1997 MERCEDES-BENZ ML500 ad blue

Fig. 130: Identifying Fuse And Relay Module, Additional Fan Connector And Plug Connector, Blue
NO REFRIGERATION/HEAT FROM AUTOMATIC AIR CONDITIONER - AF83.40-P-3400A
MODEL 163.### #A as of 289565 up to 458809, 163.### #X as of 754620 up to 777100
Operation no. of operation texts or standard texts and flat rates
If an auxiliary wiring harness (2) has not yet been
installed: ?
3 Install auxiliary wiring harness.SM83.30-P-
0009GH

If an additional wiring harness and a 40 A fuse are
already installed and the auxiliary fan does not
function: ?
4 Perform corresponding diagnosis and repair.

CategoryOp. no.Operation textTimeAcc. no.Code
P831917Replace air conditioning operating unit014 WU--
Damage
codeCauseRemedy
83 491 90The air mixing flap is not actuated by the AAC [KLA]
control and operating unit (N22) because the voltage in
the vehicle electrical system is too low during cold start.
1 Replace AAC [KLA]
control and operating
AR83.40-P-

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 157 © 2006 Mitchell Repair Information Company, LLC.

Fig. 131: Identifying Heater Capacity, Function Check, Heater
HEATER, DIAGNOSIS, FUNCTION CHECK - AD83.20-P-3000GH
MODEL 163
Heater, diagnosis, basic knowledge AD83.20-P-2000GH
Check fuses F1/6, F1/41, F1/43

Allow engine to idle at operating
temperature (approx. 80°C engine coolant
temperature) throughout the entire test
period

Outside temperature > 15°C
Open center and side air outlets manually
Recirculated air button ( ) is not
pressed (LED does not come on)
Blower switch on stage 4
Function check
Test
step/Scope of
test
Operation/Requirement Specified value Possible cause/ Remedy
1
No heat Heater switch on "blue" stopAir outlets,
unheated airWire cable for
actuating blend air
flap

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 161 © 2006 Mitchell Repair Information Company, LLC.

AIR CONDITIONING (TEMPMATIC) DIAGNOSIS OPERATIONAL CHECK - AD83.30-P-3000GH
MODEL 163 with CODE (580) air conditioning or for USA, Tempmatic

Air conditioning (Tempmatic)
(Tempmatic A/C) diagnosis,
previous knowledge
AD83.30-P-2000GH
Function check
Test step/Scope
of test Operation/Requirement Specified value Possible cause/ Remedy
1
Temperature selector on "white
zone" ( ) function switch
illuminated
Air from center level.AD83.30-P-6000-01GH
Air drying Air upwards.AD83.30-P-6000-02GH
Air distribution switch at 12 o'clockA/C compressor ON .
AD83.30-P-6000-03GH
AD83.30
-P-6000-04GH
AD83.30
-P-6000-05GH
AD83.30
-P-6000-06GH
AD83.30
-P-6000-07GH
AD83.30
-P-6000-08GH
AD83.30
-P-6000-09GH
2
Temperature selector on "white
zone" function switch
illuminatedAir downwards and
upwards.AD83.30-P-6000-08GH
Normal setting
in control mode A/C compressor ON .AD83.30-P-6000-09GH
Air distribution switch at 4 o'clock
Flow of temperature-
controlled air from
center level as well.
Coolant circulation
pump runs.

3
Temperature selector engaged on
"blue" function switch not
illuminatedAir from center level
(ambient air)AD83.30-P-6000-08GH
Normal mode
without heating
mode
A/C compressor OFF.
Air distribution switch at 9 o'clock
4
Temperature selector on "red" stop
function switch not
illuminatedHeated air
downwards, upwards
and from center level.
AD83.30-P-6000-08GH
Normal mode in
heating mode
Air distribution switch at 4 o'clockA/C compressor
OFF.

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 168 © 2006 Mitchell Repair Information Company, LLC.

Fig. 157: Checking Draining, Evacuating And Refilling Air Conditioning Function
Draining

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
1
Connect the connector (blue) (3) of the
filling unit (1) to the Schrader valve of
the high-pressure line and the connector
(red) (2) to the Schrader valve of the
suction line.
During all steps, the operating instructions
for the particular filling unit must be
followed.

*WE58.40-
Z-1002-22A
2Discharge air conditioning system
3
Drain separated oil for refrigerant
compressor out of the inspection glass for
the filling unit and determine the quantity
exactly
Drained quantity must be replaced by fresh
oil for refrigerant compressor.
Evacuate
Clean air conditioning system and

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 188 © 2006 Mitchell Repair Information Company, LLC.

conditioning (Automatic) A/C compressor 7SB16
MODEL 210 with CODE (580) Air conditioning or Tempmatic for USA with CODE (581a) Air
conditioning (Automatic) A/C compressor 7SB16
MODELS 215,220 A/C compressor 7SE16
A/C compressor
Correct oil level

Carry out work quickly, compressor oil is
hygroscopic
When evacuating refrigerant, the quantity of
compressor oil evacuated must be added again
to refrigerant circuit when refilling air
conditioning (new oil)

1Replace A/C compressor, additionally fill with
new compressor oil *BF83.55-P-
1008-01A
2Replace condenser and additionally fill with new
compressor oil *BF83.55-P-
1003-01A
3Replace evaporator and additionally fill with
compressor oil *BF83.55-P-
1004-01A
4Replace fluid reservoir and additionally fill with
compressor oil *BF83.55-P-
1005-01A
5
Replace suction pipe from evaporator to A/C
compressor and additionally fill with new
compressor oil
*BF83.55-P-
1006-01A
6
Replace pressure pipe from A/C compressor to
condenser and additionally fill with new
compressor oil
*BF83.55-P-
1007-01A
7Additional oil quantity when replacing
evaporator, rear air conditioning Model 220*BF83.55-P-
1010-01A
8Additional oil quantity when replacing rear air
conditioning lines Model 220*BF83.55-P-
1011-01A
9Switch on air conditioning and allow engine to
run at idle speed for approx. 4 minutes
Turn temperature thumb wheel of
center nozzles to stop in blue range, or
on automatic air conditioning to "Lo"
Blower at max.

10Check function of air conditioning
Air output temperature at center
nozzle must not fall below + 5
0 C, if
necessary ? Carry out diagnosis
NumberDesignationA/C
compressor
7SB16 in A/C
compressor
7SB16 A/C
compressor
ND6CA17 in

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 202 © 2006 Mitchell Repair Information Company, LLC.

side
4
Disconnect blue connector
(ML/B) from bottom of fuse
holder

5Remove lamp unit AR82.10-P-
4730GH
6
Remove original additional
fan connector (M4x1) from
additional fan and fasten to
present wiring harness (5)
with adhesive tape on clip
(6)

Install
7
Route new additional fan
connector (3) on auxiliary
wiring harness (2) to
additional fan connector and
insert
Route along original wiring harness at rear of
installation opening of lamp unit
8
Fasten auxiliary wiring
harness (2) to original wiring
harness in area of clips with
cable straps.

9
Fasten auxiliary wiring
harness ground cable (1) to
left front ground (W9)
*BA54.10-
P-1017-01C
10
Route auxiliary wiring
harness (2) into fuse and
relay module
Route fuse and relay module along wiring harness
for fuse and relay module (4) below installation
opening of lamp unit between washer water reservoir
and fender to grommet on left side of fuse and relay
module. Remove adhesive tape from rubber
grommet, thread wiring harness through and reinstall
adhesive tape.

11
Route connection terminal
of auxiliary wiring harness
(2) to blue connector
(ML/B) at bottom of fuse
holder

12
Open housing of connector
(ML/B) and remove lead
from plug location 1

13
Separate present lead
approx. 100 mm in front
connection terminal

Insert connection terminal
for auxiliary wiring harness
Ensure that connection terminal arrests correctly

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:19 PMPage 232 © 2006 Mitchell Repair Information Company, LLC.

Battery
Parts ordering notes
14
(2) into plug location 1 of
connector (ML/B) and close
connector housing.in connector.

15
Insert blue connector
(ML/B) at bottom of fuse
holder and fasten auxiliary
wiring harness (2) to
separated lead with adhesive
tape
Ensure that stripped wire ends are insulated with
adhesive tape.
16
Fasten fuse holder to fuse
and relay module with
screws

17Insert new 40 A fuse at
position f44 in fuse holder The larger line diameter of the auxiliary wiring
harness (2) allows installation of a 40 A fuse.
18Install in the reverse order
19Check function of additional
fan
NumberDesignationModel 163
BA54.10-P-1017-01CNut, ground cable to bodyNm18
Part no.DesignationQuantity
163 540 00 35Auxiliary wiring harness1
910153 000000Fuse, 40 A1

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:19 PMPage 233 © 2006 Mitchell Repair Information Company, LLC.

P 182P PRO.TYP C209-227 (M112 E26)
P 182U ALMANDINSCHWARZ METALLICLACK
P 183 722.331+602.9 UNTERTAGEAUSFUEHRUNG
P 183P PRO.TYP C209-228 (M271 E18DEML)
P 184P PRO.TYP C209-229 (M271 E18DEML)
P 185 UNTERSCHIEDSTEILE BEI 4MATIC M112
P 185P PRO.TYP C209-208/FWC3 (M271 E18DEML)
P 185U MELANITSCHWARZ - METALLICLACK
P 186 BARLUK-PUMPE BEI T1N
P 186P PRO.TYP C209-209/FWC4 (M113 E43)
P 187 EINSATZCODE FUER AGGREGATEABWICKLUNG
P 187P PRO.TYP C209-211/FWC2 (M112 E32)
P 188 KRAFTSTOFFLEITUNG BEI M111 FUER NFZ
P 188P PRO.TYP C209-214/FK19 (M113 E50)
P 189 MOTORLEITUNGSSATZ/BATTERIELEITUNG
P 189O SMARAGDSCHWARZ - METALLICLACK
P 189P PRO.TYP C209-231 (M271 E18DEML)
P 189U SMARAGDSCHWARZ - METALLICLACK
P 190 VERLAGERUNG GENERATOR/KEILRIPPENRIEMEN T1N M111
P 190P VORLAEUFIG UNGUELTIG
P 191 MECH. BREMSUNTERDRUCKPUMPE MIT AUTOM.GETRIEBE M111
P 191A AUSSTATTUNG NACH PA I
P 191P VORLAEUFIG UNGUELTIG
P 192 AENDERUNG DER DOKUMENTATION WERK DUESSELDORF M111
P 192A AUSSTATTUNG NACH PA I
P 193 VERLAENGERUNG HEIZWASSERSTUTZEN M111
P 194 EINSATZCODE FUER AGGREGATEABWICKLUNG
P 195U METEORGRAU - METALLICLACK
P 196 EINSATZCODE FUER AGGREGATEABWICKLUNG
P 196A AUSSTATTUNG NACH PA I
T 196L TYPPRUEFUNG/HOMOLOGATION
P 197 VERLAGERUNG EMO
P 197O OBSIDIANSCHWARZ - METALLICLACK
P 197U OBSIDIANSCHWARZ - METALLICLACK
P 198 KUNDENTAUGLICHKEIT
P 198A AUSSTATTUNG NACH PA I
P 199 NEUE MOTORENBAUMUSTER M111 FUER NFZ
T 1999 LACKFARBE GELB MB 1999
P 199A AUSSTATTUNG NACH PA I
P 199U BLAUSCHWARZ - METALLICLACK
P 200A LEDER
P 200B BEDIENUNGSANLEITUNG U.WARTUNGSHEFT-DAENISCH
P 200K 17-ZOLL-BEREIFUNG FUER ALLRADFAHRZEUGE
P 200L DEUTSCHLAND
T 200L VORRAT INLAND
P 200P TA 1004/1005 1011- 1026 - 9903
P 201A LEDER SCHWARZ/GRAFIT/ANTHRAZIT
P 201B BEDIENUNGSANLEITUNG U.WARTUNGSHEFT-NIEDERLAENDISCH
P 201L BR DEUTSCHLAND
P 201P TA 1001-9948
P 202 BETRIEBSANLEITUNG UND WARTUNGSHEFT - DEUTSCH
P 202A LEDER BLAU/BLAUVIOLETT/TEALBLUE/PAZIFICBLAU
P 202B BEDIENUNGSANLEITUNG U.WARTUNGSHEFT-DEUTSCH
P 202D FEDERN NACH EDV-PROGRAMM
P 202G GROSSVERSUCH
P 202K KUNDENWUNSCH
P 202P TA 1002- 9949
P 202S UNVERCODETE SONDERAUSFUEHRUNGEN
P 202V VERSUCHSSTUECKLISTE
P 202Z ZWISCHENAUSFUEHRUNG
P 203B BEDIENUNGSANLEITUNG U.WARTUNGSHEFT-RUSSISCH
P 203D FEDERN NACH EDV-PROGRAMM
P 203G GROSSVERSUCH
P 203K KUNDENWUNSCH
P 203L NDL - REGENSBURG