MERCEDES-BENZ ML350 1997 Complete Repair Manual

Fig. 137: Identifying Air Conditioning (Tempmatic) Socket Box Connection Diagram
AIR CONDITIONING (TEMPMATIC) DIAGNOSIS PREVIOUS KNOWLEDGE - AD83.30-P-2000GH
MODEL 163 with CODE (580) air conditioning or for USA, Tempmatic
Air conditioning system, location of components GF83.30-P-0003-
01GH
Survey of electrical wiring diagrams for air conditioning PE83.00-P-1100E
Connection and use of test equipment AD00.00-P-1000AZ
Notes on air conditioning (Tempmatic) (TAC) fault memory AD83.30-P-2000-
03GH
Pre-conditions for function check of air conditioning
(Tempmatic) (TAC)up to
30.11.99AD83.30-P-2000-
01GH
Pre-conditions for function check of air conditioning
(Tempmatic) (TAC)as of
01.12.99AD83.30-P-2000-
01GK
Variant coding, air conditioning (Tempmatic) (TAC) AD83.30-P-2000-
02GH
Socket box connection diagram, air conditioning
(Tempmatic) (TAC) AD83.30-P-2000-
07GH
Air conditioning (Tempmatic) (TAC) diagnostic tools AD83.30-P-2000-
04GH
Tools, testing electrical system of air conditioning
(Tempmatic) (TAC) AD83.30-P-2000-
06GH

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 167 © 2006 Mitchell Repair Information Company, LLC.

AIR CONDITIONING (TEMPMATIC) DIAGNOSIS OPERATIONAL CHECK - AD83.30-P-3000GH
MODEL 163 with CODE (580) air conditioning or for USA, Tempmatic

Air conditioning (Tempmatic)
(Tempmatic A/C) diagnosis,
previous knowledge
AD83.30-P-2000GH
Function check
Test step/Scope
of test Operation/Requirement Specified value Possible cause/ Remedy
1
Temperature selector on "white
zone" ( ) function switch
illuminated
Air from center level.AD83.30-P-6000-01GH
Air drying Air upwards.AD83.30-P-6000-02GH
Air distribution switch at 12 o'clockA/C compressor ON .
AD83.30-P-6000-03GH
AD83.30
-P-6000-04GH
AD83.30
-P-6000-05GH
AD83.30
-P-6000-06GH
AD83.30
-P-6000-07GH
AD83.30
-P-6000-08GH
AD83.30
-P-6000-09GH
2
Temperature selector on "white
zone" function switch
illuminatedAir downwards and
upwards.AD83.30-P-6000-08GH
Normal setting
in control mode A/C compressor ON .AD83.30-P-6000-09GH
Air distribution switch at 4 o'clock
Flow of temperature-
controlled air from
center level as well.
Coolant circulation
pump runs.

3
Temperature selector engaged on
"blue" function switch not
illuminatedAir from center level
(ambient air)AD83.30-P-6000-08GH
Normal mode
without heating
mode
A/C compressor OFF.
Air distribution switch at 9 o'clock
4
Temperature selector on "red" stop
function switch not
illuminatedHeated air
downwards, upwards
and from center level.
AD83.30-P-6000-08GH
Normal mode in
heating mode
Air distribution switch at 4 o'clockA/C compressor
OFF.

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 168 © 2006 Mitchell Repair Information Company, LLC.

AIR CONDITIONING (TAU) DIAGNOSIS FUNCTION CHECK ACTUAL VALUES - AD83.30-P-3001GH
MODEL 163 with CODE (580) Air conditioning or Tempmatic for USA
5
Recirculated air
mode function switch illuminated
Blower switch on stage 4Blower noise
increases significantly
Cables
Recirculated air
switch
Fresh
air/recirculated air
flap actuator motor
Air conditioning (TAU)
diagnosis previous
knowledge AD83.30-P-2000GH
Connect hand-held tester
(HHT), read out
diagnostic trouble code
memoryModel 163 up to 31.8.01AD00.00-P-2000-03C
Operational check
Test scope Operation /
Requirement Specification Possible cause / Remedy
01
Circuit 30 11-14 VWiring
Battery
02Ignition ON Operating temperature
approx. 80°CWiring
Temperature sensor
Coolant (B11/4)
All-activity module
(N10)
Engine temperature Start engine and warm up
to operating temperature.
03Ignition ON Season-dependent,
approx. 20° CWiring
Temperature sensor
Ambient air (B14)
All-activity module
(N10)
Outside temperature
04Ignition ON ONWiring
F1k21
Blower motor (M2)
All-activity module
(N10)
Blower power supply
relay (F1k21) Blower stage 4FROM
05Ignition ON ONWiring
F1k26
Auxiliary fan (M4) Auxiliary fan relay FROM

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 169 © 2006 Mitchell Repair Information Company, LLC.

AIR CONDITIONING (TAU) DIAGNOSTIC FAULT MEMORY - AD83.30-P-4000GH
MODEL 163 with CODE (580) Air conditioning or Tempmatic for USA
(F1k26) All-activity module
(N10)
08Ignition ON ONWiring
F1k19
Heating water
circulation pump
(M13)
All-activity module
(N10)
Heating water
circulation pump relay
(F1k19) FROM
09Start engine12 barAD83.30-P-6000-09GH
Refrigerant pressure illuminates
Blower stage 4
10Start engineONAD83.30-P-6000-08GH
A/C compressor (A9) illuminates
Blower stage 4FROMAll-activity module
(N10)
A9
11Ignition ON YESWiring
Control module Air
conditioning (N19)
All-activity module
(N10)
Air conditioning
request NO

Air conditioning (TAU)
diagnosis previous
knowledge
AD83.30-P-
2000GH

Connect hand-held tester
(HHT), read out
diagnostic trouble code
memory
Model 163 up to 31.8.01
When a control module's fault memory is
read out, all the faults stored in the control
module are displayed, which means that
fault codes that do not concern the system
that is currently being read out can also
appear.
AD00.00-P-
2000-03C
Fault memory
Fault code Possible cause Note Remedy
(no
communication
with HHT
possible)
Diagnostic cable AD54.21-P-
6000-02GH

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 170 © 2006 Mitchell Repair Information Company, LLC.

AIR CONDITIONING (TEMPMAT IC) TEST OF ELECTRICAL SYSTEM CIRCUIT 15 VOLTAGE SUPPLY - AD83.30-P-6000-
01GH
Fig. 138: Air Conditioning (Tem pmatic) Test Of Electrical System Circuit 15 Voltage Supply
AIR CONDITIONING (TEM PMATIC) TEST OF ELECTRICAL SYST EM CIRCUIT 31 GND - AD83.30-P-6000-02GH
Fig. 139: Air Conditioning (Tempmatic) Test Of Electrical System Circuit 31 GND
AIR CONDITIONING (TEMPM ATIC) TEST OF ELECTRICAL SYSTEM IN-CAR TEMPERA TURE SENSOR - AD83.30-P-
6000-03GH
Fig. 140: Air Conditioning (Tempmat ic) Test Of Electrical System In-Car Temperature Sensor
AIR CONDITIONING (TEMPMATIC) TEST OF ELECTRICAL SYSTEM ANTI-ICING TEM PERATURE SENSOR - AD83.30-
P-6000-04GH
No fault codeNo fault detectedIf there is a complaint in spite of this ?
Air conditioning (TAU) electrical system
testingAD83.30-P-
6000GH
B1232Refrigerant compressor
sensor (B12) AD83.30-P-
6000-09GH
B1419Electromagnetic clutch
(A9k1) Wiring
A9k1

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 171 © 2006 Mitchell Repair Information Company, LLC.

Fig. 141: Air Conditioning (Tempmatic ) Test Of Electrical System Anti-Icing Temperature Sensor
AIR CONDITIONING (TEMPMATIC) TEST OF ELECTRICAL SYSTEM TEMPERATURE SELECTOR CONTROL
VOLTAGE - AD 83.30-P-6000-05GH
Fig. 142: Air Conditioning (Tempmat ic) Test Of Electrical System Temperature Selector Control Voltage
AIR CONDITIONING (TEMPMATIC) TEST OF ELECTRICAL SYSTEM BLENDING AIR FLAP SERVO MOTOR
CONTROL VOLTAGE - AD83.30-P-6000-06GH
Fig. 143: Air Conditioning (Tempmat ic) Test Of Electrical System Blending Air Flap Servo Motor
Control Voltage
AIR CONDITIONING (TEMPMATIC) TEST OF ELECTRICAL SYSTEM BLENDING AIR FLAP SERVO MOTOR GND -
AD83.30-P-6000-07GH

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 172 © 2006 Mitchell Repair Information Company, LLC.

Fig. 144: Air Conditioning (Tempmat ic) Test Of Electrical System Blending Air Flap Servo Motor GND
AIR CONDITIONING (TEMPMATIC) TEST OF ELECTRICAL SYSTEM REFRIGERANT COMPRESSOR ACTUATION -
AD83.30-P-6000-08GH
Fig. 145: Air Conditioning (Tempmat ic) Test Of Electrical System Refrigerant Compressor Actuation
AIR CONDITIONING (TEMPM ATIC) TEST OF ELECTRICAL SYSTEM REFRIGERANT PR ESSURE SENSOR - AD83.30-P-
6000-09GH
Fig. 146: Air Conditioning (Tempm atic) Test Of Electrical System Refrigerant Pressure Sensor
OUTSIDE AIR TEMPERATURE SENSOR, TESTING EL ECTRICAL SYSTEM OF TAC - AD83.30-P-6000-24GH
as of 1.12.99

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 173 © 2006 Mitchell Repair Information Company, LLC.

Fig. 147: Outside Air Temperature Sensor, Testing Electrical System Of TAC
AIR CONDITIONING (TEMPMATIC) ELECTRICAL SYSTEM TESTING - AD83.30-P-6000GH
MODEL 163 with CODE (580) Air conditioning or Tempmatic for USA
Air conditioning component
arrangement GF83.30-P-
0003-01GH
Overview of climate control wiring
diagrams PE83.00-P-
1100E
Connect hand-held tester (HHT), read
out diagnostic trouble code memoryModel 163 up to 31.8.01
Erase fault memory in control module
(N19) using HHT when testing is completeAD00.00-P-
2000-03C
Air conditioning (Tempmatic)
diagnosis previous knowledge AD83.30-P-
2000GH
Air conditioning (Tempmatic)
diagnosis function check The testing of the fresh air/recirculated
air flap actuator motor (M39) is carried out
during the function checkAD83.30-P-
3000GH
Testing
1
Circuit 15 power supply, air
conditioning (Tempmatic) electrical
system testing
AD83.30-P-
6000-01GH
2Circuit 31 ground, air conditioning
(Tempmatic) electrical system testing AD83.30-P-
6000-02GH
3
In-car temperature sensor, air
conditioning (Tempmatic) electrical
system testing
AD83.30-P-
6000-03GH
4
Anti-icing protection temperature
sensor, air conditioning (Tempmatic)
electrical system testing
AD83.30-P-
6000-04GH
5
Temperature selector wheel control
voltage Air conditioning (Tempmatic)
electrical system testing
AD83.30-P-
6000-05GH
6
Blending air flap servo motor control
voltage, air conditioning (Tempmatic)
electrical system testing
AD83.30-P-
6000-06GH
7Blending air flap actuator motor
ground, air conditioning (Tempmatic) AD83.30-P-

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 174 © 2006 Mitchell Repair Information Company, LLC.

TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: CLIMATE CONTROL - AR83.00-Z-9163AA
MODEL 163
electrical system testing6000-07GH
8
Refrigerant compressor actuation, air
conditioning (Tempmatic) electrical
system testing
AD83.30-P-
6000-08GH
9
Refrigerant pressure sensor, air
conditioning (Tempmatic) electrical
system testing
AD83.30-P-
6000-09GH
10
Ambient temperature sensor, air
conditioning (Tempmatic) electrical
system testing
as of 01.12.99AD83.30-P-
6000-24GH
Remove/install center outlet flap
actuator motorMODEL 163...AR83.10-P-
2019GH
Removing and installing rear air
nozzleMODEL 163.113/154 /174 #A as of 289565, 163.113 #X
as of 754620, 163.128 /157 /175AR83.10-P-
4800GH
Remove, install switch unit for
heater/ ventilationMODELS 163.113/136/154/172/174 up to 31.8.01 with
CODE (580) air conditioning or Tempmatic for USAAR83.20-P-
1835GH
Remove and install heat
exchanger from heater housingMODEL 163AR83.20-P-
3400GH
Replace bulbs in push-button
control moduleMODELS 163.113/154/174/136/172 up to 31.8.01AR83.25-P-
1123GH
Remove and install series
resistor for heater blowerMODEL 163.113/128 /136 /154 /157 /172 /174 /175AR83.25-P-
1250GH
Remove/install cover at air
intakeMODEL 163.113/128 /136 /154 /157 /172 /174 /175AR83.25-P-
1405GH
Carry out quick test on air
conditioning systemMODEL 163, 901, 902, 903, 904 ...AR83.30-
D-1209A

Draining, evacuating and
refilling air conditioning,
checking function and checking
for leaks
MODEL 163...AR83.30-P-
1760GH

Remove/install defroster vent
flap actuator motor for
windshieldMODEL 163.113/154 /174 #A as of 289565, 163.113 #X
as of 754620, 163.128 /157 /175AR83.30-P-
2006GH
Remove/install footwell flap
actuator motorMODEL 163...AR83.30-P-
2007GH
Remove/install rear shutoff flap
actuator motorMODEL 163.113/154 /174 #A as of 289565, 163.113 #X
as of 754620, 163.128 /157 /175AR83.30-P-
2008GH

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 175 © 2006 Mitchell Repair Information Company, LLC.

Remove/install fresh
air/recirculated air stepper motorMODEL 163...AR83.30-P-
2010GH

Removing and installing
blending air increment
adjustment motor
MODEL 163...AR83.30-P-
2020GH
Remove and install evaporator
housingMODEL 163...AR83.30-P-
5200GH
Disassembling, assembling A/C
housingMODEL 163 with CODE (580) Air conditioning or, in
USA, Tempmatic A/CAR83.30-P-
5201GH

Correcting oil level in air
conditioning following repair or
slow refrigerant loss
MODEL 163, 202, 208, 210, 215, 220 ...AR83.30-P-
5251E

Correcting oil level in air
conditioning after replacing
parts
MODEL 163, 202, 208, 210, 215, 220 ...AR83.30-P-
5252E

Correcting oil level in air
conditioning after system
suddenly loses all refrigerant
MODEL 163, 202, 208, 210, 215, 220 ...AR83.30-P-
5253E
Remove and install expansion
valveMODEL 163...AR83.30-P-
5520GH
Remove/install evaporatorMODEL 163 with CODE (580) Air conditioning or
Tempmatic for USAAR83.30-P-
5540GH
Remove/install air conditioning
blower motorMODEL 163...AR83.30-P-
5560GH
Remove/install blower motor in
rearMODEL 163.113/154 /174 #A as of 289565, 163.113 #X
as of 754620, 163.128 /157 /175AR83.30-P-
5565GH
Remove/install auxiliary fanMODEL 163.136 /154 /157 /172 with CODE (580) Air
conditioning or Tempmatic for USAAR83.30-P-
5600GH
Remove and install
receiver/drierMODELS 163.113/136 /154 /157 /172 /174 /175 with
CODE (580) Air conditioning or Tempmatic for USAAR83.30-P-
6520GH
Remove and install
receiver/drierMODEL 163.128AR83.30-P-
6520GI
Install/remove condenserMODEL 163...AR83.30-P-
6540GH
Remove, install air conditioning
control moduleMODELS 163.113/136/154/172/174 up to 31.8.01 with
CODE (580) air conditioning or Tempmatic for USAAR83.30-P-
6600GH
Remove and install evaporator
temperature sensorMODEL 163 with CODE (580) Air conditioning or
Tempmatic for USAAR83.30-P-
8085GH
Remove/install outside air
temperature sensorMODEL 163...AR83.30-P-
8086GH
Remove/install air outlet
temperature sensorMODEL 163...AR83.30-P-
8087GH
Remove/install air outlet
temperature sensorMODEL 163...AR83.30-P-
8087GI

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 176 © 2006 Mitchell Repair Information Company, LLC.