1997 MERCEDES-BENZ ML430 battery

Connect DC clip-on probe from engine tester with oscilloscope to positive battery terminal. See Fig. 11. Start
engine. Switch on low beam. Access diode test at 3000 RPM. See Fig. 12
-Fig. 14 . Replace generator as
necessar
y.

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Generators & Regulators - 163 Chassis
me
Saturday, October 02, 2010 3:20:32 PMPage 18 © 2006 Mitchell Repair Information Company, LLC.

Fig. 14: Identifying Oscilloscope Patterns (Negative Diode Defective)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVAL & INSTALLATION
GENERATOR
Removal & Installation (Model 163)
Disconnect and shield negative battery cable. Remove air cleaner housing. Remove engine trim panel. Remove
"V" belt b
y swiveling tensioning pulley and holding in place with a drift. Disconnect generator B+ electrical
NOTE: Numbers in text refer to numbers in figures.

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Generators & Regulators - 163 Chassis
me
Saturday, October 02, 2010 3:20:32 PMPage 22 © 2006 Mitchell Repair Information Company, LLC.

connector (1) and electrical line circuit 61 (D+) (2). Remove 2 generator bolts (3). Remove generator. See Fig.
15 . To install, reverse removal procedure. Using STAR scan tool, perform electrical operational check.
Fig. 15: Removing Generator

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
VOLTAGE REGULATOR
Removal & Installation (Compact Generator)
Disconnect and shield negative battery cable. Remove generator from vehicle. See GENERATOR . Remove 3
screws (1). Unclip cover (2) by pushing apart retaining lugs (3) and remove. Remove 2 screws (4). Remove
regulator (5) toward side. See Fig. 16
. To install, reverse removal procedure. When inserting regulator (5),
ensure
ground lug (6) makes contact with regulator.
NOTE: Numbers in text refer to numbers in figures.

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Generators & Regulators - 163 Chassis
me
Saturday, October 02, 2010 3:20:32 PMPage 23 © 2006 Mitchell Repair Information Company, LLC.

Fig. 16: Removing Voltage Re gulator (Compact Generator)
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removal & Installation (Bowl-Type Generator)
Disconnect and shield negative battery cable. Remove generator from vehicle. See GENERATOR Remove 2
re
gulator screws from back of generator. Remove regulator. See Fig. 17.

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Gene rators & Regulators - 163 Chassis
me
Saturday, October 02, 2010 3:20:32 PMPage 24 © 2006 Mitchell Repair Information Company, LLC.

P01.30-0299-06

20
Bolts cylinder head
!
timing case cover

21
Cylinder head bolts

22
Cylinder head left

23
Cylinder head right

24
Left cylinder head gasket

25
Right cylinder head gasket

26
Dowel sleeves


Remove/Install

Notes on self-locking nuts and bolts
All models

AH00.00-N-0001-01A


External torx set

*001589760900

Torx bit set

*000589011000


Danger!

Risk of explosion
caused by oxyhydrogen

gas.
Risk of poisoning and caustic burns


caused by swallowing battery acid.
Risk of

injury caused by burns to skin and eyes from

battery acid or when handling damaged lead-

acid batteries
No fire, sparks, open flames or smoking.

Wear acid-resistant gloves, clothing and

safety glasses. Pour battery acid only into

suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1
Disconnect battery ground cable


Installation:
After connecting, read out

fault memory, encode radio and normalize

power windows.

Vehicles with stationary heater: Set time on

timer for stationary heater
AR54.10-P-0003A

Notes on battery
All models

AH54.10-P-0001-01A

Danger!

Risk of death

caused by vehicle slipping or

toppling off of the lifting platform.
Align vehicle between the columns of the

hydraulic hoist and position the four support

plates below the hoist support points specified

by the vehicle manufacturer.

AS00.00-Z-0010-01A

2
Place the vehicle on lifting platform

AR00.60-P-1000GH
3.1
Remove air guide (1)


Only with engine 113.942

Danger!

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

4
Drain coolant

Remove coolant hose at bottom on

radiator.

AR20.00-P-1142HA

5
Remove engine cover

6.1
Remove viscous fan (2)

All except model 163.174 /175 with

engine 113.981 /965.

Right-hand thread!

AR20.40-P-5660C

7.1
Remove the fan shroud (3).

Only model 163.154 /157 /172. Unscrew

bolts (4) from bottom of fan shroud

7.2
Remove electric fan

Only model 163.174/ 175.

AR20.40-P-5000GH

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

P01.30-0299-06

20
Bolts cylinder head
!
timing case cover

21
Cylinder head bolts

22
Cylinder head left

23
Cylinder head right

24
Left cylinder head gasket

25
Right cylinder head gasket

26
Dowel sleeves


Remove/Install

Notes on self-locking nuts and bolts
All models

AH00.00-N-0001-01A


External torx set

*001589760900

Torx bit set

*000589011000


Danger!

Risk of explosion
caused by oxyhydrogen

gas.
Risk of poisoning and caustic burns


caused by swallowing battery acid.
Risk of

injury caused by burns to skin and eyes from

battery acid or when handling damaged lead-

acid batteries
No fire, sparks, open flames or smoking.

Wear acid-resistant gloves, clothing and

safety glasses. Pour battery acid only into

suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1
Disconnect battery ground cable


Installation:
After connecting, read out

fault memory, encode radio and normalize

power windows.

Vehicles with stationary heater: Set time on

timer for stationary heater
AR54.10-P-0003A

Notes on battery
All models

AH54.10-P-0001-01A

Danger!

Risk of death

caused by vehicle slipping or

toppling off of the lifting platform.
Align vehicle between the columns of the

hydraulic hoist and position the four support

plates below the hoist support points specified

by the vehicle manufacturer.

AS00.00-Z-0010-01A

2
Place the vehicle on lifting platform

AR00.60-P-1000GH
3.1
Remove air guide (1)


Only with engine 113.942

Danger!

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

4
Drain coolant

Remove coolant hose at bottom on

radiator.

AR20.00-P-1142HA

5
Remove engine cover

6.1
Remove viscous fan (2)

All except model 163.174 /175 with

engine 113.981 /965.

Right-hand thread!

AR20.40-P-5660C

7.1
Remove the fan shroud (3).

Only model 163.154 /157 /172. Unscrew

bolts (4) from bottom of fan shroud

7.2
Remove electric fan

Only model 163.174/ 175.

AR20.40-P-5000GH

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

1.1
Unscrew bolts at rear of 2/3 seat bench and

raise rear of seat bench

Up to VIN A145272, X708318.

1.2
Remove covers at seat frame of 60% bench

seat

As of VIN A145273, X708319.

AR91.12-P-1100GH

Only remove the covers which are
identified in the document with A, D and E.

2.1
Fold 60% bench seat forward into footwell

As of VIN A145273, X708319. See

operator's manual.

3.1
Pull floor covering below rear seat mounting

bracket (1) of 60% seat forward

Carefully pull floor covering forward under

the seat console to prevent it from tearing.

As of VIN A145273, X708319.

4.1
Pull the floor covering forward under the front

corner of the left C-pillar cover (2)

Carefully pull the floor covering forward

under the cover to prevent it from tearing.

As of VIN A145273, X708319.

5
Cut into floor covering directly behind seat

retaining cable (3)

Ensure that the wiring harness (4) is not

damaged when cutting the floor covering.

As of VIN A145273, X708319. Broken

line marks the cut.

6
Fold floor mat back

Do not crease floor mat!

Fold floor mat back far enough to provide

access to cap (84) between body and fuel

pump.

7
Remove end cover (84) of body


Installation:
Replace cap and insert with

new sealing compound.


Cap (84) is sealed in with body sealer.

Heat with hot air blower to make it easier to

remove.

8
Seal fuel return line (90/11)

Pliers

*163589003700

9
Connect extraction hose (90/14) with adapter
hose to connection for fuel return line (90/11)

Extraction hose

*168589009000


Adapter hose

*163589009100

10
Connect ground cable (90/10) of extraction

pump ground terminal vehicle battery

Pumping out

11
Pump fuel out into safety container using

extraction pump


*BF47.10-P-1001-01A


*WH58.30-Z-1001-16A

12
Install in the reverse order


Fuel tank

Number

Designation
Models

163.113/
136/154/

172 up to

31.08.01
Models

163.113/
136/154/

172 as of

01.09.01


Models

163.157/

175
Model

163.128
Model

163.174

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liter
72838393

Reserve capacity
Liter
10121212

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

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