1997 MERCEDES-BENZ ML430 wiring

2001-04 STARTING & CHARGING SYSTEMS Starters - 163 Chassis
MODEL IDENTIFICATION
MODEL IDENTIFICATION
DESCRIPTION
Starter is a brush-type, series-wound el ectric motor with an overrunning clutch. Field frame contains field coils
and is enclosed by commutator/drive bushing end frame, which carries pole shoes. A splined armature shaft
carries drive assembly.
TROUBLE SHOOTING
BASIC TROUBLESHOOTING
If starter is noisy, the cause could be bent or damaged gear tooth chamfers on ring gear. This cannot be seen
with starter installed in ve hicle. Activate starter without switching ignition on. Me tallic noise should not be
heard. If noise is he ard, replace ring gear.
PRELIMINARY INSPECTION
Verify customer complaint by operating system. Visually inspect for obvious signs of mechanical and electrical
damage. Check generator belt tension and condition. Ensure that battery voltage is within specifications. Inspect
for blown fuses and damaged relays. For fuse and/or relay identification, see WIRING DIAGRAMS
.
WARNING:
Vehicles are equipped with air bag supplemental restraint system. Before
attempting any repairs involving steer ing column, instrument panel or
related components, see SERVICE PRECAUTIONS (or AIR BAG SAFETY
PRECAUTIONS) and DISABLING & ACTIVATING AIR BAG SYSTEM in
appropriate AIR BAG REST RAINT SYSTEMS article.
NOTE: When the battery is di sconnected, vehicle computer and memory system may
lose data. Driveability problems may exist until computer systems have
completed a relearn cycle. Radio will not operate until coded. Obtain code card
from customer.
NOTE: The following table identifies mo dels applicable to this article.
ModelChassisEngine Number
ML430 (2001)163.172113.942
ML320 (2001-03)163.154112.942
ML55 AMG (2001-03)163.174113.981
ML500 (2002-04)163.175113.965
ML350 (2003-04)163.157112.970

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Starters - 163 Chassis

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Starters - 163 Chassis
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Verify ground connection integrity between engine, body, battery and generator. Check for damaged wiring
harnesses and/or switches. Check fo r a broken or partially broken wire inside insulation, which could cause
system malfunction but prove good in a continuity/vol tage check with system disconnected. Ensure any
aftermarket electronic e quipment is properly installed. If fault is found, repair as necessary. If no fault is found,
check for conditions that might cause an intermittent situation.
SERVICE PRECAUTIONS
BATTERY DISCONNECT/CONNECT
Disconnect/Connect Procedures
1. Turn ignition off. Open engine hood. After opening ve hicle wait at least 4 minutes before disconnecting
battery or alarm wi ll be triggered.
2. Disconnect negative battery cable (1) and insulate cable lug to prevent unwanted contact with ground
point (W16/4). See Fig. 1
.
3. To connect, reverse disconnect procedur e. Tighten nut (5) to specification. See TORQUE
SPECIFICATIONS .
4. Perform basic programming, read Diagnostic Tr ouble Code (DTC) memory and erase DTCs from
memory. See BASIC PROGRAMMING
and RETRIEVING & ERASING DIAGNOSTIC
TROUBLE CODES .
NOTE: Numbers and letters in text refe
r to numbers and letters in figures.

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Starters - 163 Chassis
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switch pressed for 5 to 10 seconds.
6. Normalize power windows. Completely close each wi ndow with manual switch. Hold switch in closed
position for 5 seconds.
Coding radio
Hi-Line Premium With Bose(R)
1. Turn ignition on. CODE will appear on radio displa y. Enter first code number with station button. For
example, station button 1 is number 1.
2. After entering first number, CODE will disappear and first number entered will appear followed by 4
dashes. The next character to be entered flashes. Repeat procedure until all numbers are entered.
3. If an input error has occurred it can be corrected at this time by reentering the complete correct code.
4. Confirm entry of correct code with < or > button.
5. If an incorrect code number has been entered, CODE appears again on display. If an incorrect code is
entered 3 times, WAIT appears on display and ra dio locks up for approximately 10 minutes. If an
incorrect code is entered 3 times again, lock time increases to 60 mi nutes. Radio must remain switched on
during lock up time.
MB
1. Turn ignition on. CODE will appear on radio displa y. Enter first code number with station button. For
example, station button 1 is number 1.
2. After entering first number, CODE will disappear and first number entered will appear followed by 4
dashes. The next character to be entered flashes.
3. After entering all 5 numbers the first character starts flashing again. If an input error has occurred it can
be corrected at this time by reentering the complete correct code.
4. Press TUNE, AUTO/SEEK or SC butt on. If code is correct, radio automatically switches on and indicates
the station or frequency stored wi th station button 1. If an incorrect code number has been entered, CODE
appears again on display. If an inco rrect code is entered 3 times, WAIT appears on display and radio
locks up for approximately 10 minutes. If an incorrect code is entered 3 times again, radio locks up for
approximately 10 additional minutes. After 9 incorrec t attempts, lock time increases to 60 minutes.
Another 3 incorrect entries locks up radio for anothe r 60 minutes. Radio must remain switched on during
lock up time.
RETRIEVING & ER ASING DIAGNOSTIC TROUBLE CODES
RETRIEVING DIAGNOSTIC TROUBLE CODES
NOTE: Before replacing any component that scan tool suggests are faulty, ensure that
all wiring connections and harness connect ors are okay. Ensure that power and
ground circuits are functioning properl y. For circuit identification, see
appropriate WIRING DIAGRAM unde r ENGINE PERFORMANCE in SYSTEM
WIRING DIAGRAMS for vehicle being tested.

2001 Mercedes-Benz ML320
2001-04 STARTING & CHARGING SYSTEMS Starters - 163 Chassis
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WIRING DIAGRAMS
See STARTING SYSTEM wiring diagram in appr opriate SYSTEM WIRING DIAGRAMS article in
ELECTRICAL.
Engine Mount-To-Engine Carrier48 (65)
Ground Cable-To-Body13 (18)
Starter-To-Crankcase31 (42)
INCH Lbs. (N.m)
Circuit 30 Connection Nut124 (14)
Circuit 50 Connection Nut53 (6)

2001 Mercedes-Benz ML320
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AZ82.60-P-0004A
Retrofit vehicle video system
3.10.00

MODELS
163.136 /154 /172 1A as of 145273,

163.136 /154 /172 1X as of 708319,

163.113 /128 /157 /174 /175 1#

left hand drive vehicle

P82.60-2376-08

1
Central interface module

2
Video monitor

3
Video player
B

Video/DVD player wiring harness

C
Wiring harness for video monitor

4

Auxiliary interface module

5
DVD player wiring harness

A2
Radio

P82.60-2399-01 P82.60-2400-01 P82.60-2444-01

6
Antenna cable for FM modulator

7
Vehicle antenna cable

8
Self-adhesive foamed material

9
Antenna cable for FM modulator
Illustrated as of VIN A289565, X754620

13
Auxiliary interface module connector

14
Mount for center console

Illustrated up to VIN A289564, X754619

10
Wiring harness for auxiliary interface

module

11
Clip

12
Self-adhesive foamed material


Remove

1
Remove center console

f

Remove/install center console

AR68.20-P-2000GH

2
Remove center console insulating mat

3
Remove rear air duct
Up to VIN A289564, X754619. 2 screws

at rear air duct.

4
Remove radio (A2)

f

Remove/install radio

AR82.60-P-7502EA

5
Remove glove compartment

f

Remove/install glove compartment

AR68.10-P-1400GI

Torx bit set

*000589011000

6
Loosen upper section of right front door

rubber seal

7
Remove A-pillar paneling on right

f

Remove/install paneling on A-pillar

AR68.30-P-4050GH

Long wedge

*115589035900

8
Remove right sun visor

f

Remove/install sun visor

AR68.60-P-5480GH

9
Remove right front handle

Open covers for handles, press down clip

on each side of handle, at the same time

press handle upward and pull out.

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

10
Remove edge guard for tilting/sliding roof

cutout

11
Release upper right B-pillar paneling

12
Remove covers at lower rear seat

Do NOT remove center cover for lower

40% seat. Do NOT reinstall curtain on 60%

front bench seat.

f

Remove and install cover on bottom of rear

seat

AR91.12-P-1100GH

13
Release side shade at the 60% bench

Fold shade upward so that the working

area is not obstructed.

14
Remove 40% rear seat

f

Remove and install bench

AR91.12-P-1010GI

Torx bit set

*000589011000


Install

15
Retrofit central interface module (1)

AZ82.60-P-0004-01A

16
Insert antenna cable for FM modulator (6) into

vehicle antenna cable (7)

17
Cover connector with self-adhesive foamed

material (8)

18
Plug remaining antenna cable of FM

modulator (9) into radio

19
Install radio (A2)

f

Remove/install radio

AR82.60-P-7502EA

20
Retrofit video monitor (2) and wiring harness

of video monitor (C)


With
glass version of electric sliding/tilting

roof, code 414a.

AZ82.60-P-0004-02A


Except
glass version of electric

sliding/tilting roof, code 414a.
AZ82.60-P-0004-02B

21
Secure upper right B-pillar paneling

Ensure that the lugs of the seat belt height

adjustment are located correctly in the recess

clearance of the paneling.

22
Install right front handle

23
Install right sun visor

f

Remove/install sun visor

AR68.60-P-5480GH

24
Install right front A-pillar cover

f

Remove/install paneling on A-pillar

AR68.30-P-4050GH

25
Re-secure upper area of rubber door seal

26
Route wiring harness of video/DVD player

(B), additional interface module (4) and wiring

harness of video monitor (C) later
Up to VIN A289564, X754619.

AZ82.60-P-0004-03A

As of VIN A289565, X754620.

AZ82.60-P-0004-03B

27
Retrofit auxiliary interface module (4) in

center console

Up to VIN A289564, X754619.

AZ82.60-P-0004-04A

As of VIN A289565, X754620.

AZ82.60-P-0004-04B

28
Install center console insulating mat

29
Install center console

f

Remove/install center console

AR68.20-P-2000GH

30.1
Plug in plug of additional interface module

and secure the wiring harness of the

additional interface module (10) to the clip

(11) together with the wiring harness of the

rear power windows in the center console

Up to VIN A289564, X754619.

30.2
Insert auxiliary interface module (13)

connector and route between center console

mount (14) and center console.

As of VIN A289565, X754620.

31.1
Secure auxiliary interface module plug in the

left rear corner of the ashtray housing using

self-adhesive foamed material (12)

Up to VIN A289564, X754619.

32
Open ashtray and cup holder and close to

check correct function

33
Attach side shade of the 60% bench

34.1
Retrofit video player (3)

AZ82.60-P-0004-05A


*BA91.12-P-1005-03A


*BA91.12-P-1008-03A

34.2
Retrofit DVD player

AZ82.60-P-0005-01GH

35
Install 40% rear seat

f

Remove and install bench

AR91.12-P-1010GI

Torx bit set

*000589011000

Copyright DaimlerChrysler AG 09.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

AF88.70-P-1100AG
Wind noise at outside mirror on left and/or right front door
30.10.03

MODEL
163.154 #A as of 289560,

163.113 /128 #X as of 754620,

163.113 /174 #A as of 289560 up to 486952,
163.128 /157 /175 #A up to 486952

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

Range

Op. no.
Operation text

Flat rate
Acc. no.
Code

P
024204
Foam on base of outside rearview mirror, Location:.... install
004 WU
81 101 39
---

Damage Code
Cause
Remedy

81 101 39
Insufficient seal pressure between door and

base of mirror mount.
1
Remove outside rearview mirror (1)
only


on side where wind noise occurs.
AR88.70-P-9000GH


*110589035900

2
Install foam (2) onto base of mirror mount

around wiring harness.

3
Reinstall outside rearview mirror (1).

AR88.70-P-9000GH

Replace foam on inside of door around

hole where mirror wiring harness comes

through.

P88.70-2311-11

1
Outside rearview mirror

2
Foam

Mounting wedge

110 589 03 59 00

Parts ordering notes
Part no.

Designation
Quantity

163 682 25 28
Foam
2

Copyright DaimlerChrysler AG 04.08.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1

2001 SYSTEM WIRING DIAGRAMS
Mercedes-Benz - ML320
USING MITCHELL1'S WIRING DIAGRAMS
For information on using these wiring diagrams, see USING MITCHELL1'S SYSTEM WIRING
DIAGRAMS article.
AIR CONDITIONING

2001 Mercedes-Benz ML320
2001 SYSTEM WIRING DIAGRAMS Mercedes-Benz - ML320

2001 Mercedes-Benz ML320
2001 SYSTEM WIRING DIAGRAMS Mercedes-Benz - ML320
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