1997 MERCEDES-BENZ ML350 light

AR09.41-P-6817MM
Removing and installing charge air cooler
10.11.99

ENGINE
612.963 in MODEL 163.113

P09.41-2024-09

1
Headlamp units

2
Cover strips

3
Front end crossmember

4
Socket at temperature sensor
9

Bolts

11
Socket

110/2
Charge air cooler

B17
Intake air temperature sensor

5

Right hose clamp

6
Left hose clamp

7
Charge air hose to charge air cooler

8
Charge air hose from charge air cooler

Operation no. of operation texts or standard texts and flat rates
Sector

Op. no.
Operation text

P
096810
REMOVING AND INSTALLING CHARGE AIR COOLER

P
096820
REPLACING CHARGE AIR COOLER

P
096827
REPLACING CHARGE AIR COOLER (COOLER REMOVED)

Removing, installing

Danger!

Risk of injury
from fingers becoming


jammed or bruised
when removing and

installing and aligning hood, trunk lid, doors,

lids and sliding roof
When moving components ensure that no

body parts or limbs are in the area of motion.

AS00.00-Z-0011-01A

1
Open engine hood and position upright


Have an assistant secure hood

AR88.40-P-1000GI

2
Remove headlamp units (1)

AR82.10-P-4730GH

3
Remove front end crossmember (3)

Place over engine with release cable

attached.

AR62.30-P-2300GH

4
Unplug socket (4) at intake air temperature

sensor (B17)


Do not release or lock temperature sensor

(B17) in place with socket plugged in

otherwise the locking arms will be over-

tensioned. Refer to:

#

Removing and installing intake air

temperature sensor.

AR07.52-P-1465A

5
Detach hose clamps (5, 6) of the charge air

hoses (7, 8) at the charge air cooler (110/2)

6
Unscrew bolts (9) at charge air cooler

7
Remove charge air cooler (110/2)

Detach from charge air hoses.
Traces of oil, slight quantities of oil in the

charge air hose come from the crankcase

ventilation and are permissible.

8
Install in the reverse order

Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

Fig. 8: Connecting Hand Held Tester Scan Tool To OBD-II Data Link Connector
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ON-VEHICLE TESTING
WIRING CONTINUITY
1. Connect voltmeter between generator B+ terminal and ground. Voltmeter should indicate battery voltage.
If battery voltage is not indicated, check battery and check wiring between generator and battery for
corrosion, loose terminals, etc.
2. Turn ignition on and ensure instrument cluster charge indicator light (battery symbol) comes on. If light
does not come on, check wiring between generator and warning light, including indicator bulb.
GENERATOR OUTPUT
1. Ensure connections at battery and generator are clean and tight. Ensure generator, engine and body are
properly grounded. Ensure generator drive belt is properly adjusted and in good condition.
2. Connect load tester/ammeter as per tester manufacturer's instructions. Connect voltmeter leads to battery
terminals. See Fig. 9
. Start engine and run at 2200 RPM for V6 or 2500 RPM for V8. Adjust load tester
to obtain maximum generator output. DO NOT allow voltage to drop to less than 12.7 volts.
3. Maximum generator output should be within a few amps of generator rated output stamped on generator.
If output is not within a few amps of generator rated output, check generator diodes. See DIODE TEST
.
Replace
generator as necessary.

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Generators & Regulators - 163 Chassis
me
Saturday, October 02, 2010 3:20:32 PMPage 14 © 2006 Mitchell Repair Information Company, LLC.

VOLTAGE REGULATOR CONTROL
1. Connect multimeter. See Fig. 10 . Ensure charge indicator light goes out when engine is idling and with
increasing engine speed up to 3000 RPM. Apply load to battery by turning on headlights and noting
reading after 2 minutes.
2. Voltage reading should be 13-14.5 volts. If voltage is not to specification, replace voltage regulator. See
VOLTAGE REGULATOR
under REMOVAL & INSTALLATION. If regulator is okay, replace
generator. See GENERATOR under REMOVAL & INSTALLATION.

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Generators & Regulators - 163 Chassis
me
Saturday, October 02, 2010 3:20:32 PMPage 16 © 2006 Mitchell Repair Information Company, LLC.

Crankshaft Position Sensor DIY


hopefully this will help others with what appears to be a common stalling issue in the ML series.


Location:


--------


It's on the rear of the engine where the engine mates with the tranny on the driver's side. There are 2

types. Be sure to get the correct one


Here it is:


1) Get
CPS
at dealer, its a VIN specific part. $125 from my local stealer.


2) Tools needed: Socket screwdriver, Good lighting (portable) shop lights, size 8 outside torx socket,
maybe a ratche
t and extentions depending on your flexibility, magnetic part retrieval tool (skip this at

your peril), bath towel, and long sleeve shirt, step stool, blue thread locker (optional)


3) Open hood and remove engine cover, it just pulls off and on


4) Set wor
k light(s) toward back of engine, lighting behind drivers cylinder head


5) Set bath towel on front of ML to kneel on of your knees will die, wearing long sleeve shirt or your

wrists will be cut.


6) Climb up on towel and look behind engine from above and
right (see .jpg), finding torx attachment
holding your
CPS
.

7) Remove torx screw and pull out
CPS
, disconnect one way connector (wiring)


8) Replace with new (leaving wire detached for now)


9) This is the hardest step by far, and requires patience and fl exibility. Apply some thread locker and

insert screw and start the threads. Tighten with torx on socket screwdriver. This step took about 1/2

hour and numerous dropped screws and retrievals with mag tool.


10) Attach wiring to
CPS


11) Reinstall engine cov
er


12) Clean up tools, towel and lights and everything


13) Drink beer and toast yourself for saving yourself at least $100 and a day of your time dropping off

and picking up cars at shop


Hope this helps someone in the community.


Dickie


00 ML 32
0

Remove/Install

1.1
Remove engine compartment cover with

integrated air cleaner
All except Engine 112.960 in Model 170.466,

Engine 112.961 in Model 203.065/ 265

Remove air cleaner by lifting vertically up

and away from the cylinder head covers.


Installation:
With sliding compound,

slightly moisten the rubber retainers on the

cylinder head covers and the sealing ring of

the hot film mass air flow sensor in the air

cleaner housing.

1.2
Remove air cleaner housing
Engine 112.960 in Model 170.466

Engine 112.961 in Model 203.065/265

AR09.10-P-1150SVK

2
Remove crankshaft position sensor (L5)


*BA15.10-P-1001-03A

3
Install in the reverse order

4.1
Reinitialize crankshaft position sensor (L5)

using STAR DIAGNOSIS

If the crankshaft position sensor (L5) was

replaced, a re-initialization must be carried

out with STAR DIAGNOSIS in the "Control

unit adaptations" menu item.

Diagnosis system STAR DIAGNOSIS

*WE58.40-Z-1013-06A


Position sensor

Number

Designation
Engine

112.910/911/912/
913/914/915/
916/917/920/
921/922/923/
940/941/942/
943/944/945/
946/947/949/
951/953/954/
955/960/961/

970/972/973/975
Engine

113.940/941/
942/943/944/
948/960/961/
962/963/965/
966/967/968/
969/980/981/
982/984/986/

992/993

BA15.10-P-1001-03A
Crankshaft position sensor to engine block
Nm
88

Workshop equipment/MB testers
(see Workshop Equipment Manual)

WE58.40-Z-1013-06A
Compact STAR DIAGNOSIS system for passenger cars, order number 6511 1801 00

Copyright DaimlerChrysler AG 29.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

AD54.30-P-3000-03A
Display instruments/multi-function display

function check IC

Display

instruments

The display instruments must indicate according to operating

conditions.

Phototransistor (models 202, 208, 210)

Point a beam of light at the phototransistor with a pocket lamp, the

display illumination of the LCD displays (outside temperature, trip

odometer, total mileage recorder and electronic clock) must get

brighter.
Instrument cluster with multi-function display

If there are malfunctions (e.g. brake linings worn, coolant level too

low, exterior lamp failure etc.) or system faults (anti-lock brake

system faulty, supplemental restraint system faulty) the warning

display with warning information is inserted in place of outside

temperature, odometer, total mileage recorder and electronic clock.

The warning information is displayed in yellow or red depending on

the fault and a warning tone also sounds.
Copyright DaimlerChrysler AG 05.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

AR88.70-P-9040GH
Removing and installing outside rearview mirror cover
12.2.97

MODEL
163.113 /136 /154 /172 /174 up to 31.8.01

P88.70-0255-06

1
Frame

2
Mirror housing paneling

3
Catches in mirror housing

4
Outer catch

5
Bolt

6
Clips

Operation no. of operation texts or standard texts and flat rates
Range

Op. no.
Operation text

P
883424
REPLACING HOUSING FOR LEFT OUTSIDE REARVIEW MIRROR

P
883425
CONVERTING HOUSING FOR LEFT OUTSIDE REARVIEW MIRROR (MIRROR REMOVED)

P
883427
REPLACING HOUSING FOR RIGHT OUTSIDE REARVIEW MIRROR

P
883428
CONVERTING HOUSING FOR RIGHT OUTSIDE REARVIEW MIRROR (MIRROR REMOVED)

P
883430
REPLACING HOUSINGS FOR BOTH OUTSIDE REARVIEW MIRRORS


Remove/install

1
Remove mirror glass

AR88.70-P-9020GH

2
Release catch in mirror housing (3)

Press mirror housing out of frame (1) with

slight pressure

3
Release paneling for mirror housing (2) from

frame (1)

Outer catch (4) only accessible if mirror

housing is pivoted toward door

4
Remove mirror housing paneling (2)

5
Unscrew screw (5) from frame (1)

Torx bit set

*000589011000

6
Unclip frame (1) from mirror actuator motor

Pivot mirror housing back to initial

position. Unclip clips (6) from actuator motor.

6
Remove frame (1)

7
Install in the reverse order


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

GF54.21-P-4106-01GH
Extended Activity Module - Task

n

The primary tasks of the Extended Activity Module (EAM, N10/1) are

as follows:
D
To control the door sill lights

D
To suppress the auto-dimming mirror function

D
To control the headlight cleaning system (HCS)

D
To control the rear window defroster

D
To control seat heating

D
To control the power supply via control console to tilt/sliding or

louvered sunroof switch

D
To control the PTC heater booster (R22/3)

D
To control the auxiliary fan (M4)

D
To read the cruise control switch (S40) and relay data to control

module (DAS, N73/1)

D
To read the contacts for wiper speed settings 1 and 2 on

combination switch (S4) for diagnosis.

To perform these tasks the Extended Activity Module (EAM, N10/1)

reads various signals and switch settings directly.

The Extended Activity Module (EAM, N10/1) interfaces with other
control modules via the engine compartment CAN.

-----------------------------------------------------------------------------------------
Diagnosis

Diagnosis is performed using the Star diagnostic tool. To facilitate

this task, the Extended Activity Module (EAM, N10/1) is equipped

with its own diagnostics cable.
This cable is also used to diagnose the
All Activity Module (AAM,

N10)
and the
transfer case control module (N78)
.

The Extended Activity Module (EAM, N10/1) is linked to the All

Activity Module (AAM, N10) via the
engine compartment CAN
.

Data communication between the All Activity Module (AAM,

N10) and the Extended Activity Module (EAM, N10/1) is

assumed by the
CAN (N10 - N10/1)
when terminal 15 is off.

The CAN (N10 - N10/1)
is an independent CAN bus located

between the All Activity Module (AAM, N10) and the Extended

Activity Module (EAM, N10/1).
No other
control modules are

connected to the CAN (N10 - N10/1).

-----------------------------------------------------------------------------------------

Details:

Door sill lights

When the front interior light is on and one of the front doors is open,

or when the rear interior light is on and one of the back doors is open,

the door sill lights for the open door will illuminate.

Headlight cleaning system (HCS)

Activating a separate switch causes the EAM to send a turn-on signal

to the HCS pump relay.

EAM will send an additional turn-on signal to the HCS pump relay

only after the cleaning operation is completed and a "rest period" of

approximately 2.5 sec. has passed.

Auto-dimming mirror function

The auto-dimming mirror function is suppressed when the interior

light is on or reverse gear is engaged.

Auto-dimming suppression for the outside rearview mirror (slave) is

activated by the inside rearview mirror (master).

Heater booster/PTC air heater for diesel engines

EAM monitors system voltage and adjusts heater booster capacity to

minimize load on battery.
Rear window defroster

EAM sets maximum ON time for rear window defroster depending

on outdoor temperature and current vehicle speed.
D
Standard ON time:
10 min.

D
Outdoor temperature < 5
o
C:
Additional 5 min.

D
Speed >80 km/h:
Additional 3 min.

Seat heating

Sets maximum seat heating time.
D
Setting 1: max. 20 min.

D
Setting 2: max. 5 min.

Tilt/sliding or louvered sunroofs

Signal via AAM2 allows operation of tilt/sliding or louvered sunroofs

when ignition is on (standard mode) or off (keyless mode).

Ignition authorization via CAN

The EAM issues ignition authorization to AAM2 via the engine

compartment CAN depending on the requirements of the engine

control unit in connection with the FBM.

Copyright DaimlerChrysler AG 18.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1