battery MERCEDES-BENZ ML320 1997 Complete Repair Manual

Shown on model 230
Fig. 1: Identifying Garage Door Opener Buttons
- Shown On Model 230
Garage door opener, function
The garage door opener consists of an intelligent radio remote control with three transmitter buttons capable of
learning. Various receivers for opening and closing systems and doors can be activated with the three buttons,
garage door opener button 1 (A67s1), garage door opener button 2 (A67s2) or garage door opener button 3
(A67s3).
Program remote control
Function requirements:
Term. 15R or 15 ON
Press and hold down garage door opener button 1 (A67s1), garage door opener button 2 (A67s2) or
garage door opener button 3 (A67s3).
The garage door opener indicator lamp (A67e4) starts flashing (frequency 1 Hz).
Continue to actuate garage door opener button 1 (A67s1), garage door opener button 2 (A67s2) or garage
door opener button 3 (A67s3) and hold garage door remote control with transmit button pressed for t < 90
s.
After successful programming, the garage door opener indicator lamp (A67e4) flashes rapidly (f = 5.5
Hz) for approx. 10 s.
Release the two transmit buttons and program additional transmitters as required.
Time switch-off
To protect the vehicle battery, the transmitter unit switches off the learn-in mode when programming is not
accomplished within approx. 100 s.
Transmitter mode

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Interior Equipment - 163 Chassis
me
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MODEL 129, 163, 170, 202, 208, 210 as of 1.6.98,215, 220 with CODE (231a) Garage door opener
GARAGE DOOR OPENER DIAGNOSIS, FUNCTION CHECK - AD68.05-P-3000A
MODEL 129, 163, 170, 202, 208, 210 as of 1.6.98,215, 220 with CODE (231a) Garage door opener
GARAGE DOOR OPENER DIAGNOSIS, TROUBLE-SHOOTING - AD68.05-P-5000A
MODELS 129, 163, 170, 202, 208, 210 as of 1.6.98,215, 220 with CODE (231a) Garage door opener
Garage door opener locationModels 129, 202, 208, 210, 215, 220GF68.05-P-1100-01A
Model 170GF68.05-P-1100-01B
Model 163GF68.05-P-1100-01C
Electrical wiring diagramsModel 163PE68.00-P-1100D
Model 170PE68.00-P-1100C
Models 202, 208PE68.00-P-1100B
Model 210PE68.00-P-1100A
Model 220PE68.00-P-1100SA
Model 129, volume 2, FG 68
Connection and use of test equipment AD00.00-P-1000AZ
Diagnostic tools, garage door opener AD68.05-P-2000-01A
Compatibility test for garage door opener AD68.05-P-2000-02A
Garage door opener diagnosis, previous knowledge AD68.05-P-
2000A
Key to diagnostic symbols AD00.00-P-
2001A

Fuses in order
Battery voltage 11-14V
Ignition: ON

Function check
Scope of test Operation / requirement Specified value Possible
cause / remedy
1
Transmitting

push-button
The desired transmitting push-button is programmed.
The vehicle is inside the garage door range.
The garage door opener signal has a range of at least
85% of the range of the garage door hand transmitter or
15m.
Press programmed transmitting push-button.
Garage door is
activated.AD68.05-P-
5000A

Garage door opener
diagnosis, previous
knowledge
AD68.05-P-2000A

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Interior Equipment - 163 Chassis
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Saturday, October 02, 2010 3:35:21 PMPage 10 © 2006 Mitchell Repair Information Company, LLC.

Fuses in order.
Battery voltage
11-14 V
Ignition: ON

Troubleshooting
Complaint Possible cause Note Remedy
The garage door
cannot be
activated with the
garage door
opener installed
in the vehicle.
The garage door opener
has not been
programmed correctly.
GF68.05-P-0001A
The garage door is
defective
Check garage door: Activate
the garage door with the
hand transmitter. If the
garage door cannot be
opened and closed with the
hand transmitter, the garage
door has a mechanical or
electrical defect.

The garage door's
receiver and the garage
door opener installed in
the vehicle are not
compatible.
A list of compatible garage
doors is included in the
passenger car sales manualIf the used garage door is not
listed check compatibility
with compatibility tester.

Compatibility check of
electrical system for garage
door opener Models 129, 170,
202, 208, 210 as of 1.6.98, 163
as of 1.9.01, 215, 220 with
CODE (231a) garage door
opener Compatibility check for
garage door opener.
AD68.05-P-6000-02A
AD68.05
-P-2000-02A

Voltage supply to
garage door opener
interrupted.Model 208 as of 1.6.98, except
CODE (249a)
Automatic dimming inside
rearview mirror
AD68.05-P-6000-01A

Model 202 as of 1.6.98, Model
210 as of 1.6.98, except CODE
(249a)
Automatic dimming inside
rearview mirror
AD68.05-P-6000-01C
Model 202 as of 1.6.98, Model
208 as of 1.6.98, Model 210 as
of 1.6.98, with CODE (249a) AD68.05-P-6000-01G

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Interior Equipment - 163 Chassis
me
Saturday, October 02, 2010 3:35:21 PMPage 11 © 2006 Mitchell Repair Information Company, LLC.

MODELS 129, 163, 170, 202, 208, 210 as of 1.6.98,215, 220 with CODE (231a) Garage door opener
TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: INTERIOR EQUIPMENT - AR68.00-Z-9163AA
MODEL 163
Garage door opener diagnosis,
previous knowledge AD68.05-P-
2000A
Fuses in order.
Battery voltage 11-14 V

Checking
1Compatibility check of electrical
system for garage door openerModels 129, 170, 202, 208, 210 as of 1.6.98,
163 as of 1.9.01,
215, 220 with CODE (231a) garage door openerAD68.05-P-
6000-02A
2Voltage supply for test of electrical
system for garage door openerModel 208 as of 1.6.98, except CODE (249a)
Automatic dimming inside rearview mirrorAD68.05-P-
6000-01A
3Voltage supply for test of electrical
system for garage door openerModel 129 as of 1.6.98AD68.05-P-
6000-01B
4Voltage supply for test of electrical
system for garage door openerModels 202, 210 as of 1.6.98, except CODE
(249a) Automatic dimming inside rearview
mirrorAD68.05-P-
6000-01C
5Voltage supply for test of electrical
system for garage door openerModel 170 as of 1.6.98AD68.05-P-
6000-01D
6Voltage supply for test of electrical
system for garage door openerModel 163 as of 1.6.98AD68.05-P-
6000-01E
7Voltage supply for test of electrical
system for garage door openerModels 215, 220AD68.05-P-
6000-01F
8Voltage supply for test of electrical
system for garage door openerModels 202, 208, 210 as of 1.6.98, with CODE
(249a) Automatic dimming inside rearview
mirrorAD68.05-P-
6000-01G
Removing and installing
instrument panelMODEL 163.113 /128 /136 /154 /157 /172 /174 /175AR68.10-P-
1000GH
Remove/install center section of
instrument panelMODEL 163.113 /128 /136 /154 /157 /172 /174 /175AR68.10-P-
1030GH
Remove/install bottom section of
instrument panelMODELS 163.113 /128 /136 /154 /157 /172 /174 /175AR68.10-P-
1040GH
Removing and installing side air
nozzleMODELS 163.113 /128 /136 /154 /157 /172 /174 /175AR68.10-P-
1100GH
Remove/install instrument panel
carrierMODEL 163.113 /128 /136 /154 /157 /172 /174 /175AR68.10-P-
1111GH
Removing and installing center AR68.10-P-

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Interior Equipment - 163 Chassis
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Fig. 13: Identifying Instrument Panel Bottom Section Components

Remove/install
1Shift transmission selection lever to
position "1" Secure vehicle to prevent it
moving away.
2Disconnect ground cable of battery AR54.10-P-
0003A
3Remove combination switch with
paneling (3) AR54.25-P-
2800GH
4Remove cover frame of instrument cluster
(2)
5Unscrew the screws (7). 3 screws up to 08/99. 1 screw as of
09/99.
6Unscrew screws in left footwell (5) on the
lower part of the instrument panel (4)
7Remove center section of instrument
panel (11) AR68.10-P-
1030GH
Remove switch unit for heater / AR83.20-P-

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Interior Equipment - 163 Chassis
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AR20.40-P-5000M
Remove/install electric fan
24.8.99

ENGINE
612.963 in MODEL 163.113

P20.40-2015-06

Shown on Model 163.113 with

Engine 612.963

1
Clutch

2
Electrical lines circuit 30

3
Clips

4
Captive nuts

5
Bolts

M4/7
Electric suction fan engine and AC

with integrated control


Remove/Install


Danger!
Risk of injury
to
fingers being jammed or

squeezed
when removing and installing or

aligning hoods, doors, trunk lid/tailgate or

sliding roof.
When moving components, ensure that no

body parts or limbs are within the operating

range of moving parts.

AS00.00-Z-0011-01A


Danger!
Risk of death.
Death may result if vehicle

slips or topples from the lifting platform.
Align vehicle between the columns of the

lifting platform and position the four support

plates
at the lifting platform support points

specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

1
Place the vehicle on lifting platform

AR00.60-P-1000GH

2
Open engine hood and raise to vertical position

Have second person secure hood.

AR88.40-P-1000GI

3
Connect quiescent current retention device


*WH58.30-Z-1005-09A

4
Disconnect ground cable of battery

AR54.10-P-0003A

5
Detach coupling (1) at electrical connector of

fan

6
Disconnect electrical lines circuit 30 (2) at
electric fan

7
Unclip wiring harness from bracket

8
Remove front part of noise encapsulation

AR94.30-P-5400GH

9
Detach clamps (3) at bottom side of electric fan

10
Unscrew screws (5)

11
Remove captive nuts (4)

12
Unhinge electric suction fan engine and AC

with integrated control (M4/7) at top of

radiator and take out toward bottom


Installation:
Insert retaining lugs of

electric fan into the mounts at radiator.

13
Install in the reverse order

Commercially available tools

Number

Designation
Make (e. g.)
Order number

WH58.30-Z-1005-09A
CMP 12.2 quiescent current retention unit
Hans Zeheter

Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

Danger!

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
Open engine hood and raise to vertical position

Have second person secure hood.

AR88.40-P-1000GI

2
Connect no load current retention unit


*WH58.30-Z-1005-09A

3
Disconnect battery ground cable

AR54.10-P-0003A

4
Remove trim panel of cylinder head cover

AR01.20-P-5014-02B


*BA01.20-P-1002-01A


*BA01.20-P-1003-01A

5
Remove bottom part of noise encapsulation

at front

AR94.30-P-5400GH

6
Remove electric fan (1)

Remove toward bottom.

AR20.40-P-5000M

7
Drain coolant

At radiator.

AR20.00-P-1142M


Notes on coolant
All engines

AH20.00-N-2080-01A

8
Remove charge air cooler (110/2)

AR09.41-P-6817MM

9.1
Attach guard plate for radiator/condenser

With automatic air conditioning, code

581a and AC system or Tempmatic USA,

code 580.

Attach additional AC condenser in the

vehicle.

y

Guard plate for radiator/condenser
Engine 606 in model 124,
Engine 606.961 in model 140,

Engine 112, 113, 604, 605, 611.960 in

MODEL 202,

Engine 602.983, 612.966 in MODEL 461,

Engine 628.962, 612.965, 606.964, 112.945,

113.962/ 982 in MODEL 463,

Engine 111, 112, 611.962, 612.962 in model

203,

Engines 112, 113, 611.961, 612.961, 613.961

in MODEL 210,

Engine 112 in model 170,

Engine 112 in MODEL 220,

Engine 113 in MODEL 211, 215, 220,

Engine 112 in MODEL 208,

Engine 112, 612.963, 628.963 in MODEL 163,
Engine 112.923 /943, 113.961 in MODEL 129,

Engine 137, 275 in MODEL 215, 220,

Engine 613.960, 628.960 in MODEL 220,

Engine 113.992 in model 230.474,

Engine 271 in model 209, 203,

Engine 285.950 in model 240.078 /178,

Engine 612.967 in model 209.316,

Engine 648 in model 220

Engine 112.951 in model 639.601/603/

605/701/703/705/801/803/805

Engine 646.983/984 in model 639.601/

603/605/701/703/705/801/803/805

Engine 646.982 in model

639.601/603/605/701/703/705

WF58.50-P-0110-01A

10
Remove seal rail (11)

11
Extract steering oil from reservoir

Hand pump

*210589007100

12.1
Disconnect power steering oil line (return line

radiator

!
power steering pump supply

reservoir) (18)

Seal connections.


Installation:
Install new sealing rings.


*BA46.30-P-1012-01A


Clamp

*000589543700

Set of stop plugs

*129589009100

12.2
Disconnect power steering oil line (feed line of

steering gear

!
radiator) (19)


Clamp

*000589543700

Set of stop plugs

*129589009100

Hexagon socket wrench

*WH58.30-Z-1001-06A

Hexagon socket wrench

*WH58.30-Z-1002-06A

Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

P82.60-0001-06

The figure shows removal of radio in

model 202

51
Removal assembly

A2
Radio

Remove/Install

1
Disconnect battery ground cable

On model 163, 210, insulate cable

terminal for ground lead to prevent

unintentional contact between disconnected

ground lead and ground point W10

AR54.10-P-0003A

Model 463 except 463.241 with code 979

AR54.10-P-0003G

Model 463.241 with code 979

AR54.10-P-0003PV

2
Pull out radio (A2)

Insert removal fixture (51) for this purpose.


*000589886300

Push back retaining springs (arrow) on

removed radio (A2) and pull out removal

fixture (51).

k

MB radio
Model 202

BT82.60-P-9309-01A

k

MB radio
as of 02/97

BT82.60-P-9309-01B

k

MB radio
MODEL 129 as of 02/91

BT82.60-P-9309-01C

3
Disconnect electrical connectors

4
Install in the reverse order

5
Enter radio code
Code 750, 751

AR82.60-P-7502-01A

Code 510a, 512a, 515a, 516a, 755, ER5,

ER6, ER7

AR82.60-P-7502-01B

Model 129

AR82.60-P-7502-01C

Model 168, 414

AR82.60-P-7502-01GC

Model 163

AR82.60-P-7502-01GH

Removal assembly

000 589 88 63 00

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

2001-04 STARTING & CHARGING SYSTEMS Starters - 163 Chassis
MODEL IDENTIFICATION
MODEL IDENTIFICATION
DESCRIPTION
Starter is a brush-type, series-wound el ectric motor with an overrunning clutch. Field frame contains field coils
and is enclosed by commutator/drive bushing end frame, which carries pole shoes. A splined armature shaft
carries drive assembly.
TROUBLE SHOOTING
BASIC TROUBLESHOOTING
If starter is noisy, the cause could be bent or damaged gear tooth chamfers on ring gear. This cannot be seen
with starter installed in ve hicle. Activate starter without switching ignition on. Me tallic noise should not be
heard. If noise is he ard, replace ring gear.
PRELIMINARY INSPECTION
Verify customer complaint by operating system. Visually inspect for obvious signs of mechanical and electrical
damage. Check generator belt tension and condition. Ensure that battery voltage is within specifications. Inspect
for blown fuses and damaged relays. For fuse and/or relay identification, see WIRING DIAGRAMS
.
WARNING:
Vehicles are equipped with air bag supplemental restraint system. Before
attempting any repairs involving steer ing column, instrument panel or
related components, see SERVICE PRECAUTIONS (or AIR BAG SAFETY
PRECAUTIONS) and DISABLING & ACTIVATING AIR BAG SYSTEM in
appropriate AIR BAG REST RAINT SYSTEMS article.
NOTE: When the battery is di sconnected, vehicle computer and memory system may
lose data. Driveability problems may exist until computer systems have
completed a relearn cycle. Radio will not operate until coded. Obtain code card
from customer.
NOTE: The following table identifies mo dels applicable to this article.
ModelChassisEngine Number
ML430 (2001)163.172113.942
ML320 (2001-03)163.154112.942
ML55 AMG (2001-03)163.174113.981
ML500 (2002-04)163.175113.965
ML350 (2003-04)163.157112.970

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Starters - 163 Chassis

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Starters - 163 Chassis
me
Saturday, October 02, 2010 3:19:47 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.
me
Saturday, October 02, 2010 3:19:50 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.

Verify ground connection integrity between engine, body, battery and generator. Check for damaged wiring
harnesses and/or switches. Check fo r a broken or partially broken wire inside insulation, which could cause
system malfunction but prove good in a continuity/vol tage check with system disconnected. Ensure any
aftermarket electronic e quipment is properly installed. If fault is found, repair as necessary. If no fault is found,
check for conditions that might cause an intermittent situation.
SERVICE PRECAUTIONS
BATTERY DISCONNECT/CONNECT
Disconnect/Connect Procedures
1. Turn ignition off. Open engine hood. After opening ve hicle wait at least 4 minutes before disconnecting
battery or alarm wi ll be triggered.
2. Disconnect negative battery cable (1) and insulate cable lug to prevent unwanted contact with ground
point (W16/4). See Fig. 1
.
3. To connect, reverse disconnect procedur e. Tighten nut (5) to specification. See TORQUE
SPECIFICATIONS .
4. Perform basic programming, read Diagnostic Tr ouble Code (DTC) memory and erase DTCs from
memory. See BASIC PROGRAMMING
and RETRIEVING & ERASING DIAGNOSTIC
TROUBLE CODES .
NOTE: Numbers and letters in text refe
r to numbers and letters in figures.

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Starters - 163 Chassis
me
Saturday, October 02, 2010 3:19:47 PMPage 2 © 2006 Mitchell Repair Information Company, LLC.