MERCEDES-BENZ ML430 1997 Complete Repair Manual

WINDSHIELD WASHER WATER RESERVOIR LEAKY - AF82.35-P-4043B
headlamps and glass
splinters from broken
xenon bulbs
Risk of poisoning
caused by inhaling
mercury vapor and by
swallowing/skin contact
with toxic salts and
mercury compoundsEnsure that the working area is
sufficiently ventilated.
82 119 We receive at the diagnostic
centers of the plants more and
more xenon control units and
xenon lamps which are o.k.
To avoid this high number of
problem parts with no
reproducible faults, we would ask
you to use the following
procedure for troubleshooting:
1 Perform diagnosis according to
instructions in WIS.
Model 202, 208, 210AD82.10-P-1001AZ
If the fault cannot be
recognized or the faulty
component determined: ?
2 Interchange the xenon lamps
(right to left).
For the time being do not
replace system components.
If the fault of the xenon lamp
still exists: ?
3 Remove/install/replace xenon
lamp.
If the fault remains in the
headlamp the cause may be the
xenon control unit or a fault on
the vehicle side.
We are aware of the fact that
this procedure may possibly lead
to another stay in the workshop o
f
the vehicle in question.
However, we see no other
alternative if the redebiting of
warranty and goodwill costs is to
be avoided.


2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
Saturday, October 02, 2010 3:30:06 PMPage 166 © 2006 Mitchell Repair Information Company, LLC.

MODEL 163.113/136/154/172 With 5 L reservoir
INSTALLING SOUND SYSTEM JUMPER HARNESS - AF82.60-P-1010-01AG
1. Insert sound system jumper harness through radio opening
Position jumper harness within cockpit assembly so that jumper harness is routed above HVAC
venturi tube and lays across base of steering column.
2. Plug male radio harness connector A/B (1) into corresponding female connector (2) of jumper harness
3. Secure connectors, phone antenna and phone power lead with cable tie (3) next to radio harness mounting
clip on HVAC case
Fi
g. 98: Identifying Phone Power Lead With Cable Tie, Male Radio Connector And Corresponding
Female Connector
4. Attach jumper harness (4) to steering column mounting bracket with integrated harness clip (5) and clip
on female amplifier connector (6) of jumper harness
5. Secure jumper harness (4) to dash support bracket with cable tie (7)
Install cable tie on convolute tubin
g protected area of jumper harness.
Damage codeCauseRemedy
Stress fracture in
windshield washer water
reservoir.1 Replace windshield
washer water reservoir
with large capacity
reservoir.SM82.35-P-0002GH

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
Saturday, October 02, 2010 3:30:06 PMPage 167 © 2006 Mitchell Repair Information Company, LLC.

Fig. 99: Identifying Female Amplifier Connector, Cable Tie And Harness Clip
6. Cut slot in insulation to access sound system amplifier (A2/13) electrical connectors.
7. Disconnect male connector A/B (9) on sound system am plifier and plug into female amplifier connector
(6) of jumper harness
8. Plug male connector A/B (8) of jumper harness into corresponding connection on sound system amplifier
9. Refit insulation
Fig. 100: Identifying Sound System Amplifier, Plug Male Connector A/B And Integrated Harness
Clip
HUMMING SOUND FROM SPEAKERS WITH RADIO SET ON LOW VO LUME - AF82.60-P-1010AG

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electr ical System - Body - 163 Chassis
me
Saturday, October 02, 2010 3:30:06 PMPage 168 © 2006 Mitchell Repair Information Company, LLC.

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.

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
Saturday, October 02, 2010 3:30:06 PMPage 169 © 2006 Mitchell Repair Information Company, LLC.

INTERMITTENT INTERRUPTIONS OF RADIO RECEPTION IN RDS MODE - AF82.60-P-1101A
MODELS 163,168,170, 208, 210 with CODE (756a) MB radio Audio 10 RDS with CD compartment
PROBLEM WITH RADIO RECEPTION AFTER INSTALLING SUN SHIELD FILM - AF82.60-P-1105A
MODEL 163, 202, 203, 208, 209, 210, 211, 215, 220
Modification notes
Damage codeCauseRemedy
Under unfavorable
reception conditions in
FM-RDS mode, the radio
may frequently switch to
alternative frequencies of
one and the same radio
station. Due to the equipment
and antenna design there
is no remedy available.
During switchover,
reception may be
interrupted for a brief
period.Do not replace any radios
subject to this complaint
only!
11.2.00Supersedes STIP 82.60-
030 dated 10.2.00
Damage codeCauseRemedy
Complaint is caused by
retrofitting metallized
window foils. When installing
window foils, cut foil
outside of vehicle to
avoid damaging the
antennas and heating
wires
Metallized foil:
AM reception
reduced approx. 70
%, among other
problems search
stop no longer
possible
FM reception
reduced approx. 10
% .
TV reception
reduced approx. 10
Do not use metallized
foil.
Advise customer of
negative effects to
reception

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
Saturday, October 02, 2010 3:30:07 PMPage 170 © 2006 Mitchell Repair Information Company, LLC.

AM RADIO RECEPTION DIFFICULTIES - AF82.60-P-6005A
MODEL 163.136 /154 /172 ## up to 146760
Revisions
%.
Range of radio
remote control for
central locking
reduced by up 50 %

Non-metallized foil:
Only slight
reduction of
functions described
above.
01.09.99Supersedes STI no.
82.60-024 dated 01.09.99
CauseRemedy
Loss of noise filtering
function of the antenna
splitter (A2/5) and the
AM/FM amplifier
(A2/18) due to poor
ground connection.1 Remove AM/FM
amplifierAR82.62-P-8347GH
AM radio reception is
being adversely affected
by background noise and
electrical interference,
resulting in the station
signal being overridden.2 Remove antenna
splitterAR82.70-P-8953GH
The painted surface of the
vehicle's body, combined
with the protective
coating on the mounting
screws, may not provide
an adequate ground.3 Remove paint/E-
coating from vehicle
body at mounting points
of antenna splitter and
AM/FM amplifier
4 Remove protective
coating on shoulder of
antenna splitter and
amplifier mounting
screws

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
Saturday, October 02, 2010 3:30:07 PMPage 171 © 2006 Mitchell Repair Information Company, LLC.

CDS AND DVDS ARE NOT EJECTED - AF82.60-P-6061A
MODEL 129, 140, 163, 168, 170, 171, 202, 203, 208, 209, 210, 211, 215, 220, 230, 414, 463
Modification notes
5 Reinstall antenna
splitterAR82.70-P-8953GH
6 Reinstall AM/FM
amplifierAR82.62-P-8347GH
17.5.04Cause/remedy 3 added
Damage codeCauseRemedy
The causes listed in
this document are not a
malfunction of the CD
drive. Operations in
this context are not
covered b
y warranty or
goodwill .

Cause 1: Remedy 1:
CD thickness is not within
tolerance, e.g. DVDs with
recordings on both sides
(side 1: video data, side 2
audio data).1 Inform customer that
CDs should correspond
to specifications.
CD occasionally not
pulled in, light pressure
required in addition. Then,
CD is not ejected. Drives fulfill
specifications.
CD does not satisfy
specifications. According to
CD standards, the thickness
must be within the tolerance
range of 1.1 mm -1.5 mm.
Previously measured CDs
had a thickness of > or = 1.6
mm.
NoneCause 2: Remedy 2:
Self-made CDs/DVDs used
with self-adhesive labels.1 Advise customers not
to use CDs/DVDs with
self-adhesive labels.
Due to the various
materials used, the length
expansion differs at higher Please also advise
your coworkers in Sales.

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
Saturday, October 02, 2010 3:30:07 PMPage 172 © 2006 Mitchell Repair Information Company, LLC.

temperatures causing the
label to become wavy (see
arrows) or the CD/DVD to
deform.
In both cases, the
CDs/DVDs can get stuck
and damage to the drive
mechanism is possible.
CDs/DVDs are not
ejected.
CDs/DVDs are not
completely ejected.

All head units with
CD/DVD drive, all CD
changers as well as
navigation processors with
single-slot drive are
affected.
NoneCause 3: Remedy 3:
CDs with a diameter of 8 cm
are used (with and without
adapter).1 Please inform the
customer that 8 cm CDs
are not to be used (even
with an adapter).
The pull in/eject
mechanism of the drive is
Drives not designed for 8
cm CDs. Drives fulfill
specifications.
If an adapter is used for 8
cm CDs, the thickness of the
CD increases which leads to
problems when inserting
and ejecting CDs.
Furthermore, there is the
danger that the 8 cm CD
will be pushed out of the
adapter while being pulled
in/ejected and thereby block
the mechanism.

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
Saturday, October 02, 2010 3:30:07 PMPage 173 © 2006 Mitchell Repair Information Company, LLC.

Fig. 101: Identifying Waves On CD Label
GLOBAL POSITIONING SYSTEM (GPS) MALFUNCTION - AF82.61-P-6010A
MODEL 163.113 /136 /154 /172 /174 #A as of 145273 up to 289564, 163.113 /154 #X as of 708319 up to
754619 with CODE (353) Audio 30 APS
Operation no. of operation texts or standard texts and flat rates
SectorOp. no.Operation textTimeAcc. no.Code
P023578REPLACE REAR
ANTENNA FOR
GLOBAL
POSITIONING
SYSTEM (GPS)
(AFTER TESTING)003 AW/0,3 h82 858 52-
Damage codeCauseRemedy
Inadequate seal between
antenna base and vehicle
roof causes antenna
connector to corrode.
The parts kit for the
Global Positioning
System (GPS) antenna
was updated. Instead of a
foam seal (4), a grommet
(5) is now used to seal the
antenna base to the
vehicle roof. The new
163 820 18 75 part 1 Replace GPS antenna.
Use new parts kit
only.AR82.61-P-7474GI

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
Saturday, October 02, 2010 3:30:07 PMPage 174 © 2006 Mitchell Repair Information Company, LLC.

Fig. 102: Identifying GPS Rear Antenna Components
Parts ordering notes
TELEPHONE CALL INTERRUPTED - AF82.70-P-1009A
MODEL 129, 163, 168, 170, 171, 202, 203, 208, 209, 210, 211, 215, 220, 230, 460, 461, 463 with CODE
(312) GSM portable cellular telephone with CODE (316) MB GSM cellular telephone (D2B) with CODE
(317) GSM portable cellular telephone (D2B) with CODE (347) TELE AID emergency call system (D2B)
with CODE (380) Preinstallation for MB phone "CTEL", complete with CODE (381) MB phone
"Standard" in console on right side of dome with CODE (382) MB phone "CTEL" in console on right
side of dome with CODE (383) With telephone "Standard" in console on right side of dome with
integrated TELEAID emergency call system, hands-free system and antenna with CODE (386)
Preinstallation for "portable CTEL" UPCI telephone system with CODE (388) "Portable CTEL" UPCI
telephone system with CODE (852) CTEL preinstallation assembly at dome with CODE (853) MB
standard cellular telephone with CODE (854) MB portable cellular telephone with CODE (855) TELE
AID
number replaces the
former 163 820 06 75
part number.
Part no.DesignationQuantity
163 820 18 75Antenna1
Damage codeCauseRemedy

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
Saturday, October 02, 2010 3:30:07 PMPage 175 © 2006 Mitchell Repair Information Company, LLC.