MERCEDES-BENZ ML430 1997 Complete Repair Manual

Remove/install air outlet
temperature sensorMODEL 163...AR83.30-P-
8087GJ

Remove, install in-car
temperature sensor for aspirator
blower (M9)MODELS 163.113/136/154/172/174 as of 1.9.99 up to
31.8.01AR83.30-P-
8100GH

Remove/install switch
unit/automatic air conditioning
control moduleMODEL 163.113/154 /174 #A as of 289565, 163.113 #X
as of 754620, 163.128 /157 /175AR83.40-P-
6500GH
Remove and install sun sensorMODEL 163...AR83.40-P-
6720GH
Remove/install summer/winter
operation switchMODEL 163, 168, 170, 202, 208 ...AR83.70-P-
0001A
Removing, installing stationary
heater antennaMODEL 163.### 1# Retrofitted stationary heater with
Telestart T60AR83.70-P-
0002B
Remove/install stationary heater
antennaMODEL 163.### 1# Retrofitted stationary heater with
Telestart T70AR83.70-P-
0002BA
Remove/install Telestart
receiverMODEL 163, 168, 170, 202, 208, 210 ...AR83.70-P-
0003BA
Removing and installing
telestart receiverMODEL 163.### 1# Retrofitted telestart T60AR83.70-P-
0003H
Checking Telestart remote
controlMODEL 163, 168, 170, 202, 208, 210 Telestart T60AR83.70-P-
0005A
Check Telestart transmitterMODEL 163, 168, 170, 202, 203, 208, 209,
210,211,220,463...AR83.70-P-
0005IA
Check emission level, adjust if
necessaryMODEL 163, 168, 170, 202, 208, 210 ...AR83.70-P-
1177H
Remove/install heater unitMODELS 163.136/154/157/172/174/175 1# Retrofitted
Thermo Top C stationary heaterAR83.70-P-
5302I
Remove/install heaterMODEL 163.113 1# Retrofitted Thermo Top C stationary
heaterAR83.70-P-
5302IA
Remove/install heaterMODEL 163.128 Retrofitted Thermo Top C stationary
heaterAR83.70-P-
5302IB
Remove/install combustion air
blower unitMODEL 163, 168, 170, 202, 208, 210 ...AR83.70-P-
5555G
Removing and installing fuel
metering pumpMODEL 163.### 1# up to 31.12.99 Retrofitted Thermo
Top C stationary heaterAR83.70-P-
5652G
Remove/install coolant
circulation pumpMODEL 163.### (except 163.128) 1# Retrofitted
Thermo Top C stationary heaterAR83.70-P-
5700E
Remove/install burner insertMODEL 163, 168, 170, 202, 208, 210 ...AR83.70-P-
5772G
Remove/install burner insert
with glow pinMODEL 129, 163, 168, 170, 202, 203, 209, 210, 211,
215, 219, 220, 230, 240 ...AR83.70-P-
5773A
Remove/install timerMODEL 163, 168, 170, 202, 208 ...AR83.70-P-
5892D

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 177 © 2006 Mitchell Repair Information Company, LLC.

REMOVE/INSTALL CENTER OUTLET FLAP ACTUATOR MOTOR - AR83.10-P-2019GH
MODEL 163.113 #A as of 289565, 163.113 #X as of 754620, 163.154 /174 #A as of 289565, 163.128/157/175
Fig. 148: Identifying Center Outlet Flap Actuator Motor Components

REMOVING AND INSTALLING REAR AIR NOZZLE - AR83.10-P-4800GH
MODEL 163.113 /154 /174 #A as of 289565, 163.113 #X as of 754620, 163.128/157/175
Remove/install control
module/heat exchanger unitMODEL 163, 168, 170, 202, 208, 210 ...AR83.70-P-
5935G

Remove/install
1.1Remove instrument cluster Left-hand drive vehicle only.AR54.30-P-
6015GH
1.2Remove glove compartment Right-hand drive vehicle only.AR68.10-P-
1400GI
2Unscrew screws (1)
3Remove center outlet flap actuator
motor (M2/22) from air duct Installation: Adjust zero position of
actuator motor with STAR DIAGNOSIS.
4Disconnect connector
5Install in the reverse order

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 178 © 2006 Mitchell Repair Information Company, LLC.

Fig. 149: Identifying Rear Air Nozzle Components
REMOVE, INSTALL SWITCH UNIT FOR HEATER/VENTILATION - AR83.20-P-1835GH
MODELS 163.113/136/154/172/174 up to 31.8.01 with CODE (580) air conditioning or Tempmatic for
USA
Remove/install
1Remove rear center console (1) AR68.20-P-2020GI
2Loosen retaining clamps (2) on the sides of the air nozzle (3)
3Remove air nozzle (3) from the rear center console
4Install in the reverse order

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 179 © 2006 Mitchell Repair Information Company, LLC.

Fig. 150: Identifying Switch Unit For Heater/Ventilation Components
REMOVE AND INSTALL HEAT EXCHANGER FROM HEATER HOUSING - AR83.20-P-3400GH
MODEL 163

Remove/install
1Remove radio AR82.60-P-
7502EA
2Remove center part of instrument panel (1) AR68.10-P-
1030GH
3Unscrew bolts at heater/AC controls (4) and
remove controls
4Detach cable (2, 3) Unclip cables at
heater/AC controls.
5Disconnect connector (X72/3) at heater/AC
controls (4)
6Install in the reverse order

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 180 © 2006 Mitchell Repair Information Company, LLC.

Fig. 151: Identifying Heat Exchanger Components
REPLACE BULBS IN PUSH-BUTTON CONTROL MODULE - AR83.25-P-1123GH
MODELS 163.113/154/174/136/172 up to 31.8.01

Remove/Install
1Remove AC housing AR83.30-P-
5200GH
2Remove bolt (1) from the covering on the
air duct (2)The bolt lies under the air
duct seal.
3Remove lever for blend air flap (3)
4Unscrew bolt (4) at bracket (5).
5Remove heat exchanger (6) upward
6Install in the reverse order
7Inspect cooling system for leaks AR20.00-P-
1010HA

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 181 © 2006 Mitchell Repair Information Company, LLC.

Fig. 152: Identifying Push-button Control Module Components
Commercially available tools
REMOVE AND INSTALL SERIES RESISTOR FOR HEATER BLOWER - AR83.25-P-1250GH
MODEL 163.113 /128 /136 /154 /157 /172 /174 /175
Shown on model 163 up to VIN A289564, X754619

Removal, installation
1Detach rotary knob (3) at push-
button control module (1) Installation: Rotary knob can only be
pushed on the shaft in one position.
2Remove bulb (2) *WH58.30-Z-
1040-02A
3Install in the reverse order
NumberDesignation
WH58.30-Z-1040-02ATweezers, straight 160 mm with rounded tips

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 182 © 2006 Mitchell Repair Information Company, LLC.

Fig. 153: Identifying Series Resistor For Heater Blower Components (Shown On Model 163 Up To VIN
A289564, X754619)
REMOVE/INSTALL COVER AT AIR INTAKE - AR83.25-P-1405GH
MODEL 163.113 /128 /136 /154 /157 /172 /174 /175

Remove/install
1Remove cover below instrument panel (2) (on right)Up to VIN A145272,
X708318.AR68.10-P-
1520GH
As of VINA145273,
X708319.AR68.10-P-
1520GI
2Disconnect connector (4) on blower motor series
resistor group (R14)
3Unscrew screws (3) from blower motor series
resistor group (R14) on heater housing (1)
4Remove blower motor series resistor group (R14)
5Install in the reverse order

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 183 © 2006 Mitchell Repair Information Company, LLC.

Fig. 154: Identifying Components For Cover At Air Intake - Model
163.113 /128 /136 /154 /157 /172 /174 /175
CHECKING AIR CONDITIONING SYSTEM FOR LEAKAGE - AR83.30-D-1209-01A
Workshop equipment

Remove/install

Injury hazard by trapping or crushing, in
extreme cases with loss of limbs when
reaching into windshield wiper mechanismAlways remove ignition key when
working on windshield wiper
mechanism.AS82.30-Z-
0001-01A
1Remove wiper arms (1) AR82.30-P-
6100GH
2Detach rubber seal (2) from firewall
3Remove metal clips (5)
4Unscrew nuts (4) at firewall Remove foam insert.
5Seal off washer fluid hose at check valve
6Remove cover (3) together with water
deflector panel (6)
If damaged, detach water
deflector panel (6) from cover (3).
Installation: Lubricate upper
edge of cover and windshield at
bottom with soapy water.

7Install in the reverse order

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 184 © 2006 Mitchell Repair Information Company, LLC.

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

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 185 © 2006 Mitchell Repair Information Company, LLC.

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 ?


2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 186 © 2006 Mitchell Repair Information Company, LLC.