Sensor MERCEDES-BENZ ML500 1997 Complete Repair Manual

AIR CONDITIONING (TAU) DIAGNOSIS FUNCTION CHECK ACTUAL VALUES - AD83.30-P-3001GH
MODEL 163 with CODE (580) Air conditioning or Tempmatic for USA
5
Recirculated air
mode function switch illuminated
Blower switch on stage 4Blower noise
increases significantly
Cables
Recirculated air
switch
Fresh
air/recirculated air
flap actuator motor
Air conditioning (TAU)
diagnosis previous
knowledge AD83.30-P-2000GH
Connect hand-held tester
(HHT), read out
diagnostic trouble code
memoryModel 163 up to 31.8.01AD00.00-P-2000-03C
Operational check
Test scope Operation /
Requirement Specification Possible cause / Remedy
01
Circuit 30 11-14 VWiring
Battery
02Ignition ON Operating temperature
approx. 80°CWiring
Temperature sensor
Coolant (B11/4)
All-activity module
(N10)
Engine temperature Start engine and warm up
to operating temperature.
03Ignition ON Season-dependent,
approx. 20° CWiring
Temperature sensor
Ambient air (B14)
All-activity module
(N10)
Outside temperature
04Ignition ON ONWiring
F1k21
Blower motor (M2)
All-activity module
(N10)
Blower power supply
relay (F1k21) Blower stage 4FROM
05Ignition ON ONWiring
F1k26
Auxiliary fan (M4) Auxiliary fan relay FROM

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 169 © 2006 Mitchell Repair Information Company, LLC.

AIR CONDITIONING (TEMPMAT IC) TEST OF ELECTRICAL SYSTEM CIRCUIT 15 VOLTAGE SUPPLY - AD83.30-P-6000-
01GH
Fig. 138: Air Conditioning (Tem pmatic) Test Of Electrical System Circuit 15 Voltage Supply
AIR CONDITIONING (TEM PMATIC) TEST OF ELECTRICAL SYST EM CIRCUIT 31 GND - AD83.30-P-6000-02GH
Fig. 139: Air Conditioning (Tempmatic) Test Of Electrical System Circuit 31 GND
AIR CONDITIONING (TEMPM ATIC) TEST OF ELECTRICAL SYSTEM IN-CAR TEMPERA TURE SENSOR - AD83.30-P-
6000-03GH
Fig. 140: Air Conditioning (Tempmat ic) Test Of Electrical System In-Car Temperature Sensor
AIR CONDITIONING (TEMPMATIC) TEST OF ELECTRICAL SYSTEM ANTI-ICING TEM PERATURE SENSOR - AD83.30-
P-6000-04GH
No fault codeNo fault detectedIf there is a complaint in spite of this ?
Air conditioning (TAU) electrical system
testingAD83.30-P-
6000GH
B1232Refrigerant compressor
sensor (B12) AD83.30-P-
6000-09GH
B1419Electromagnetic clutch
(A9k1) Wiring
A9k1

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 171 © 2006 Mitchell Repair Information Company, LLC.

Fig. 141: Air Conditioning (Tempmatic ) Test Of Electrical System Anti-Icing Temperature Sensor
AIR CONDITIONING (TEMPMATIC) TEST OF ELECTRICAL SYSTEM TEMPERATURE SELECTOR CONTROL
VOLTAGE - AD 83.30-P-6000-05GH
Fig. 142: Air Conditioning (Tempmat ic) Test Of Electrical System Temperature Selector Control Voltage
AIR CONDITIONING (TEMPMATIC) TEST OF ELECTRICAL SYSTEM BLENDING AIR FLAP SERVO MOTOR
CONTROL VOLTAGE - AD83.30-P-6000-06GH
Fig. 143: Air Conditioning (Tempmat ic) Test Of Electrical System Blending Air Flap Servo Motor
Control Voltage
AIR CONDITIONING (TEMPMATIC) TEST OF ELECTRICAL SYSTEM BLENDING AIR FLAP SERVO MOTOR GND -
AD83.30-P-6000-07GH

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 172 © 2006 Mitchell Repair Information Company, LLC.

Fig. 144: Air Conditioning (Tempmat ic) Test Of Electrical System Blending Air Flap Servo Motor GND
AIR CONDITIONING (TEMPMATIC) TEST OF ELECTRICAL SYSTEM REFRIGERANT COMPRESSOR ACTUATION -
AD83.30-P-6000-08GH
Fig. 145: Air Conditioning (Tempmat ic) Test Of Electrical System Refrigerant Compressor Actuation
AIR CONDITIONING (TEMPM ATIC) TEST OF ELECTRICAL SYSTEM REFRIGERANT PR ESSURE SENSOR - AD83.30-P-
6000-09GH
Fig. 146: Air Conditioning (Tempm atic) Test Of Electrical System Refrigerant Pressure Sensor
OUTSIDE AIR TEMPERATURE SENSOR, TESTING EL ECTRICAL SYSTEM OF TAC - AD83.30-P-6000-24GH
as of 1.12.99

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 173 © 2006 Mitchell Repair Information Company, LLC.

Fig. 147: Outside Air Temperature Sensor, Testing Electrical System Of TAC
AIR CONDITIONING (TEMPMATIC) ELECTRICAL SYSTEM TESTING - AD83.30-P-6000GH
MODEL 163 with CODE (580) Air conditioning or Tempmatic for USA
Air conditioning component
arrangement GF83.30-P-
0003-01GH
Overview of climate control wiring
diagrams PE83.00-P-
1100E
Connect hand-held tester (HHT), read
out diagnostic trouble code memoryModel 163 up to 31.8.01
Erase fault memory in control module
(N19) using HHT when testing is completeAD00.00-P-
2000-03C
Air conditioning (Tempmatic)
diagnosis previous knowledge AD83.30-P-
2000GH
Air conditioning (Tempmatic)
diagnosis function check The testing of the fresh air/recirculated
air flap actuator motor (M39) is carried out
during the function checkAD83.30-P-
3000GH
Testing
1
Circuit 15 power supply, air
conditioning (Tempmatic) electrical
system testing
AD83.30-P-
6000-01GH
2Circuit 31 ground, air conditioning
(Tempmatic) electrical system testing AD83.30-P-
6000-02GH
3
In-car temperature sensor, air
conditioning (Tempmatic) electrical
system testing
AD83.30-P-
6000-03GH
4
Anti-icing protection temperature
sensor, air conditioning (Tempmatic)
electrical system testing
AD83.30-P-
6000-04GH
5
Temperature selector wheel control
voltage Air conditioning (Tempmatic)
electrical system testing
AD83.30-P-
6000-05GH
6
Blending air flap servo motor control
voltage, air conditioning (Tempmatic)
electrical system testing
AD83.30-P-
6000-06GH
7Blending air flap actuator motor
ground, air conditioning (Tempmatic) AD83.30-P-

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 174 © 2006 Mitchell Repair Information Company, LLC.

TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: CLIMATE CONTROL - AR83.00-Z-9163AA
MODEL 163
electrical system testing6000-07GH
8
Refrigerant compressor actuation, air
conditioning (Tempmatic) electrical
system testing
AD83.30-P-
6000-08GH
9
Refrigerant pressure sensor, air
conditioning (Tempmatic) electrical
system testing
AD83.30-P-
6000-09GH
10
Ambient temperature sensor, air
conditioning (Tempmatic) electrical
system testing
as of 01.12.99AD83.30-P-
6000-24GH
Remove/install center outlet flap
actuator motorMODEL 163...AR83.10-P-
2019GH
Removing and installing rear air
nozzleMODEL 163.113/154 /174 #A as of 289565, 163.113 #X
as of 754620, 163.128 /157 /175AR83.10-P-
4800GH
Remove, install switch unit for
heater/ ventilationMODELS 163.113/136/154/172/174 up to 31.8.01 with
CODE (580) air conditioning or Tempmatic for USAAR83.20-P-
1835GH
Remove and install heat
exchanger from heater housingMODEL 163AR83.20-P-
3400GH
Replace bulbs in push-button
control moduleMODELS 163.113/154/174/136/172 up to 31.8.01AR83.25-P-
1123GH
Remove and install series
resistor for heater blowerMODEL 163.113/128 /136 /154 /157 /172 /174 /175AR83.25-P-
1250GH
Remove/install cover at air
intakeMODEL 163.113/128 /136 /154 /157 /172 /174 /175AR83.25-P-
1405GH
Carry out quick test on air
conditioning systemMODEL 163, 901, 902, 903, 904 ...AR83.30-
D-1209A

Draining, evacuating and
refilling air conditioning,
checking function and checking
for leaks
MODEL 163...AR83.30-P-
1760GH

Remove/install defroster vent
flap actuator motor for
windshieldMODEL 163.113/154 /174 #A as of 289565, 163.113 #X
as of 754620, 163.128 /157 /175AR83.30-P-
2006GH
Remove/install footwell flap
actuator motorMODEL 163...AR83.30-P-
2007GH
Remove/install rear shutoff flap
actuator motorMODEL 163.113/154 /174 #A as of 289565, 163.113 #X
as of 754620, 163.128 /157 /175AR83.30-P-
2008GH

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 175 © 2006 Mitchell Repair Information Company, LLC.

Remove/install fresh
air/recirculated air stepper motorMODEL 163...AR83.30-P-
2010GH

Removing and installing
blending air increment
adjustment motor
MODEL 163...AR83.30-P-
2020GH
Remove and install evaporator
housingMODEL 163...AR83.30-P-
5200GH
Disassembling, assembling A/C
housingMODEL 163 with CODE (580) Air conditioning or, in
USA, Tempmatic A/CAR83.30-P-
5201GH

Correcting oil level in air
conditioning following repair or
slow refrigerant loss
MODEL 163, 202, 208, 210, 215, 220 ...AR83.30-P-
5251E

Correcting oil level in air
conditioning after replacing
parts
MODEL 163, 202, 208, 210, 215, 220 ...AR83.30-P-
5252E

Correcting oil level in air
conditioning after system
suddenly loses all refrigerant
MODEL 163, 202, 208, 210, 215, 220 ...AR83.30-P-
5253E
Remove and install expansion
valveMODEL 163...AR83.30-P-
5520GH
Remove/install evaporatorMODEL 163 with CODE (580) Air conditioning or
Tempmatic for USAAR83.30-P-
5540GH
Remove/install air conditioning
blower motorMODEL 163...AR83.30-P-
5560GH
Remove/install blower motor in
rearMODEL 163.113/154 /174 #A as of 289565, 163.113 #X
as of 754620, 163.128 /157 /175AR83.30-P-
5565GH
Remove/install auxiliary fanMODEL 163.136 /154 /157 /172 with CODE (580) Air
conditioning or Tempmatic for USAAR83.30-P-
5600GH
Remove and install
receiver/drierMODELS 163.113/136 /154 /157 /172 /174 /175 with
CODE (580) Air conditioning or Tempmatic for USAAR83.30-P-
6520GH
Remove and install
receiver/drierMODEL 163.128AR83.30-P-
6520GI
Install/remove condenserMODEL 163...AR83.30-P-
6540GH
Remove, install air conditioning
control moduleMODELS 163.113/136/154/172/174 up to 31.8.01 with
CODE (580) air conditioning or Tempmatic for USAAR83.30-P-
6600GH
Remove and install evaporator
temperature sensorMODEL 163 with CODE (580) Air conditioning or
Tempmatic for USAAR83.30-P-
8085GH
Remove/install outside air
temperature sensorMODEL 163...AR83.30-P-
8086GH
Remove/install air outlet
temperature sensorMODEL 163...AR83.30-P-
8087GH
Remove/install air outlet
temperature sensorMODEL 163...AR83.30-P-
8087GI

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 176 © 2006 Mitchell Repair Information Company, LLC.

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.

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.

Commercially available tools
Workshop equipment
DRAINING, EVACUATING AND REFILLING AIR CONDITIONING, CHECKING FUNCTION AND CHECKING FOR
LEAKS - AR83.30-P-1760GH
MODELS 163.113 /128 /136 /154 /157 /172 /174 /175 with CODE (580) Air conditioning or Tempmatic for
USA
Replace refrigerant compressor RPM sensor
Models 901-904
Not in model 163AR83.55-D-
5320A
7
Set blower rotary
switch to maximum
blower setting

8Check that refrigerant
flows free of bubbles
If the system is filled sufficiently, the refrigerant must flow
through the inspection glass (2) free of bubbles. A newly-
filled system may initially reveal bubbles. In this case, wait
for approx. 10 min. and check inspection glass again.
Does not reveal bubble-free flow ?

Check entire air conditioning circuit for leaks using leak
detector (3).AR83.30-D-
1209-01A
Air conditioning system leak detector*WE58.40-Z-
1002-20A
9Determine air outlet
temperature

Switch blower rotary switch to stage "1".
Insert sensor of temperature measurement device (1) into the
air outlet of the center nozzles.
After running for a period of 5 min., the air outlet temperature
must not be less than 2°C and more than 12°C. After 5 min., at
the latest, the refrigerant compressor must also be connected
and disconnected.
If the refrigerant compressor is disconnected at below 2°C ?
Check evaporator temperature switch. If the air outlet
temperature is not achieved ?
Check the connection and disconnection of the refrigerant
compressor or the refrigerant pressure upstream and
downstream of the refrigerant compressor.
*WH58.30-Z-
1005-08A
10
Switch air conditioning
off and shut vehicle
engine off

NumberDesignation
WH58.30-Z-1005-08ATemperature measuring device
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 187 © 2006 Mitchell Repair Information Company, LLC.