1997 MERCEDES-BENZ ML430 cooling

Parts ordering notes
HEATER DOES NOT FUNCTION - AF83.40-P-6008A
MODEL 163.154 /174 /175 #A as of 289565 up to 348398 with CODE (494) USA version with CODE (580)
Automatic air conditioning
MODEL 163.113 /154 /174 /175 #A as of 289565 up to 348412, 163.113 /128 #X as of 754620 up to 772006
except CODE (494) USA version with CODE (580) Automatic air conditioning
Modification notes
Operation no. of operation texts or standard texts and flat rates
This fault occurs only on AAC [KLA] control and
operating units (N22) with part number A163 820 25 89,
A163 820 28 89, A163 820 42 89 and A163 820 43 89 unit (N22)6500GH
Part no.DesignationQuantity
163 820 49 89ECE AAC [KLA] control and operating unit1
163 820 50 89USA AAC [KLA] control and operating unit1
12.5.04Information revised in step 11; WE table added; part number revised
CategoryOp. no.Operation text
P023610Perform diagnosis on left air mixing flap actuator motor (M2/6)
Damage
codeCauseRemedy
83 491
90
The automatic air
conditioning control unit
(N22) does not communicate
with the blending air flap
actuator motor (M2/6).
1 Connect STAR DIAGNOSIS and perform short
test.
AD00.00-P-
2000-04A
*WH58.30
-
Z-1048-13A

If fault codes are present: ?
2 Perform diagnosis and repair according to fault
code description.

If NO fault codes are present: ?
Perform following test when engine is cold.
3 Select "Actual values" with STAR DIAGNOSIS
under "Automatic air conditioning".
4 Select "M2/6 (blending air flap actuator motor)".

5 Set temperature control to maximum cooling and
wait 30 seconds Observe the actual value of the
blending air flap actuator motor (M2/6) and switch
over the temperature control switch to maximum
heating.

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 158 © 2006 Mitchell Repair Information Company, LLC.

HEATER, DIAGNOSIS, BASIC KNOWLEDGE - AD83.20-P-2000GH
MODEL 163
HEATER CAPACITY, FUNCTION CHECK, HEATER - AD83.20-P-3000-01GH
Test sequence
Heater switch (2) on "red" stop
Blower switch (1) on stage 4
Air distribution switch (3) in 12 o'clock position
Recirculated air button ( ) not pressed (LED does not come on)
Test period > 5 minutes
Engine speed 2000 rpm
Engine coolant temperature > 80°C
 Read out temperature measuring instrument (4)
Temperature display > 55°C

If the measured values stated above are not achieved, the following components and functions should be
checked:
Engine coolant temperature
Furring in cooling system and heat exchanger
Blend air flap function
Coolant circulation pump (M13)
WH58.30-Z-1002-08ADigital temperature measuring instrument (measuring range -20° to +70°)
WH58.30-Z-1004-08AAir temperature probe
Electric wiring diagrams, location of ground points and connectors PE83.00-P-1100E
Connection and use of test equipment AD00.00-P-1000AZ
Diagnosis tools, heater AD83.20-P-2000-01GC

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 160 © 2006 Mitchell Repair Information Company, LLC.

AIR CONDITIONING (TEMPMATIC) DIAGNOSIS CONTENTS - AD83.30-P-1000GHZ
MODEL 163 with CODE (580) Air conditioning or for USA, Tempmatic
AIR CONDITIONING (TEMPMATIC) PRECONDITIONS FOR OPERATIONAL CHECK - AD83.30-P-2000-01GH
up to 30.11.99
Heater push-button
unit
2
Full heat Heater switch on "red" stopAir outlets, heated
air
Wire cable for
actuating air blend
flap
Heater push-button
unit
3
Recirculated
air mode Heater switch in any position Recirculated
air button ( ) is pressed (LED comes
on)Air flow from
center outlet
increases
noticeably
Cables
Recirculated air
button
Actuator motor for
recirculated air flap
element (M39)
Heater push-button
unit
4
Heat output Connect temperature measuring instrument
Heater switch on "red" stop
Air outlet
temperature at
defroster outlet >
55°C
Engine coolant
temperature
Hot water coolant
circulation pump
Furring in cooling
system and heat
exchanger
Test sequenceAD83.20-P-3000-01GH
K 2.6 [] 11Air conditioning (Tempmatic) (Tempmatic A/C) diagnosis, previous
knowledge AD83.30-P-
2000GH
K 2.6 [] 12Air conditioning (Tempmatic) (Tempmatic A/C) diagnosis, function
check AD83.30-P-
3000GH
K 2.6 [] 13Air conditioning (Tempmatic) (Tempmatic A/C) diagnosis, function
check actual values AD83.30-P-
3001GH
K 2.6 []
14AAir conditioning (Tempmatic) (Tempmatic A/C) diagnosis, fault memory AD83.30-P-
4000GH
K 2.6 [] 21Air conditioning (Tempmatic) (Tempmatic A/C), testing electrical
system AD83.30-P-
6000GH

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 162 © 2006 Mitchell Repair Information Company, LLC.

Fig. 151: Identifying Heat Exchanger Components
REPLACE BULBS IN PUSH-BUTTON CONTROL MODULE - AR83.25-P-1123GH
MODELS 163.113/154/174/136/172 up to 31.8.01

Remove/Install
1Remove AC housing AR83.30-P-
5200GH
2Remove bolt (1) from the covering on the
air duct (2)The bolt lies under the air
duct seal.
3Remove lever for blend air flap (3)
4Unscrew bolt (4) at bracket (5).
5Remove heat exchanger (6) upward
6Install in the reverse order
7Inspect cooling system for leaks AR20.00-P-
1010HA

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 181 © 2006 Mitchell Repair Information Company, LLC.

Fig. 164: Identifying Evaporator Housing Components (2 Of 2)

Remove/install

Risk of explosion from welding or
soldering work on closed air
conditioning system. Risk of
poisoning. Inhaling overheated
refrigerant vapors may be toxic.
Risk of injury from skin and eye
contact with liquid refrigerant.Do not carry out any welding work on the
closed air conditioning system or in the
surrounding area. No smoking or open
flames. Wear eye protection and
protective gloves. Work only in well
ventilated areas. Carry out repair work on
the air conditioning system circuit only
after the system has been discharged.
AS83.00-Z-
0001-01A
Procedures if air conditioning
system is damaged or leakingAll models
AH83.30-
N-0004-
01A

Protect air conditioning circuit and
components from moisture when
carrying out repair work
All models fitted with air conditioning
AH83.30-
N-0005-
01A
Notes on handling refrigerant
R134aAll models fitted with air conditioning
AH83.30-
N-0003-
01A
Risk of injury to skin and eyes
suffering scalding from contact
with hot coolant spray. Risk of
Do not open cooling system unless
coolant temperature is below 90°C. Open
cap slowly and release the pressure. Do
not pour coolant into beverage bottles.
AS20.00-Z-
0001-01A

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 196 © 2006 Mitchell Repair Information Company, LLC.

Air conditioning system
DISASSEMBLING, ASSEMBLING A/C HOUSING - AR83.30-P-5201GH
MODEL 163 with CODE (580) Air conditioning or, in USA, Tempmatic A/C
13Unclip ETC control module
(N15/3)
14Detach connector from blend air
flap actuator (M16/8)
15Detach connector from recirculated
air flap actuator motor (M39)
16Detach evaporator temperature
sensor connector (B10/6x1)
17Detach blower motor series resistor
connector (6)
18Detach blower motor connector (5)
19.1Remove air conditioning control
module (N19) Only up to 31.08.01.AR83.30-
P-6600GH
20Unclip cable set at evaporator
housing Installation: Ensure correct routing of
cable set.
21Remove sound deadener (2)
22Detach water drain hose from AC
housing lower side(1)
23Remove AC housing (1) Unclip evaporator housing from air
distributor and remove upward.
24Install in the reverse order
25Inspect cooling system for leaks AR20.00-
P-1010HA
NumberDesignationModel Series 163
BA83.30-P-1003-01BNut to pipeline on expansion valveNM10

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 198 © 2006 Mitchell Repair Information Company, LLC.

Remove/install

Risk of injury to skin and eyes
suffering scalding from contact with
hot coolant spray. Risk of poisoning
from swallowing coolant.
Do not open cooling system unless coolant
temperature is below 90°C. Open cap slowly
and release the pressure. Do not pour
coolant into beverage bottles.
Wear protective gloves, protective clothing
and eye protection.
AS20.00-Z-
0001-01A

Risk of explosion from welding or
soldering work on closed air
conditioning system. Risk of
poisoning. Inhaling overheated
refrigerant vapors may be toxic. Risk
of injury from skin and eye contact
with liquid refrigerant.Do not carry out any welding work on the
closed air conditioning system or in the
surrounding area. No smoking or open
flames. Wear eye protection and protective
gloves. Work only in well ventilated areas.
Carry out repair work on the air
conditioning system circuit only after the
system has been discharged.
AS83.00-Z-
0001-01A
Procedures if air conditioning system
is damaged or leakingAll models
AH83.30-
N-0004-
01A

Protect air conditioning circuit and
components from moisture when
carrying out repair work
All models fitted with air conditioning
AH83.30-
N-0005-
01A
Notes on handling refrigerant R134aAll models fitted with air conditioning
AH83.30-
N-0003-
01A
1Drain coolant J Engine 112, 113.AR20.00-P-
1142HA
Engine 111.AR20.00-P-
1142HG
Engine 612.963.AR20.00-P-
1142M
2Unscrew coolant compensating
reservoir (1) on firewall Lay compensating reservoir to one side.
3Disconnect coolant delivery/return
hoses for heat exchanger (2) Remove hose clamps from coolant hoses.
4Discharge air conditioning system
Installation: Evacuate air conditioning,
refill and check for proper operation and
leaktightness.AR83.30-P-
1760GH
5Remove cover on expansion valve
(4)
6Remove nut (3) on expansion valve
(4) Replace self-locking nut.
*BA83.30-
P-1003-01B
7Disconnect refrigerant lines from
expansion valve Installation: Install new sealing rings
and moisten with compressor oil.

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:19 PMPage 220 © 2006 Mitchell Repair Information Company, LLC.

Dashboard
Air conditioning system
8Remove wiper system AR82.30-P-
6400GH
9Remove nuts (5) from instrument
panel at firewall
*BA68.10-
P-1001-
01A
10Remove paneling from A-pillar AR68.30-P-
4050GH
11Remove plastic nuts on driver's side
at paneling below instrument panel
12Remove paneling on right in footwell AR68.30-P-
4010GH
13
Remove rubber covers on side at the
A-pillars and unscrew screws for
instrument panel at A-pillar (arrows)

*BA68.10-
P-1002-
01A
14Remove center console AR68.20-P-
2000GH
15Unscrew bolt (6) underneath the
instrument panel
*BA68.10-
P-1003-
01A
16Withdraw instrument panel to the
rear Bring in helper. Cushion front edge of
selector lever module so that lower edge of
instrument panel is not damaged.

17Turn instrument panel around so that
the back is accessible Do not overstretch interior wiring
harness.
18Detach outside temperature sensor
connector (B10/5x1)
19Disconnect cable from temperature
sensor to evaporator housing Installation: Ensure clean cable routing.
20Remove outside temperature sensor
(B10/5) from air duct 2 bolts.
21Install in the reverse order
22Inspect cooling system for leaks AR20.00-P-
1010HA
NumberDesignationModel Series 163
BA68.10-P-1001-01ANut, dashboard to firewallNM8
BA68.10-P-1002-01ABolt, dashboard to A-pillarNM19
BA68.10-P-1003-01ABolt, dashboard to transmission tunnelNM30
NumberDesignationModel Series 163
BA83.30-P-1003-01BNut to pipeline on expansion valveNM10

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:19 PMPage 221 © 2006 Mitchell Repair Information Company, LLC.