engine MERCEDES-BENZ ML320 1997 Complete Repair Manual

How it works
An infrared transmitter (2)sends infrared light to a lens (1) which directs the beam to the windshield (4) . The
intensity of the light reflected by the windshield is measured by an IR receiver (3)located at the opposite end of
the lens.
Dry windshield (Fig. A)
When the area around the rain sensor (B38) is dry nearly all of the light is reflected and the IR receiver
(3) measures a high level of light intensity.
Wet windshield (Fig. B)
When the reflection area is wet, some of the light is scattered away from the glass of the windshield. This
reduces the intensity of the reflected light and the IR receiver (3) measures a lower level of light intensity.
The light intensity measured by the IR receiver (3) provides a measure of the rain intensity on the windshield.
Lower light intensities indicate higher levels of rain intensity on the windshield.
Fig. 26: Identifying Infrared Transmitter And IR Receiver

Rain sensor data flow
The rain sensor (B38) networks with the All Activity Module (AAM, N10) via the engine compartment CAN.
More than
just a "rain sensor," the unit also comprises integrated light sensors for the vehicle lighting

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
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system . Data from the light sensors is also sent to the All Activity Module (AAM, N10) via the engine
compartment CAN.
Power supply
Power is supplied to the rain sensor (B38) via KI. 15 so that these functions are available only when the ignition
is on.
RAIN SENSOR - LOCATION/TASK/DESIGN/FUNCTION - GF82.30-P-4103GH
MODEL 163 with code 345a Rain sensor
Fig. 27: Identifying Rain Sensor Location

Rain Sensor - LocationThe rain sensor (B38) is
adhered to the inside
surface of the windshield.
Rain Sensor - TaskThe rain sensor (B38)
assesses the rain
intensity on the
windshield and
automatically adjusts the
intermittent wiper speed.
In addition, light sensors
gauge ambient light

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
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WIPER MOTOR, FUNCTION - GF82.30-P-4104-01GH
The wiper arm can be driven by the motor with two speeds. The motor runs at high or low speed depending on
brush voltage present.
The cam switch switches circuit 31b from circuit 15 to circuit 31 when the windshield wiper runs through the
park position.
WIPER MOTOR, DESIGN - GF82.30-P-4104-02GH
The windshield wiper is driven by the wiper motor (M6/1) , an electric motor with three brushes and gear. The
cam switch is located on the output shaft.
Fig. 28: Identifying Wiper Motor

WIPER MOTOR, LOCATION/PURPOSE/DESIGN/FUNCTION - GF82.30-P-4104GH
MODEL 163
conditions and this data
is used to control the
vehicle's light system.
Rain Sensor - DesignThe rain sensor (B38)
comprises an IR
transmitter and receiver
unit, light sensorsand an
electronic data analysis
and interface circuit. The
rain sensor (B38) is
connected to the engine
compartment CAN .
Rain Sensor - Function GF82.30-P-4103-02GH

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
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MODEL 163 with CODE (259) Radio Premium with Bose sound system
Parts ordering notes
PROGRAM CHANGE ALTHOUGH RDS [RADIO DATA SYSTEM] AND REGIONALIZATION ARE SWITCHED ON -
AF82.60-P-1062A
MODEL 129, 140, 163, 168, 170, 171, 202, 203, 208, 209, 210, 211, 215, 220, 230, 463 with RDS radio
Damage codeCauseRemedy
Speaker wires picking up
interference noise from
surrounding wiring1 Remove radioAR82.60-P-7502EA
2 Remove upper center
console storage
compartment
3 Remove lower dash
panel below steering
columnAR68.10-P-1500GH
4 Install sound system
jumper harness
AF82.60-P-1010-01AG
5 Reinstall in opposite
order
Part no.DesignationQuantity
163 540 98 05Jumper harness for Bose sound
system1
Damage codeCauseRemedy
Station change without
obvious cause.
Some radio stations
which had originally
transmitted regional
identification have been
transmitting the RDS
signals without regional
identification for some
time.
Without regional
identification it is no
longer possible to
separate stations with the
same station name which
transmit different
programs.1 Point out the facts to
the customer.
Do not replace any
devices, state of the art
engineering.

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COMAND OPERATING AND DISPLAY SYSTEM SCREEN REMAINS DARK AFTER STARTING ENGINE - AF82.85-P-
2001A
MODEL 163, 203, 208, 210, 215, 220, 230, 463 with CODE (352) COMAND operating and display system
NAVIGATION SYSTEM DISPLAYS INCORRECT ADDRESS - AF82.85-P-2100A
MODEL 163.154 /174 #A as of 289565, 163.157/175 with CODE (357) Navigation system - additional unit
with CODE (494a) USA version
Mainland USA only,
DVD version 2002-2 only
Operation no. of the operation texts or standard texts and flat rates
203 820 07 51Clip for portable CTEL mountAs required
203 820 52 15Interference suppression converterAs required
Damage codeCauseRemedy
Current vehicle voltage. Do not remove/install
COMAND.
1. Point out to customer
that in the event of
problems the fault can
be eliminated by
switching off/on
(ON/OFF button) the
COMAND.
RangeOp. no.Operation textFlat rateAcc. no.Code
P023917Flash Navigation
system0.3 h82 853 90-
Damage codeCauseRemedy
Database mismatch.1 Start engine.
2 Turn on MCS unit.
3 Press NAVI MENU
button.
4 Ensure MAP REGION
is set to MAINLAND US
under SYSTEM SETUP
menu.
5 Eject customer
Navigation DVD.

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Parts ordering notes
ERROR IN COMAND OPERATING AND DISPLAY SYSTEM - AF82.85-P-6000-01B
Error patterns for COMAND update CD 10/2001.
The service update CD COMAND with part number W 215 589 00 22 00 eliminates the following complaints:
COMAND: A 220 820 37 89
Error patterns:
Increased quiescent current.
The personal symbols on the map are not updated during active guidance.
Voice control does not react to commands
Occasionally no sound (duration approx. 1 second).
COMAND: A 203 820 91 89, A 463 820 10 89
Error patterns:
Increased quiescent current.
6 Insert update CD into
Navigation unit and close
MCS door.
7 Follow on-screen
instructions until update
is complete.
DO NOT turn off
engine.
8 Remove update CD
when download is
complete.
Disregard error
message stating disc
cannot be read: There is
no map information on
the update CD.
9 Insert customer
Navigation DVD and
input any new address to
verify accuracy.
Part no.DesignationQuantity
T-2787-163Navigation update CD1

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LEFT REAR LOUDSPEAKE R OUTPUT, TESTING ELEC TRICAL SYSTEM RADIO (RD) - AD82.60-P-6000-04A
Fig. 119: Left Rear Loudspeaker Output, Testing Electrical System Radio (RD)
RIGHT REAR LOUDSPEAKER OUTPUT, TESTING ELECTRICAL SYS TEM, RADIO (RD) - AD82.60-P-6000-05A
Fig. 120: Right Rear Loudspeaker Output , Testing Electrical System, Radio (RD)
RADIO INTERFERENCE, TESTING ELECTRICAL SYSTEM, RADIO (RD) - AD82.60-P-6000-06A
Scope of testMeasuring
instrument/
Test
connectionOperation/RequirementSpecified
valuePossible
cause/Remedy
1.0 Radio (A2) or
Radio :
navigation
operating
unit (APS)
(A2/29)
Radio
interference
when engine
is not running Radio: ON
Set even transmitter
frequency without
transmitter reception (e.g.
96.0).
Ignition: ON No
interferenceGround
connections
Cables
Electronic
components
==>1.1
1.1 Radio
interference
when engine
is running Radio: ON
Set even transmitter
frequency without
transmitter reception (e.g. No
interferenceGround
connections
Cables

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RADIO RECEPTION, TESTING ELECTRICAL SYSTEM, RADIO (RD) - AD82.60-P-6000-07A
ACTUATION FOR AUTO MATIC ANTENNA, TESTING E LECTRICAL SYSTEM, RADIO (RD) - AD82.60-P-6000-08A
expect
Fig. 121: Actuation For Automatic Antenn a, Testing Electrical System, Radio (RD)

96.0)
Engine: Start Electronic
components
Ignition system
Engine timing
Values in order :
Antenna systems
(AS)
Scope of testMeasuring
instrument/
Test
connectionOperation/RequirementSpecified
valuePossible
cause/Remedy
1.0 Radio (A2)
or Radio :
navigation
operating
unit (APS)
(A2/29)
Radio
reception Radio: ON
Set station with good
reception:
Carry out road testRadio
reception in
orderGround
connections
Cables
Radio or APS
radio and
navigation
operating unit
Radio transmitter
Broadcasting
corporation
Values in order:
Antenna systems
(AS)

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REMOVE/INSTALL HEADLAMP UNIT - AR82.10-P-4730GH
MODEL 163.113 /128 /136 /154 /157 /172 /174 /175
Fig. 163: Identifying Headlamp Unit Components

paneling (4)
2Unscrew screw (2) of turn
signal lamp (3) in the
exterior mirror paneling
(4)
3Remove turn signal lamp
(3) from the exterior
mirror paneling (4)
4Install in the reverse order
Remove/Install
1Open engine hood
2Unlock cover (1) at the
clip (arrow A) under the
lamp unit and unhook Installation: Lock
clip again.
3Unscrew screw (2)
4Unscrew nuts (3). Installation: Align
the lamp unit so that the

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Fig. 224: Checking Headlamp Adjustment
Check
1Drive vehicle to level
surfaceThe vehicle level must
not change when the
brakes are applied.
Vehicle must be in ready-
for-the-road condition
(unladen weight, fuel tank
full or proper additional
weight).
Correctly adjust tire
pressure.
Load driver's seat with 75
kg or a person (except
USA)
2Align headlamp
adjustment tester to
vehicle and adjust height
according to marking in
lens
Follow the operating
instructions for headlamp
beam setting equipment
exactly*WE58.40-Z-1006-19A
Risk of accident from
vehicle starting off by
itself when engine
running. Risk of injury
suffered in the form of
bruises or burns to the
hands when reaching in
while the engine cranks
or runsSecure vehicle to prevent
it from moving off by
itself.
Wear closed and close-
fitting work clothes.
Do not touch hot or
rotating parts.AS00.00-Z-0005-01A

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