1997 MERCEDES-BENZ ML350 headlamp

SURVEY OF SYSTEM COMPONENTS FOR HEADLAMP CLEANING SYSTEM (HCS),
LOCATION/TASK/DESIGN/FUNCTION - GF82.15-P-9998GHZ
MODEL 163 as of 01.9.01 with CODE (600a) headlamp cleaning system
INTERIOR LIGHTING (IL), LOCATION OF COMPONENTS - GF82.20-P-0002-01GH
Location of components
Fig. 15: Identifying Interior Lighting (IL) Components Location
headlamp cleaning
system, taskglass
Function of headlamp
cleaning system
telescopic nozzles GF82.15-P-2100-04GH
Headlamp cleaning system (HCS),
location of components GF82.15-P-0002-
03GH
Telescopic nozzle for headlamp
cleaning system,
location/task/design/function GF82.15-P-2100GH
Table of contents, function description
for headlamp cleaning system (HCS) GF82.15-P-
0998GHZ

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
Saturday, October 02, 2010 3:30:04 PMPage 30 © 2006 Mitchell Repair Information Company, LLC.

Navigation system - additional unit with CODE (818b) Single CD player - additional unit with CODE
(491) U.S. version
It is necessary to distinguish between audio and service sources on the radio and navigation module (A2/56) :
Audio sources are:
Radio
CD player
CC player
CD changer (code 819a)
Service sources include:
Voice output on navigation
telephone
Signal editing required for volume and tone settings is accomplished by the audio component integrated into
the radio and navigation module (A2/56)
If the vehicle is additionally equipped with a sound system (code 810), the sound amplifier (A2/13) ensures
final audio signal amplification.
Volume setting
By turning the volume knob the volume of the corresponding mode changes.
Tone setting
The tone settings as well as the general brightness adjustment of the display can be reached by pressing
the multifunction key" ADJ ". If the multifunction key" ADJ " is pressed for longer than 2 s all tone
settings of all modes jump back to the center position. This is confirmed by a short peep tone. The
adjustment possibilities for treble/bass, balance and fader are summarized in one display.
They can be selected by actuating the multifunction keys " " and " ". The corresponding setting can be
changed by actuating the multifunction keys"- " and "+ " or "L ", "R ", "F " and "R ".
These settings can also be made with the "joystick " in an analogous manner. When the headlamps are
switched on the brightness setting of the display can be reached by pressing the multifunction key" BRT" in the
tone setting menu. Here it is possible to select between " bright " and "dark ". Simultaneously pressing the
multifunction keys " - " and "+ " or "L " and "R " or "F " and "R " resets the corresponding setting in the
current mode to the center position
Tone setting is not possible in the telephone or navigation mode. The tone or brightness setting can be exited
by pressing the multifunction key EXIT ".
Voice output, function GF82.85-P-3001GI

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
Saturday, October 02, 2010 3:30:05 PMPage 68 © 2006 Mitchell Repair Information Company, LLC.

Fig. 97: Identifying E-Call Backup Antenna Location
SAFETY PRECAUTIONS
SAFETY INFORMATION: ELECTRICAL SYSTEM BODY - AS82.00-Z-9999ZZ
MODEL all
E-Call backup antenna,
locationThe EMERGENCY
CALL backup antenna
(A2/50) is mounted on the
inside of the rear bumper .
E-Call backup antenna,
purposeTransmitting and
receiving the
EMERGENCY CALL
signals if reception via the
CTEL and GPS roof
antenna (A2/49) is poor.
Risk of death caused by
high voltage at xenon
headlamps. Risk of
explosion/risk of fire
caused by highly
flammable materials in MODEL all...AS82.10-Z-0001-01A

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
Saturday, October 02, 2010 3:30:06 PMPage 161 © 2006 Mitchell Repair Information Company, LLC.

RISK OF DEATH, RISK OF EXPLOSION/RISK OF FIRE, RISK OF INJURY & RISK OF POISONING - AS82.10-Z-0001-01A
Do not come into contact with parts that are under high voltage. Persons with active electronic implants
(e.g. heart pacemakers) must never work on xenon headlamps. Switch off entire lighting system. Wear
insulated safety shoes, safety glasses and protective gloves. Remove highly inflammable materials from
the hazard area. Ensure sufficient ventilation in the working area.
Potential risks
Risk of death
Due to the high voltages involved, contact with live components at the xenon headlamps could be life
threatening!
Electric shocks can cause fibrillation of the heart or even cardiac arrest.
In addition, respiratory muscles may cramp up and result in respiratory failure.
Serious, possibly life-threatening, brain function disruptions are also possible.
It ma
y take a few minutes for the consequences of an electrical shock to manifest themselves.
the vicinity of damaged
xenon bulbs. Risk of
injury caused by UV
light, hot components at
xenon headlamps and
glass splinters produced
by bursting xenon bulbs.
Risk of poisoning caused
by inhalation of mercury
vapors and by toxic salts
and mercury compounds
being ingested or coming
into contact with skin
Injury hazard from
pinching and crushing, in
extreme cases extremities
can even be cut off when
caught in windshield
wiper mechanism.MODEL allAS82.30-Z-0001-01A
The demagnetizing coil
presents a lethal hazard
for persons with active
electronic implants (e.g.
heart pacemakers).MODEL 140...AS82.85-Z-0001-01A

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
Saturday, October 02, 2010 3:30:06 PMPage 162 © 2006 Mitchell Repair Information Company, LLC.

Risk of explosion/risk of fire
Highly flammable materials in the vicinity of damaged, energized xenon bulbs may result in explosion or cause
fires.
Risk of injury
UV light may escape when operating xenon bulbs not properly installed in the xenon headlamps. This UV light
may cause damage to the eyes (conjunctival infection) and to skin burns (sunburns) if skin is unprotected.
In both intact or faulty xenon headlamps, hot or glowing components may cause serious burn injuries if they
come into contact with unprotected skin or eyes.
Glass splinters produced by the destruction of xenon bulbs may cause cut injuries in unprotected skin and
unprotected eyes.
Risk of poisoning
When xenon bulbs are destroyed, serious health problems may be caused if the mercury vapors produced are
inhaled or if mercury compounds or toxic salts are ingested or absorbed through the skin. Possible
consequences include nausea, vomiting and gastrointestinal disruptions as well as degradation of the kidneys
and the central nervous system. Skin and eye damage may also result.
Safety precautions/instructions
Persons with electronic implants (e.g. pacemakers) must never work on xenon headlamps.
Wear safety shoes (with rubber soles).
Prior to working on xenon headlamps (e.g. replacing parts, hooking up test equipment, etc.), the complete
lighting system must be switched off and the xenon headlamps must be disconnected from the on-board
electrical system.
If the xenon headlamps are switched on, never touch components under high voltage.
If the xenon headlamps are switched on, maintain a clearance of at least 30 mm to components under high
voltage.
Avoid all contact with hot components.
Wait at least 3 min after switching off xenon bulbs before touching them.
Do not damage or destroy xenon bulbs.
Safety precautions/instructions
Never operate xenon bulbs unless they are properly installed in xenon headlamps with UV-absorbing
headlamp lenses.
Keep all highly flammable materials away from working area.
Wear suitable protective gloves and safety glasses.
Ensure that the workplace is sufficiently ventilated.

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

Consult a physician immediately.
Always consult a medical service or physician after administering first aid.
INJURY HAZARD FROM PINCHING AND CRUSHING, IN EXTREME CASES EXTREMITIES CAN EVEN BE CUT OFF
WHEN CAUGHT IN WINDSHIELD WIPER MECHANISM. - AS82.30-Z-0001-01A
Always remove ignition key before working on windshield wiper mechanism.
Injury hazard
When working in the area of the windshield wiper mechanism with the ignition key in position "1" or "2" the
wiper arm or wiper linkage can be pushed out of its end position and start running unintentionally . This can
result in severe injuries by cutting, pinching or crushing body parts.
Rules of behavior/protective measures
Always remove ignition key before working on windshield wiper mechanism.
Secure operating range of mechanism against reaching in.
Keep sufficient distance away from moving parts.
Supervise hazard area.
Wear tight fitting clothing and hair net.
TROUBLE DIAGNOSIS
HIGH BEAMS AND/OR LOW BEAMS DO NOT WORK - AF82.10-P-2009B
MODEL 129,140,163,170, 202, 208, 210, 215, 220 with CODE (612) Xenon headlamp unit
Modification notes
4.4.00Supersedes STIP 82.10-
019 from 24.03.2000
Damage codeCauseRemedy
Risk of death caused
by high voltage levels
present at xenon
headlamps.
Risk of explosion/risk
of fire caused by highly
inflammable substances
at damaged xenon bulbs
Risk of injury caused
by UV light, hot
components at xenon Do not come into contact with
parts that are under high voltage.
Persons with active electronic
implants (e.g. heart pacemakers)
must never work on xenon
headlamps. Switch off the
complete lighting system. Wear
insulated safety shoes, safety
glasses and protective gloves.
Remove highly inflammable
materials from the hazard area. AS82.10-Z-0001-01A

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
Saturday, October 02, 2010 3:30:06 PMPage 165 © 2006 Mitchell Repair Information Company, LLC.

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.

TESTING & REPAIR
TESTING AND REPAIR WORK: PASSENGER CARS: ELECTRICAL SYSTEM BODY - AR82.00-Z-9163AA
MODEL 163
Battery voltage 1114 V
Fuses in order
Radio in order
Testing
1Voltage supply, testing
electrical system, CD changerModels 202, 208, 210
up to 05/98 and models
124, 168AD82.64-P-6000-01A
2Voltage supply, testing
electrical system, CD changerModels 163AD82.64-P-6000-01B
3Voltage supply, testing
electrical system, CD changerModels 129, 202, 208,
210 as of 6/98AD82.64-P-6000-01C
4Operating function, testing
electrical system, CD changer AD82.64-P-6000-02A
Removing and
installing bulbs o
f
headlamp unit
MODEL 163.113/136 /154 /172 /174 up to
31.8.01AR82.10-P-
1201GH
Remove/install
fog lamp bulbMODEL 163.113/128 /136 /154 /157 /172 /175
with CODE (U49) Styling package MODEL
163.174AR82.10-P-
1825GH
Remove/install
fog lamp bulbMODEL 163...AR82.10-P-
1825GI
Remove/install
headlight beam
adjustment
control moduleMODELS 163.154 /172 /113 with CODE (612b)
Xenon headlamp unit MODELS
163.174 /175 /128/157AR82.10-P-
4081GH
Remove/install
electric headlamp
range adjustment
motorMODEL 163.154 /172 /113 with CODE (612)
Xenon headlamp unit MODEL
163.174 /175 /128/157AR82.10-P-
4082GH
Remove/install
xenon headlamp
control unitMODEL 163...AR82.10-P-
4632GH
Remove/install
xenon headlamp
control unitMODEL 163.113 #X as of 754620,
163.113 /154 /174 #A as of 289565,
163.128 /157 /175AR82.10-P-
4632GI
Remove/install
turn signal lampsMODEL 163...AR82.10-P-
4725GH

2001 Mercedes-Benz ML320
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis
me
Saturday, October 02, 2010 3:30:08 PMPage 249 © 2006 Mitchell Repair Information Company, LLC.