instrument panel MERCEDES-BENZ ML500 1997 Complete Repair Manual

3
Remove engine hood hinge on the front

passenger side

AR88.40-P-3060GH

*BR00.45-Z-1004-01A


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
Remove air conditioning blower motor

AR83.30-P-5560GH

6
Print 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.

7
Cut out template

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

studs

9
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.

10
Center the engine hood hinge support on the

template using the markings (9, 10, 11)

11
Remove template

12
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

13
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

14
Plug weld each hole

*WE58.40-Z-1005-02A

15
Plug welds should be flat and ground smooth

16
Remove covers and clean the repair area

17
Prime untreated points in the area of the

engine hood hinge support

18
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.

19
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.

20
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

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

Mode control knob controls air distribution throughout the passenger compartment. Air distribution doors are
controlled by cables activated by the mode control knob. See Fig. 1
. Four mode positions are available with
detents in-between to adjust airflow for personal comfort.
Defrost
Set mode control knob to 12-o'clock position. Air will exit from defrost outlets and side window vents.
Vent
Set mode control knob to 9-o'clock position. Air will exit from instrument panel outlets.
Floor
Set mode control knob to 6-o'clock position. Air will exit from floor outlets.
Blend/Bi-Level
Set mode control knob to 3-o'clock position. Air will exit from defrost, instrument panel, and floor outlets.
TEMPERATURE CONTROL KNOB
Air temperature is controlled by a variable resistor rotary control switch. See Fig. 1 . Switch receives voltage
signal and depending upon position, controls voltage signal sent to air mix damper door motor. See Fig. 2
.
Volta
ge controls position of motor for heating and cooling.

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2000-01 MANUAL A/C-HEATER SYSTEMS ML 320, ML 430 & ML 55
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Fig. 2: Locating Climate Control Components
Courtesy of MERCEDES-BENZ OF NORTH AMERICA
FRESH/RECIRCULATION SWITCH
Fresh/recirculation switch controls voltage signal to fresh air recirculation door motor. See Fig. 1 and Fig. 2 .
With switch indicator light on, air will recirculate. With switch indicator light off, air will enter from outside of
vehicle.
A/C CONTROL MODULE
The A/C control module (A/C amplifier) is the control unit for the A/C system. See Fig. 2 . The module
receives inputs from various sensors and processes the information to control various outputs for the A/C
system for optimal control.
The A/C control module inputs are as follows:
A/C Switch
In-Vehicle Air Temperature Sensor
Temperature Selector Knob
Blower Motor Knob
Evaporator Temperature Sensor
Air Mix Damper Door Position Sensor
The A/C control module output functions are as follows:
Air Mix Damper Door Motor
All Activity Module
Fresh/Recirculation Door Motor
ALL ACTIVITY MODULE
All Activity Module (AAM) receives inputs to determine if specified conditions have been met to allow
operation of A/C-heater system. If conditions are met, the AAM will send signals to the A/C compressor,
condenser fans relay and the blower motor relay to command or enable operation.
IN-VEHICLE TEMPERATURE SENSOR
The in-vehicle temperature sensor is a negative temperature coefficient resistor. Sensor sends signals to the A/C
control module to maintain in-vehicle temperature. Sensor is located on the center panel of the instrument
cluster.
DUST FILTER
A dust filter provides filtering of air entering or recirculating in the passenger's compartment. The dust filter is
mounted between blower motor and evaporator, below passen
ger's side of instrument panel, to left of blower

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2000-01 MANUAL A/C-HEATER SYSTEMS ML 320, ML 430 & ML 55
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A/C EVAPORATOR HOUSING UNIT
Removal & Installation
1. Drain engine coolant. Remove coolant expansion reservoir nuts, disconnect hoses and remove reservoir.
Discharge A/C system, using approved refrigerant recovery/recycling equipment.
2. Remove expansion valve self-locking nut and discard. See Fig. 5
. Disconnect refrigerant lines from
expansion valve. Plug exposed refrigerant lines to protect A/C system from moisture and debris.
3. Remove instrument panel. See INSTRUMENT PANEL
. Remove Electronic Transmission Control
(ETC) module. See Fig. 4
. Disconnect air mix flap actuator connector.
4. Disconnect recirculated air flap element. Disconnect evaporator temperature sensor. Disconnect blower
motor resistor and blower motor connectors. Remove A/C push button control module. Release wiring
harness.
5. Remove insulating mat. See Fig. 5
. Disconnect water drain hose from bottom of A/C housing. Release
A/C housing-to-air distributor clips and remove A/C housing upward. To install, reverse removal
procedure. Recode radio. See RECODING RADIO
under PROGRAMMING. WARNING:To avoid injury from accidental air bag deployment, read and carefully
follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR
BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY article in
GENERAL SERVICING.
CAUTION: Before disconnecting battery, obtain 5-digit radio security code from
vehicle owner. Radio will be disabled until properly recoded.

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2000-01 MANUAL A/C-HEATER SYSTEMS ML 320, ML 430 & ML 55
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Fig. 4: Removing Evaporator Housing Unit
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
A/C MIX FLAP ACTUATOR
Removal & Installation
Remove instrument panel. See INSTRUMENT PANEL . Disconnect air mix flap actuator connector. Remove
3 screws and remove air mix flap actuator. To install reverse removal procedure.
A/C PUSH BUTTON CONTROL MODULE
Removal & Installation
Disconnect negative battery cable. Remove A/C push button control panel. See A/C PUSH BUTTON
CONTROL PANEL . Remove 4 A/C push button control module screws and remove control module from

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2000-01 MANUAL A/C-HEATER SYSTEMS ML 320, ML 430 & ML 55
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A/C housing. Disconnect control module connector. To install reverse removal procedure. Recode 5-digit radio
security code. Using HHT, check for DTC and erase, and set clock.
A/C PUSH BUTTON CONTROL PANEL
Removal & Installation
1. Obtain 5-digit radio security code from vehicle owner. Disconnect negative battery cable. Using radio
removal plates, remove radio. Disconnect electrical connectors.
2. Remove instrument panel center section. Remove 4 A/C control panel screws and remove control panel.
Release pull cables and disconnect connectors. To install, reverse removal procedure. Recode radio. See
RECODING RADIO
under PROGRAMMING.
BLOWER MOTOR
Removal & Installation
Remove passenger-side instrument panel under cover. Remove blower motor mounting screws from A/C
housing unit. Disconnect blower motor connector and remove blower motor. To install, reverse removal
procedure.
COMPRESSOR
Removal & Installation
1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove accessory
drive belt. Disconnect low pressure refrigerant line from compressor. Discard "O" rings. Plug exposed
openings to protect A/C system from debris and moisture.
2. Disconnect high pressure refrigerant line from compressor. Discard "O" rings. Plug exposed openings to
protect A/C system from debris and moisture. Disconnect electrical connector. Remove compressor
mounting bolts.
3. Raise and support vehicle. Remove compressor from under vehicle without spilling refrigerant oil. To
install, reverse removal procedure. Ensure refrigerant oil quantity in compressor is correct. See
COMPRESSOR REFRIGERANT OIL CHECKING under GENERAL SERVICING. Tighten bolts to
specification. See TORQUE SPECIFICATIONS
.
CONDENSER
Removal & Installation
1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove cooling fans.
See COOLING FANS
. Disconnect refrigerant line from receiver-drier. See Fig. 5 . Discard "O" rings.
2. Plug exposed openings to protect A/C system from debris and moisture. Remove refrigerant line from
condenser. Remove radiator upper rubber seal. See Fig. 6
. Remove condenser upper mounting screws.
Lift condenser upward and remove. NOTE: Each time A/C compressor is removed and installed, receiver-drier must be
replaced.

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2000-01 MANUAL A/C-HEATER SYSTEMS ML 320, ML 430 & ML 55
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Fig. 6: Removing Cooling Fans & Condenser
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
COOLING FANS
Removal & Installation
Remove headlight units. Remove upper frame crossmember, release hood release control cable and remove
crossmember. See Fig. 6
. Remove 2 cooling fans frame bolts on radiator. Disconnect cooling fan connector.
Release outside temperature sensor wiring harness. Pull up on cooling fan and remove. To install, reverse
removal procedure. Ensure cooling fan bottom guides are properly seated in lower mounts.
EVAPORATOR
Removal & Installation
Remove A/C housing unit. See A/C HOUSING UNIT . Remove expansion valve. See Fig. 5 . Discard "O"
rings. Disassemble A/C housing unit. Remove evaporator. Remove evaporator temperature sensor. To install,
reverse removal procedure. Use NEW "O" rings lubricated with refrigerant oil. If installing a new or repair
evaporator, add 1.35 ounces of NEW refrigerant oil to evaporator.
EXPANSION VALVE
Removal & Installation
1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Without disconnecting
coolant hoses, remove coolant expansion reservoir and set aside. Remove refrigerant line bracket and
loosen clamps. See Fig. 5
. Pull refrigerant lines out of expansion valve.
2. Remove expansion valve self-locking nut and discard. Remove expansion valve. Discard "O" rings. To
install, reverse removal procedure. Use NEW "O" rings lubricated with refrigerant oil. Tighten NEW self-
locking nut to specification. See TORQUE SPECIFICATIONS
.
INSTRUMENT PANEL & INSTRUMENT PANEL CARRIER
Removal & Installation
1. Secure vehicle against rolling. Set transmission selector to "D" position. Obtain radio security code.
Disconnect negative battery cable. Remove driver-side air bag.
2. Place match marks on steering wheel and steering shaft. Remove steering wheel, upper steering column
covers and combination switch. Remove instrument cluster cover frame. Remove one instrument panel
lower section bolt.
3. Remove screws in footwell from left side of instrument panel bottom section. Remove instrument panel
center section. Remove 4 A/C control panel screws and remove control panel. See Fig. 1
. Release pull
cables and disconnect connectors.
4. Remove screws from center section. Remove glove box. Remove screws in footwell from right side of
instrument panel bottom section. Remove entry courtesy lights. Remove end covers and screws.
5. Release 4 "A" clips between instrument panel bottom section and upper section. See Fig. 7
. Release
parkin
g brake release cable from handle. With assistance, remove instrument panel bottom section.

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2000-01 MANUAL A/C-HEATER SYSTEMS ML 320, ML 430 & ML 55
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6. Remove A-pillar panel trim. Remove instrument cluster. Remove defroster vent cover. Remove air vents
and side air nozzles. With assistance, remove upper instrument panel.
7. Remove passenger-side air bag. Remove right side lower instrument panel cover. Remove instrument
panel carrier screws from A/C housing unit. Remove left side lower instrument panel cover.
8. Remove insulating mat between steering column and instrument panel carrier. Remove steering column
bolts and nuts from instrument panel carrier. See Fig. 8
. Remove instrument panel carrier center tunnel
bolts. Disconnect steering column connectors.
9. Remove wiring harness from instrument panel carrier. Remove wiper washer system. Remove instrument
panel carrier nuts from engine compartment side of firewall.
10. Remove A-pillar bolt covers and remove instrument panel carrier A-pillar bolts. With assistance, remove
instrument panel carrier through passenger door. To install, reverse removal procedure.
11. Ensure instrument panel bottom section guide tongues "B" are seated into instrument panel upper section
mounts. See Fig. 8
. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS .
Recode radio. See RECODING RADIO
under PROGRAMMING.
Fig. 7: Removing Instrument Panel Bottom Section

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

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2000-01 MANUAL A/C-HEATER SYSTEMS ML 320, ML 430 & ML 55
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Fig. 8: Removing Instrument Panel Upper Section & Instrument Panel Carrier
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
INTAKE AIR DUST FILTER
Removal & Installation
Remove passenger-side instrument panel lower trim panel. Release retaining clip and remove dust filter cover.
Pull dust filter down and out. See Fig. 9
. To install, reverse removal procedure.

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Fig. 3: Identifying Air Inlet
AIR DUCT LOCATIONS - GF83.10-P-2101-01GH
The lateral nozzle and side window defroster nozzle (3) air ducts are on the left and right below the instrument
panel.
The windshield defroster nozzle air duct (2) is on top of the heater/evaporator housing (front center) below the
instrument panel.
The center nozzle air duct (1) is on top of the heater box/evaporator housing behind the center nozzle.
The front footwell air duct (4) is integrated in the heater/evaporator housing.
The rear footwell air duct (5) is below the center console.

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1998-2005 HVAC Climate Control - 163 Chassis
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