 1001-02K Cooling system Total filling capacity Litersapprox. 10.0 approx. 10.5 approx. 11.75 Capacity of anticorrosion/antifreeze agent down to -37C Litersapprox. 5.0 approx. 5.0 approx. 6.0 Filling capacity of anticorrosion/antifreeze down to -45C Litersapprox. 5.5 approx. 5.5 approx. 6.5 Specifications for Operating Fluids SheetBB00.40-P- 0310-01A BB00.40-P-0310- 01A BB00.40-P- 0310-01A SheetBB00.40-P- 0325-00A BB00.40-P-0325- 00A BB00.40-P- 0325-00A Number Designation Engine 112.942 in models 163, 113.940/980 in models 210, 113.943/984 in models 208, 113.944 in model 202 Engine 112.945 in models 463.209/232/233/244/245/250 Engines 112.951/976 in model 639 without code H13 or HZ7 BF20.00- P-1001- 02K Cooling system Total filling capacity Litersapprox. 11.0approx. 11.5 approx. 8.1 Capacity of anticorrosion/antifreeze agent down to -37C Litersapprox. 5.5 approx. 5.8 approx. 4.1 Filling capacity of anticorrosion/antifreeze down to -45C Litersapprox. 6.0 approx. 6.4 approx. 4.5
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 114 2005 Mitchell Repair Information Company, LLC. COOLING SYSTEM COOLING SYSTEM COOLING SYSTEM Specifications for Operating Fluids SheetBB00.40-P- 0310-01A BB00.40-P-0310-01A BB00.40-P- 0310-01A SheetBB00.40-P- 0325-00A BB00.40-P-0325-00A BB00.40-P- 0325-00A Number Designation Engines 112.951/976 in model 639 with code H13 or HZ7 Engine 112.960 in model 170.466 AMG Engine 112.961 in models 203.065/265 AMG BF20.00-P- 1001-02K Cooling system Total filling capacity Litersapprox. 9.9 approx. 8.0 approx. 10.5 Capacity of anticorrosion/antifreeze agent down to -37C Litersapprox. 5 - - Filling capacity of anticorrosion/antifreeze down to -45C Litersapprox. 5.5 - - Specifications for Operating Fluids SheetBB00.40-P- 0310-01A - - SheetBB00.40-P- 0325-00A - - Number Designation Engines 112.970 113.965 in model 163 Engine 112.973 in model 230.467 Engine 112.975 in model 220 BF20.00-P- 1001-02K Cooling system Total filling capacity Litersapprox. 12.0 approx. 10.8 approx. 10.4 Capacity of anticorrosion/antifreeze agent down to -37C Litersapprox. 6.0 approx. 5.4 approx. 5.2 Filling capacity of anticorrosion/antifreeze down to -45C Litersapprox. 6.75 approx. 6 approx. 5.7 Specifications for Operating Fluids SheetBB00.40-P- 0310-01A BB00.40-P- 0310-01A BB00.40-P- 0310-01A SheetBB00.40-P- 0325-00A BB00.40-P- 0310-01A BB00.40-P- 0310-01A Number Designation Engines 113.941/960 in model 220 Engines 113.942/981 in model 163 Engines 113.948/966 in model 220
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 115 2005 Mitchell Repair Information Company, LLC. COOLING SYSTEM COOLING SYSTEM BF20.00-P- 1001-02K Cooling system Total filling capacity Litersapprox. 11.5 approx. 11.5 approx. 11.6 Capacity of anticorrosion/antifreeze agent down to -37C Litersapprox. 5.75 approx. 5.75 approx. 5.8 Filling capacity of anticorrosion/antifreeze down to -45C Liters6.25 approx. 6.25 6.4 Specifications for Operating Fluids SheetBB00.40-P- 0310-01A BB00.40-P- 0310-01A BB00.40-P- 0310-01A SheetBB00.40-P- 0325-00A BB00.40-P- 0325-00A BB00.40-P- 0325-00A Number Designation Engine 113.960/986 in model 215 Engine 113.961 in model 129 Engine 113.962 in models 463.206/240/241/247/248/249/254 BF20.00- P-1001- 02K Cooling system Total filling capacity Litersapprox. 11.5approx. 12.75 approx. 12 Capacity of anticorrosion/antifreeze agent down to -37C Litersapprox. 5.75approx. 6.25 approx. 6 Filling capacity of anticorrosion/antifreeze down to -45C Litersapprox. 6.25approx. 7.0 approx. 6.6 Specifications for Operating Fluids SheetBB00.40-P- 0310-01A BB00.40- P-0310- 01A BB00.40-P-0310-01A SheetBB00.40-P- 0325-00A BB00.40- P-0325- 00A BB00.40-P-0325-00A Number Designation Engine 113.963 in model 230.475 Engine 113.964 in model 164 Engine 113.967/969 in model 211 BF20.00-P- 1001-02K Cooling system Total filling capacity Litersapprox. 11.5 approx. 10.00 approx. 10.75 Capacity of anticorrosion/antifreeze agent down to -37C Litersapprox. 5.8 approx. 5.00 approx. 5.25 Filling capacity of anticorrosion/antifreeze Litersapprox. 6.5 approx. 5.5 approx. 6.0
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 116 2005 Mitchell Repair Information Company, LLC. COOLING SYSTEM COOLING SYSTEM down to -45C Specifications for Operating Fluids SheetBB00.40-P- 0310-01A BB00.40-P- 0310-01A BB00.40-P- 0310-01A SheetBB00.40-P- 0325-00A BB00.40-P- 0325-00A BB00.40-P- 0325-00A Number Designation Engine 113.967 in model 219 Engine 113.968 in model 209, 211 Engine 113.969 in model 211 Engine 113.982 in models 463.241/243/246 BF20.00-P- 1001-02K Cooling system Total filling capacity Liters approx. 10.65 approx. 11.5 approx. 11.9 Capacity of anticorrosion/ antifreeze agent down to -37C Liters approx. 5.65 approx. 5.75 approx. 5.95 Filling capacity of anticorrosion/antifreeze down to -45C Liters approx. 6.0 approx. 6.25 approx. 6.55 Specifications for Operating Fluids Sheet BB00.40-P- 0310-01A BB00.40-P- 0310-01A BB00.40-P-0310- 01A Sheet BB00.40-P- 0325-00A BB00.40-P- 0325-00A BB00.40-P-0325- 00A Number Designation Engine 113.986/991 in model 220 Engine 113.987/988 Engine 113.989 in model 171 BF20.00-P- 1001-02K Cooling system Total filling capacity Litersapprox. 13.5 approx. 11.5 approx. 11.5 Capacity of anticorrosion/ antifreeze agent down to -37C Litersapprox. 6.8 approx. 5.8 approx. 5.55 Filling capacity of anticorrosion/ antifreeze down to -45C Litersapprox. 7.4 approx. 6.3 approx. 6.1 Specifications for Operating Fluids SheetBB00.40-P- 0310-01A BB00.40-P- 0310-01A BB00.40-P- 0310-01A SheetBB00.40-P- BB00.40-P- BB00.40-P-
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 117 2005 Mitchell Repair Information Company, LLC. COOLING SYSTEM COOLING SYSTEM CAPACITIES: PASSENGER CARS: ENGINE COOLING SYSTEM - BF20.00-Z-9999AZ MODEL all 0325-00A 0325-00A 0325-00A Number Designation Engine 113.990 Engine 113.991 in model 215 Engines 113.992/995 in model 230 BF20.00-P- 1001-02K Cooling system Total filling capacity Litersapprox. 13.2 approx. 14.5 approx. 13.0 Capacity of anticorrosion/ antifreeze agent down to -37C Litersapprox. 6.6 approx. 7.3 approx. 6.5 Filling capacity of anticorrosion/ antifreeze down to -45C Litersapprox. 7.3 approx. 8 approx. 7.3 Specifications for Operating Fluids SheetBB00.40-P- 0310-01A BB00.40-P- 0310-01A BB00.40-P- 0310-01A SheetBB00.40-P- 0325-00A BB00.40-P- 0325-00A BB00.40-P- 0325-00A Number Designation Engine 113.993 in model 463.270/271 BF20.00-P-1001- 02K Cooling system Total filling capacity Litersapprox. 13.0 Capacity of anticorrosion/antifreeze agent down to -37C Litersapprox. 6.5 Filling capacity of anticorrosion/antifreeze down to -45C Litersapprox. 7.3 Specifications for Operating Fluids SheetBB00.40-P-0310- 01A SheetBB00.40-P-0325- 00A Cooling system ENGINE 104... BF20.00-P-1000-02A Cooling system ENGINE 119 BF20.00-P-1000-02B Cooling system ENGINE 120 BF20.00-P-1000-02C Cooling system ENGINE 601, 602, 603 BF20.00-P-1000-02D
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 118 2005 Mitchell Repair Information Company, LLC. TORQUE SPECIFICATIONS ENGINE COOLING - BA20.00-P-1000 Coolant preheater - BA20.00-P-1000-01A Engine 111, 112, 113, 119, 155, 271 COOLANT PREHEATER COOLANT PREHEATER Engine cooling, general - BA20.00-P-1000-02B Cooling system ENGINE 604, 605, 606, 611, 612, 613, 628, 647, 648... BF20.00-P-1000-02E Cooling system ENGINE 111... BF20.00-P-1000-02F Cooling system ENGINE 112, 113... BF20.00-P-1000-02K Cooling system ENGINE 166... BF20.00-P-1000-02L Cooling system ENGINE 137.970 BF20.00-P-1000-02M Cooling system ENGINE 668... BF20.00-P-1000-02N Cooling system ENGINE 271 BF20.00-P-1000-02P Cooling system ENGINE 275, 285... BF20.00-P-1000-02Q Cooling system ENGINE 155.980 BF20.00-P-1000-02S Cooling system ENGINE 156, 272, 273... BF20.00-P-1000-02U Cooling system ENGINE 266, 640... BF20.00-P-1000-02V Cooling system ENGINE 642 in MODEL 164, 203, 204, 209, 211, 219, 221, 251 ENGINE 642 in MODEL 463 BF20.00-P-1000-02W Cooling system MODEL 251 with ENGINE 113 BF20.00-P-1000-02X Cooling system ENGINE 629 in MODEL 164, 221, 211 BF20.00-P-1000-02Y Mixture ratio for coolant ENGINE all BF20.00-P-1000-04A Number Designation Engine 111 Engine 112, 113 Engine 119 BA20.00-P-1001- 01A Coolant preheater in engine block Nm70 35 70 Number Designation Engine 155 Engine 271 BA20.00-P-1001- 01A Coolant preheater in engine block Nm- 70
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:11 AM Page 122 2005 Mitchell Repair Information Company, LLC. Engine 112 MODIFICATION NOTES COOLANT PUMP, COOLANT THERMOSTAT 1.9.04 Value changed from 10 Nm to 14 Nm Value in model series 1003 modified on engine 112.910/911/912/913/914/915/916/917/ 920/921/922/923/940/941/942/943/944/ 945/946/947/949/953/954/955/960/961/ 970/972/973/975
Value changed from 10 Nm to 14 Nm Value in model series 1004 modified on engine 112.910/911/912/913/914/915/916/917/ 920/921/922/923/940/941/942/943/944/ 945/946/947/949/953/954/955/960/961/ 970/972/973/975
Value changed from 10 Nm to 14 Nm Figure in line 1004 engine 112.951 modified
Number Designation Engine 112.910/911/912/913/914/915/ 916/917/920/ 921/922/923/ 940/941/942/ 943/944/945/ 946/947/949/ 953/954/955/ 960/961/970/ 972/973/975 Engine 112.951/976 BA20.10-P- 1001-01M Self- tapping bolt of coolant pump to timing case Thread not pre-tapped M6 Nm14 - Thread not pre-tapped M8 Nm35 - Thread pre- tapped M6 Nm10 - Thread pre- tapped M8 Nm25 - BA20.10-P- 1002-01M Belt pulley to coolant pump Nm9 9 BA20.10-P- 1003-01M Bolt of coolant thermostat housing M6 Nm14 14 BA20.10-P- 1004-01M Coolant pump at the timing case M7 Nm14 14 BA20.10-P- 1005-01M Bolt of coolant pump to timing case cover and crankcase M8 Nm- 20 BA20.10-P- 1006-01M Bolt of thermostat to timing case cover Nm- 14
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:12 AM Page 123 2005 Mitchell Repair Information Company, LLC. RADIATOR, COOLANT HOSES - BA20.20-P-1000-01A Engines 103, 111, 112, 113, 119, 137, 155, 272, 273, 275 RADIATOR, COOLANT HOSES RADIATOR, COOLANT HOSES RADIATOR, COOLANT HOSES Number Designation Engine 103 Engine 111 except 111.977 Engine 111.977 Engine 112 except 112.942/970, engine 113.940/941/ 943/944/945/ 946/948/960/ 961/962/963/ 966/967/968/ 969/980/982/ 984/986/992/ 993/995 BA20.20-P- 1001-01A Union nut, automatic transmission oil line to radiator Nm20 20 20 20 BA20.20-P- 1002-01A Nut for transmission oil cooler in refrigerant cooler Nm20 25 25 - BA20.20-P- 1003-01A Banjo bolt M12 x 1.5 Nm- - - 30 BA20.20-P- 1004-01A Hose clamp Nm- - 3 - Number Designation Engine 112.942/970, 113.942/ 965/981 Engine 113.987/ 988/990/ 991 Engine 113.989 Engine 119 BA20.20-P- 1001-01A Union nut, automatic transmission oil line to radiator Nm20 18 18 20 BA20.20-P- 1002-01A Nut for transmission oil cooler in refrigerant cooler Nm- - - - BA20.20-P- 1003-01A Banjo bolt M12 x 1.5 Nm30 30 30 - BA20.20-P- 1004-01A Hose clamp Nm3 - - -
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:12 AM Page 124 2005 Mitchell Repair Information Company, LLC. FAN, FAN CLUTCH - BA20.40-P-1000 Fan, fan clutch - BA20.40-P-1000-01A Engine 103, 104, 111, 119, 120, 601, 602, 603, 604, 605, 606, 612 Fan, fan clutch Number Designation Engine 137.970 Engine 155 Engines 272, 273 in model 230 Engine 275 BA20.20-P- 1001-01A Union nut, automatic transmission oil line to radiator Nm20 - 20 25 BA20.20-P- 1002-01A Nut for transmission oil cooler in refrigerant cooler Nm- - - - BA20.20-P- 1003-01A Banjo bolt M12 x 1.5 Nm30 - 30 - BA20.20-P- 1004-01A Hose clamp Nm- - - - Number Designation Engine 103 Engine 104 Engine 119 Engine 111 BA20.40-P- 1001-01A Bolt of fan to viscous fan clutch NM10 10 10 10 BA20.40-P- 1002-01A Tighten bolt between viscous fan clutch and bearing liner using approved special tool NM- - 41 40 BA20.40-P- 1003-01A Tighten bolt between viscous fan clutch and bearing liner using screwdriver and torque wrench NM45 45 45 45 BA20.40-P- 1004-01A Fan bearing bracket to crankcase NM45 - 21 - BA20.40-P- 1005-01A Bolt of belt pulley to fan NM- - - - BA20.40-P- 1006-01A Union nut to bearing liner NM- - - -
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:12 AM Page 125 2005 Mitchell Repair Information Company, LLC. Fan, fan clutch Fan, fan clutch Number Designation Engine 120 Engine 601 in model 202 Engine 601, 602 except 602.982, 603 Engine 604 BA20.40-P- 1001-01A Bolt of fan to viscous fan clutch NM10 10 10 10 BA20.40-P- 1002-01A Tighten bolt between viscous fan clutch and bearing liner using approved special tool NM45 - 40 - BA20.40-P- 1003-01A Tighten bolt between viscous fan clutch and bearing liner using screwdriver and torque wrench NM41 - 45 45 BA20.40-P- 1004-01A Fan bearing bracket to crankcase NM- - - - BA20.40-P- 1005-01A Bolt of belt pulley to fan NM13 - - - BA20.40-P- 1006-01A Union nut to bearing liner NM- 45 - - Number Designation Engines 605, 606 Engine 612.965/ 966 Engine 613.961 BA20.40-P- 1001-01A Bolt of fan to viscous fan clutch NM10 10 10 BA20.40-P- 1002-01A Tighten bolt between viscous fan clutch and bearing liner using approved special tool NM40 45 45 BA20.40-P- 1003-01A Tighten bolt between viscous fan clutch and bearing liner using screwdriver and torque wrench NM45 - -
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:12 AM Page 126 2005 Mitchell Repair Information Company, LLC. Fan, fan clutch - BA20.40-P-1000-01B Engine 112, 113, 155 FAN, FAN CLUTCH BA20.40-P- 1004-01A Fan bearing bracket to crankcase NM- - - BA20.40-P- 1005-01A Bolt of belt pulley to fan NM- - - BA20.40-P- 1006-01A Union nut to bearing liner NM- - - Number Designation Engine 112.910/911/ 912/913/914/ 915/916/917/ 920/921/922/ 923/940/941/ 942/943/944/ 945/946/947/ 949/951/953/ 954/955/960/ 961/970/972/ 973/975/976 Engine 113 Engine 155 BA20.40-P-1001- 01B Fan to viscous clutch Nm10 10 - BA20.40-P-1002- 01B Viscous clutch to bearing body Nm45 45 -
2003 Mercedes-Benz SLK320 1998-2004 ENGINE Engine Cooling System - 170 Chassis Microsoft Friday, October 30, 2009 7:30:12 AM Page 127 2005 Mitchell Repair Information Company, LLC.