engine MERCEDES-BENZ ML320 1997 Complete Repair Manual

Fig. 132: Locating In-Car Temperature Sensor With Aspirator Nozzle
1. Check condition of fuses F16, F41, F43, F44.
2. Check aspirator nozzle for in-car temperature sensor as follows: With ignition switched on, place a piece
of paper (arrow) of 1cm surface area on grill in front of in-car temperature sensor with aspirator nozzle
(B10/4). With sufficient ventil ation (aspirator nozzle to blow er), paper remains on grill.
3. Allow engine to idle at operating temperature (engine coolant temperature approx. 80°C) during the
complete duration of the test.
4. Outside temperature > 15°C.
5. Open center and side air outlets manually.
6. Recirculated air switch not pressed.
7. Set blower switch to stage 4.
AIR CONDITIONING (TEMPMATIC ) PRECONDITIONS FOR OPERATIONAL CHECK - AD83.30-P-2000-01GK
as of 1.12.99

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Fig. 133: Locating In-Car Temperature Sensor With Aspirator Blower
1. Check status of fuses F16, F41, F43, F44.
2. Check aspirator blower for in-car temperature sensor: With ignition switched on, place a piece of paper
(arrow) of 1cm surface area on grill in front of in-car temperature sensor (B10/4) with aspirator blower.
With sufficient ventilation (a spirator blower to blower), paper remains on grill.
3. Allow engine to idle for entire duration of test at operating temperature (approx. 80°C coolant
temperature).
4. Outside temperature > 15°C
5. Open center and side nozzles manually.
6. Recirculating air sw itch not pressed.
7. Blower switch on step 1.
Observe run-on time.
AIR CONDITIONING (T EMPMATIC) VERSION CO DING - AD83.30-P-2000-02GH
Variant coding is carried out by the HHT and is menu -assisted. Communication is possible as soon as the
ignition key is inserted in the ignition lock (the igniti on lock position is not important). Variant coding (position
1) is reached from the main menu via control module adaptations (position 5). The following two options are
available in variant coding:
1. Read out coding and transfer to new control module.
2. Readout/change coding.
Position 2 must be selected in order to read out th e air conditioning coding. The air conditioning variant coding
is found under position 07 in the following listing.

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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

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1998-2005 HVAC Climate Control - 163 Chassis
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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

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1. Start vehicle engine and switch on air conditioning system.
2. Check entire air conditioning circuit using leak detector probe (1).
Remain for some time in areas where leaks are suspected.

Since refrigerant is heavier than air and sinks, always guide leak detector probe (1) underneath the locations
where leaks are suspected.
Line connections, screwed pipe connections, condensers and evaporators are the most frequent cause of
refrigerant leaks.
Fig. 155: Identifying Air Conditioning System Leak Detector Probe

CARRY OUT QUICK TEST ON AIR CONDITIONING SYSTEM - AR83.30-D-1209A
MODEL 163 with CODE (580) Air conditioning or Tempmatic for USA
MODELS 901.0/3 /4, 902.0/3 /4, 903.0/3 /4, 904.0/3 /4 with CODE (H06) Air conditioning
WE58.40-Z-1002-20AAir conditioning leak detector

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Fig. 156: Identifying Quick Test On Air Conditioning System - Shown On Models 901, 902, 903, 904
Shown on models 901, 902, 903, 904
Prerequisites for
testing
1Place vehicle with open
windows in the shade
2Set heater control valve
to "cold"
3
Set heating and
ventilation system to
fresh air mode

4
Fully open lateral
nozzles, center nozzles
and footwell flaps

5Start vehicle engine and
allow to idle
Inspecting
6Switch air conditioning
on
When the air conditioning is switched on, the vehicle
engine's idle speed must increase. No idle speed increase ?
Check function of refrigerant compressor RPM sensor in the
event of complaint ?


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Commercially available tools
Workshop equipment
DRAINING, EVACUATING AND REFILLING AIR CONDITIONING, CHECKING FUNCTION AND CHECKING FOR
LEAKS - AR83.30-P-1760GH
MODELS 163.113 /128 /136 /154 /157 /172 /174 /175 with CODE (580) Air conditioning or Tempmatic for
USA
Replace refrigerant compressor RPM sensor
Models 901-904
Not in model 163AR83.55-D-
5320A
7
Set blower rotary
switch to maximum
blower setting

8Check that refrigerant
flows free of bubbles
If the system is filled sufficiently, the refrigerant must flow
through the inspection glass (2) free of bubbles. A newly-
filled system may initially reveal bubbles. In this case, wait
for approx. 10 min. and check inspection glass again.
Does not reveal bubble-free flow ?

Check entire air conditioning circuit for leaks using leak
detector (3).AR83.30-D-
1209-01A
Air conditioning system leak detector*WE58.40-Z-
1002-20A
9Determine air outlet
temperature

Switch blower rotary switch to stage "1".
Insert sensor of temperature measurement device (1) into the
air outlet of the center nozzles.
After running for a period of 5 min., the air outlet temperature
must not be less than 2°C and more than 12°C. After 5 min., at
the latest, the refrigerant compressor must also be connected
and disconnected.
If the refrigerant compressor is disconnected at below 2°C ?
Check evaporator temperature switch. If the air outlet
temperature is not achieved ?
Check the connection and disconnection of the refrigerant
compressor or the refrigerant pressure upstream and
downstream of the refrigerant compressor.
*WH58.30-Z-
1005-08A
10
Switch air conditioning
off and shut vehicle
engine off

NumberDesignation
WH58.30-Z-1005-08ATemperature measuring device
WE58.40-Z-1002-20AAir conditioning leak detector

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Air conditioning system
Workshop equipment
REMOVE/INSTALL DEFROSTER VENT FLAP ACTUATOR MOTOR FOR WINDSHIELD - AR83.30-P-2006GH
MODEL 163.113 /154 /174 #A as of 289565, 163.113 #X as of 754620, 163.128/157/175
4evacuate
Filling
5Supplement oil for refrigerant
compressor The exact quantity determined when
drained must be used.
6Fill air conditioning system *BF83.30-P-
1001-01B
Testing
7Inspect air conditioning system for leaks
with leak detector *WE58.40-
Z-1002-20A

8
Risk of accident. Accidents may result if
the vehicle starts off unintentionally with
the engine running. Risk of injury from
bruises and burns if you hold your hand
near engine when it is started or when it
is running. Check function of air
conditioningSecure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.
Run engine at idle speed for about 4
minutes and check all the component
functions which are of relevance for proper
operation of the air conditioning system.
AS00.00-Z-
0005-01A
NumberDesignationModel Series 163
BF83.30-P-1001-01BRefrigerantsFilling quantityg750
Specifications for Operating FluidsSheetBB00.40-P-0361-00A
WE58.40-Z-1002-20AAir conditioning leak detector
WE58.40-Z-1002-22AAir conditioning service station

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poisoning from swallowing
coolant.Wear protective gloves, protective
clothing and eye protection.
1Drain coolantEngine 111 in MODEL 163.AR20.00-P-
1142HG
Engines 112 /113 in MODEL 163.AR20.00-
P-1142HA
Engine 628.963 in MODEL 163.128.AR20.00-P-
1142HB
Engine 612.963 in MODEL 163.113.AR20.00-P-
1142M
2.1 Detach
brake line
from the
front end of
the radiator
Only required for right-hand steering.
3.1 Detach
ignition
cable from
the front end
of the
radiator
Only required on right-hand drive vehicles
with ENGINES 111 /112/113.
4Release coolant overflow from
battery shield
5Disconnect upper coolant hose
from the electric coolant pump Detach hose clamp from the upper
coolant hose.
6Unscrew nuts from expansion
reservoir at firewall
7Remove expansion reservoir from
the firewall and lay aside
8Disconnect coolant delivery/return
hoses for heat exchanger (17) Detach hose clamps from coolant
delivery/ return hoses for heat exchanger.
9Discharge air conditioning system
Installation: Evacuate air
conditioning, refill and check for proper
operation and leaktightness.AR83.30-
P-1760GH
10Unscrew self-locking nut (16) at
the expansion valve (15) Replace self-locking nut.
*BA83.30-
P-1003-01B
11
Detach low-pressure refrigerant
line (13) and high-pressure
refrigerant line (14) from expansion
valve (15)
Installation: Install new sealing rings
and moisten with compressor oil.
12Remove instrument panel carrier
(4) AR68.10-
P-1111GH

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conditioning (Automatic) A/C compressor 7SB16
MODEL 210 with CODE (580) Air conditioning or Tempmatic for USA with CODE (581a) Air
conditioning (Automatic) A/C compressor 7SB16
MODELS 215,220 A/C compressor 7SE16
A/C compressor
Correct oil level

Carry out work quickly, compressor oil is
hygroscopic
When evacuating refrigerant, the quantity of
compressor oil evacuated must be added again
to refrigerant circuit when refilling air
conditioning (new oil)

1Replace A/C compressor, additionally fill with
new compressor oil *BF83.55-P-
1008-01A
2Replace condenser and additionally fill with new
compressor oil *BF83.55-P-
1003-01A
3Replace evaporator and additionally fill with
compressor oil *BF83.55-P-
1004-01A
4Replace fluid reservoir and additionally fill with
compressor oil *BF83.55-P-
1005-01A
5
Replace suction pipe from evaporator to A/C
compressor and additionally fill with new
compressor oil
*BF83.55-P-
1006-01A
6
Replace pressure pipe from A/C compressor to
condenser and additionally fill with new
compressor oil
*BF83.55-P-
1007-01A
7Additional oil quantity when replacing
evaporator, rear air conditioning Model 220*BF83.55-P-
1010-01A
8Additional oil quantity when replacing rear air
conditioning lines Model 220*BF83.55-P-
1011-01A
9Switch on air conditioning and allow engine to
run at idle speed for approx. 4 minutes
Turn temperature thumb wheel of
center nozzles to stop in blue range, or
on automatic air conditioning to "Lo"
Blower at max.

10Check function of air conditioning
Air output temperature at center
nozzle must not fall below + 5
0 C, if
necessary ? Carry out diagnosis
NumberDesignationA/C
compressor
7SB16 in A/C
compressor
7SB16 A/C
compressor
ND6CA17 in

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