instrument panel MERCEDES-BENZ ML500 1997 Complete Repair Manual

Fig. 403: Identifying Connector, Connection Line & Interface
5. Apply special glue to rear of microphone (arrow) and glue hands-free system microphone (B25) included
in installation kit to headliner.
Align microphone so that pickup opening points towards driver.
Fig. 404: Locating Rear Of Microphone & Hands
-Free System Microphone (B25)
6. Glue microphone lead behind headliner as shown in figure and along right A-pillar below instrument
panel to radio shaft.
7. Connect all control and operation modules and connect battery for checking proper function of telephone.
Avoid error messa
ges from unconnected control modules.

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
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2001-04 STARTING & CHARGING SYSTEMS
Generators & Regulators - 163 Chassis
IDENTIFICATION
CHASSIS & ENGINE IDENTIFICATION
DESCRIPTION
Bosch generators are available in various amp ratings depending on engine application. Voltage regulators are
transistorized and internal to generator. See GENERATOR APPLICATION
table.
GENERATOR APPLICATION
ADJUSTMENTS
DRIVE BELT ROUTING
For drive belt routing, see Fig. 1 . WARNING:Vehicles are equipped with air bag supplemental restraint system. Before
attempting any repairs involving steering column, instrument panel or
related components, see SERVICE PRECAUTIONS (or AIR BAG SAFETY
PRECAUTIONS) and DISABLING & ACTIVATING AIR BAG SYSTEM in
appropriate AIR BAG RESTRAINT SYSTEMS article.
NOTE: When the battery is disconnected, vehicle computer and memory system may
lose data. Driveability problems may exist until computer systems have
completed a relearn cycle.
Model (Year)ChassisEngine
ML55 AMG (2001-03)163.174113.981
ML320 (2001-02)163.154112.942
ML350 (2003-04)163.157112.970
ML430 (2001)163.172113.942
ML500 (2002-04)163.175113.965
ApplicationAmp Rating
V6115
V8150
NOTE: Vehicles have automatic belt tensioners. No adjustment is necessary.

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

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Generators & Regulators - 163 Chassis
me
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Saturday, October 02, 2010 3:20:35 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.

3. Normalize side power windows. See NORMALIZING POWER WINDOWS .
4. Start engine and run at idle. Turn steering wheel from one lock position to the other to activate steering
angle sensor. Center steering wheel. Message "EI. STAB. PROGRAM GO TO GARAGE" should erase
from multifunction display panel.
5. If equipped, normalize tilting/sliding roof. See NORMALIZING TILTING/SLIDING ROOF
.
6. If equipped, normalize memory power seats, steering column and outside mirror if components are
installed. See NORMALIZING MEMORY POWER SEATS, STEERING COLUMN & OUTSIDE
MIRROR .
Normalizing Power Windows
1. Completely close each window with manual switch. Hold switch in closed position for .3 second.
2. Repeat procedure for each power window.
Normalizing Memory Power Seats, Steering Column & Outside Mirror
1. Using manual switch, move seat to each end position and hold for .3 second. Repeat procedure for each
switch except rear stop of backrest.
2. Repeat procedure for end positions of steering wheel and outside mirrors.
Normalizing Tilting/Sliding Roof
Open roof with SR switch until mechanical stop is reached. Continue to press switch for .5 seconds.
Setting Time
1. Use bottom left button on steering wheel to scroll through menus on instrument cluster to "Settings"
menu.
2. Move selection marker with + or - button to "Time" submenu.
3. Press up or down arrows to "Clock, hours" setting. Confirm selection marker is on the hour setting.
4. Press + or - to set hour. Press reset knob in instrument cluster to confirm.
5. Move selection marker with + or - button to "Time" submenu.
6. Press up or down arrows to "Clock, minutes" setting. Confirm selection marker is on the minutes setting.
7. Press + or - to set minute. Press reset knob in instrument cluster to confirm.
TESTING
If generator malfunctions, check for Diagnostic Trouble Codes (DTCs) in Motor Electronics Sequential Fuel
Injection (ME-SFI) system. See appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE. If
cause of generator malfunction is not engine performance related, replace generator.
RETRIEVING & ERASING DIAGNOSTIC TROUBLE CODES
NOTE: Before replacing any component that scan tool suggests are faulty, ensure that
all wiring connections and harness connectors are okay. Ensure that power and

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Generators & Regulators - 163 Chassis
me
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AR54.21-P-1200GH
Remove/install Extended-Activity-Module (EAM)
11.7.00

MODEL
163.136 /154 /172 #A as of 145273,

163.136 /154 /172 #X as of 708319,

163.113 /128 /157 /174 /175

P54.21-2098-06

1
Lock

2
Extended-Activity-Module (EAM)


Remove/install

1.1
Read out coding of Extended-Activity-Module

(EAM)

Only

when replacing the EAM and if it can

still be read out using STAR DIAGNOSIS.

2
Remove cover under the instrument panel (left)

AR68.10-P-1500GH

3
Loosen the lock (1) which secures the EAM in

the bracket

4
Remove the Extended-Activity-Module (EAM)

(2) downwards out of the bracket

5
Disconnect connectors

6
Remove drive authorization module

AR54.21-P-1300GH

7
Install in the reverse order

8.1
Code the EAM

Only

when installing a new EAM.

AR54.21-P-1200-01GH

9
Turn ignition key into position 1 and wait for

40 seconds before first starting the engine.

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After a level has dropped below a warning threshold, the remaining distance or the remaining time is displayed
in text panel (b) and the tool symbol (a) appears in the display (top ill.). In addition, ASSYST features a low
engine oil level display. If the oil level is too low or too high, this appears in text panel (b) and the oil can
symbol (a) is displayed (bottom ill.).
( The illustrations relate to models with multifunction display. For other models, refer to document:
"ASSYST display facilities".)
Service A/B display
All models will feature an automatic display of the service (A or B) by no later than modification year 00/1.
More detailed information is contained in the document displaying service.
Fig. 320: Identifying Service A/B Display

In view of the complexity of the system, ASSYST features its own processor in the instrument cluster.
ASSYST is supplied with the time information from the electronic clock integrated in the instrument cluster.
The other data required are supplied over the CAN dataline by the traction systems control module (N47) and
by the injection system control module (N3).
CAN data required for ASSYST:
wheel speed signals for calculating the vehicle speed and distance (from traction systems control module,
N47)
Coolant temperature (from injection system control module, N3)
Engine oil temperature (from injection system control module, N3)
Oil level (from injection system control module, N3)
Engine speed (from injection system control module, N3)
Load torque (from injection system control module, N3)
Oil correction factor (from injection system control module, N3)
Active service system (ASSYST) GF00.20-P-0003-03A

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
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AR68.10-P-1400GI
Remove/install glove compartment
22.4.99

MODEL
163.136 /154 /172 #A as of 145273,

163.136 /154 /172 #X as of 708319,

163.113 /128 /157 /174 /175

P68.10-2330-06

1
Glove compartment lid

2
Screws

3
Glove compartment

4
Instrument panel

5
Spreading rivets

E13/1
Glove compartment lamp


Remove/Install

1
Open glove compartment lid (1)

2
Unclip glove compartment lamp (E13/1) and

disconnect connector

3
Unscrew bolt (2)

Torx bit set

*000589011000

4
Remove upper spreading rivets (5) from glove

compartment (3)

Press pressure pin approx. 4 mm upward

and remove spreading rivet downward.

5
Pull glove compartment (3) out of instrument

panel (4)

6
Install in the reverse order

Align upper edge of glove compartment lid
(1) in relation to instrument panel (4).

Torx bit set

000 589 01 10 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 1

AR68.10-P-1300GH
Adjust glove compartment lid
4.2.97

MODEL
163.136 /154 /172 #A up to 145272

P68.10-0517-06

1
Glove compartment lid

2
Instrument panel

3
Screws

4
Striker eye

5
Hinge screw

6
Hinge

Arrows
Air gap and adjustment possibilities

on hinge

Adjusting


During entire operation pay attention to

uniform transition, gap and adjustment

possibilities on hinge (arrows) between glove

compartment lid (1) and instrument panel (2).

1
Loosen screws (3) on striker eye (4)


Installation:
Adjust transition at top of

striker eye (4).Glove compartment lid (1)

should make slight contact to stop buffers.

2
Remove glove compartment

AR68.10-P-1400GH

3
Adjust gap

For this purpose loosen hinge screw (5)

from hinge (6).

4
Install glove compartment

AR68.10-P-1400GH

5
Check for easy motion and proper function

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR68.10-P-1300GH
Adjust glove compartment lid
4.2.97

MODEL
163.136 /154 /172 #A up to 145272

P68.10-0517-06

1
Glove compartment lid

2
Instrument panel

3
Screws

4
Striker eye

5
Hinge screw

6
Hinge

Arrows
Air gap and adjustment possibilities

on hinge

Adjusting


During entire operation pay attention to

uniform transition, gap and adjustment

possibilities on hinge (arrows) between glove

compartment lid (1) and instrument panel (2).

1
Loosen screws (3) on striker eye (4)


Installation:
Adjust transition at top of

striker eye (4).Glove compartment lid (1)

should make slight contact to stop buffers.

2
Remove glove compartment

AR68.10-P-1400GH

3
Adjust gap

For this purpose loosen hinge screw (5)

from hinge (6).

4
Install glove compartment

AR68.10-P-1400GH

5
Check for easy motion and proper function

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR88.40-P-3100GH
Remove/install control cable for engine hood
5.5.00

MODEL
163.113 /128 /136 /154 /157 /172 /174 /175

P88.40-2140-06

Illustrated up to VIN A145272, X708318

1
Clips

2
Rubber grommet

3
Engine hood control cable


Removing and installing

1
Open engine hood and raise to vertical position
Up to VIN A145272, X708318.

AR88.40-P-1000GH

As of VIN A145273, X708319.

AR88.40-P-1000GI

2.1
Remove upper frame cross member
Only up to VIN A145272, X708318

AR62.30-P-2300GH
2.2Remove engine hood lock
Only as of VIN A145273, X708319.

AR88.40-P-3200GI

3.1
Unhook engine hood control cable from clip at

bottom of radiator cross member
Only as of VIN A145273, X708319.

4
Remove cover from fuse and relay box

5 screws.

5
Unhook clips (1) from body

6
Remove left cover below instrument panel
Left hand drive vehicle.

AR68.10-P-1500GH

Vehicles with right-hand steering up to

VIN A145272, X708318.

AR68.10-P-1520GH

Vehicles with right-hand steering as of

VIN A145273, X708319.

AR68.10-P-1520GI

7
Remove paneling in left footwell

AR68.30-P-4010GH

8
Unhook engine hood control cable at side at

clip in footwell

9
Remove rubber grommet (2) from fuse and

relay box

10
Pull out engine hood control cable (3) through
firewall on engine side and remove


Installation:
Ensure that engine hood

control cable is routed cleanly along fuse and

relay box.

11
Install in the reverse order

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Page 1

Danger!

Risk of explosion
from explosive gas.
Risk

of poisoning and caustic burns from

swallowing battery electrolyte.
Risk of injury


through burns to skin and eyes from battery

acid or when handling damaged lead-acid

batteries
No fire, sparks, naked flames or smoking.

Wear protective gloves, acid-resistant

clothing and safety glasses. Pour battery

electrolyte only into suitable and appropriately

marked containers.

AS54.10-Z-0001-01A

4
Remove battery

AR54.10-P-0005GH

5
Press out template (6) and adapt the size to

the correct dimensions (a, b)Determine ACTUAL dimension (a) from the

drawing.

Divide the SPECIFIED dimension (a) by the

determined ACTUAL dimension (a) and copy

the template to the original size with the

corresponding factor.

Check dimensions for both axles.

6
Cut out template

7
Cut out holes (7, 8) for engine hood hinge

studs

8
Position template in the engine hood hinge

support using the stud holes

The template is drawn for the left side.

Turn over to obtain the right side.

9
Center the engine hood hinge support on the

template using the markings (9, 10, 11)

10
Remove template

11
Drill a hole at each center punch mark (3, 4, 5)

Only drill through the 2 upper panels. Do

not drill through the reinforcement panel (3rd

panel).


*201589005100

12
Cover windshield, paint surface and adjacent

components adequately in order to avoid

damage due to welding work

Cover apertures in the body in order to

prevent flying sparks: the foam in the

instrument panel burns easily.

c

General information on repairs to body

AH60.00-N-0001-01A


Danger!

The high voltage used for arc welding

presents a lethal hazard
.
Explosion hazard


when welding in area of materials easily

inflammable.
Injury hazard
from welding

spatter and UV-light while welding.
Risk of

poisoning
when inhaling welding vapors.
Use insulating mats. Wear protective clothing,

safety glasses, and protective mask.

Remove

highly inflammable materials from the danger

zone. Use air extractor.

AS00.00-Z-0007-01A

13
Plug weld each hole

*WE58.40-Z-1005-02A

14
Plug welds should be flat and ground smooth

15
Remove covers and clean the repair area

16
Prime untreated points in the area of the

engine hood hinge support

17
Prime the underside of the reinforcement

panel of the engine hood hinge

Access to underside of engine hood hinge

support through the recess for the wiper motor.

18
Spray the underside of the reinforcement

panel of the engine hood hinge support with

wax preservative

Access to underside of engine hood hinge

support through the recess for the wiper motor.

19
Install in the reverse order

Weld spot miller

201 589 00 51 00

Workshop equipment/MB testers
(see Workshop Equipment Manual)

WE58.40-Z-1005-02A
MIG inert gas welding equipment, aluminum weldable, sold by company Wieländer & Schill

Repair products

Number

Designation
Order number

BR00.45-Z-1004-01A
MB body sealant for sealing seams (suitable for painting)
001 989 63 20

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