1997 MERCEDES-BENZ ML500 charging

by vehicle starting off by
itself when engine is
running. Risk of injury
caused by contusions and
burns during starting
procedure or when
working near the running
enginefrom moving by itself.
Wear closed and snug-fitting
work clothes.
Do not grasp hot or rotating
parts.
4Start engine
5Check function of charge
indicator lamp when
engine is idling and with
increasing engine speed
(up to 3000 rpm) Charge indicator lamp
must extinguish.
6Load battery (G1) using a
permanent consumer and
check regulation voltage
of alternator (G2)Engines 111, 112, 113*BE15.40-P-1001-02A
Engines 612, 628*BE15.40-P-1001-02C
Volt ampere tester with
load resistance*WH58.30-Z-1002-09A
Volt ampere tester ETT
011.00*WH58.30-Z-1003-09A
Regulation voltage > 15.0
V: ?
Replace regulator

Engine 628

Engines 111, 112, 113
Replace alternator
(G2)
AR15.40-P-5760GH
Engine 612
Regulation voltage < 13.0
V: ?
Check electrical
connections for
charging system for
transition resistances;
repair if necessary.

Electrical connections OK: ?
AR15.40-P-5032GI
Check alternator (G2)
diodes AR15.40-P-9301-02EA

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 55 © 2006 Mitchell Repair Information Company, LLC.

Check values for regulator
Check values for regulator
Commercially available tools
CHECKING CHARGING CURRENT OF ALTERNATOR - AR15.40-P-5011GH
Engine tester with
oscilloscope
If diodes are faulty: ?
Replace alternator
(G2)
*WH58.30-Z-1046-13A
Engine 111, 112, 113AR15.40-P-5032GH
Engine 612AR15.40-P-5032GI
Engine 628AR15.40-P-5032IA
7Turn off engine
8Disconnect volt ampere
tester (079) Volt ampere tester with
load resistance*WH58.30-Z-1002-09A
Volt ampere tester ETT
011.00*WH58.30-Z-1003-09A
NumberDesignationEngines 103,104,111,
112,113,119, 120,
137, 155, 166, 275
BE15.40-P-1001-
02ARegulating voltage
(at battery)Loading: only on
permanent consumerV13 to 15
Engine speedrpm3000
measured afterminapprox.2
NumberDesignationEngines
601,602,603, 604,
605, 606,
611,613,628, 646,
647, 668Engine 612
except 612.966
BE15.40-P-
1001-02CRegulating
voltage (at
battery)Loading: only on
permanent
consumerV13 to 1513 to 15
Engine speedrpm30003000
measured afterminapprox.2approx.2
NumberDesignation
WH58.30-Z-1002-09AVolt-amp(s) tester with load resistance (no longer
available)
WH58.30-Z-1003-09AVolt ampere tester
WH58.30-Z-1046-13AEngine tester with oscilloscope

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 56 © 2006 Mitchell Repair Information Company, LLC.

ENGINES 111.977, 112.942/970, 113.942/965/981, 612.963, 628.963 in MODEL 163
Fig. 31: Identifying Checking For Alternator Charging Current

Modification notes
18.10.05Charging current of
alternatorEngine 111*BE15.40-P-1001-01A
Checking
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 batteriesNo fire, sparks, open flames
or smoking. Wear acid-
resistant gloves, clothing
and goggles. Only pour
battery acid into suitable
and appropriately marked
containers.AS54.10-Z-0001-01A
Notes on battery AH54.10-P-0001-01A
1Check regulation voltage
of alternator AR15.40-P-5010GH
2Connect volt ampere
tester (079) with current
clamp (065) according to Volt ampere tester with
load resistance*WH58.30-Z-1002-09A
Volt ampere tester ETT *WH58.30-Z-1003-09A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 57 © 2006 Mitchell Repair Information Company, LLC.

connection diagram011.00
Risk of accident caused
by vehicle starting off by
itself when engine is
running. Risk of injury
caused by contusions and
burns during starting
procedure or when
working near the running
engineSecure vehicle to prevent it
from moving by itself.
Wear closed and snug-
fitting work clothes.
Do not grasp hot or rotating
parts.AS00.00-Z-0005-01A
3Start engine
4Load battery (G1) with
volt ampere tester (079)
and check charging
current of alternator (G2)
with increased engine
speed Vary load resistance
long enough until the
maximum load current is
achieved; when this is
done, the regulating voltage
must not drop below 12.7
V.
Engines 111, 612*BE15.40-P-1001-01A
Engines 112, 113*BE15.40-P-1001-01K
Engine 628*BE15.40-P-1001-01J
Volt ampere tester with
load resistance*WH58.30-Z-1002-09A
Volt ampere tester ETT
011.00*WH58.30-Z-1003-09A
Charging current below
desired value: ?
Check diodes for
alternator (G2).
AR15.40-P-9301-02EA
Engine tester with
oscilloscope
If diodes are faulty: ?
Replace alternator
(G2)
*WH58.30-Z-1046-13A
Engines 111, 112, 113AR15.40-P-5032GH
Engine 612AR15.40-P-5032GI
Engine 628 with water-
cooled alternator (G2)AR15.40-P-5032IA
Engine 628 with air-cooled
alternator (G2)AR15.40-P-5032GD
5Turn off engine
6Disconnect volt ampere
tester (079) with current Volt ampere tester with
load resistance*WH58.30-Z-1002-09A

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 58 © 2006 Mitchell Repair Information Company, LLC.

Check values for alternator
Check values for alternator
Check values for alternator
Commercially available tools
clamp (065) Volt ampere tester ETT
011.00*WH58.30-Z-1003-09A
NumberDesignationEngine 111 in
models 163, 203
Engine 111 in
models 202, 208
with code 910
Bosch/ ValeoEngine 612 in
models 163,203,
209, 210, 463
Delphi
BE15.40-P-1001-
01ACharging current
of alternatormax.A120190
min.A90150
Engine speedrpm25002500
RatioI=2.932.53
NumberDesignationEngine 628.963
in model 163
NF 14V 150AEngine 628.963
in model 163
E10 14V 90-
200A
BE15.40-P-1001-
01JCharging current
of alternatormax.A150200
min.A120160
Engine speedrpm25002500
RatioI=2.82.93
NumberDesignationEngine 112 in
models 163, 170,
202, 203, 208,
209, in model 210
without code 978,
in model 211
without code 910,
Bosch/ValeoEngine 113 in
models
163,171,203,208,
209,210,211,215,
219, 220, 230 except
models 211.076/276,
215.374, 219.376,
220.074/174,
230.472/474 Bosch
BE15.40-P-
1001-01KCharging
current of
alternatormax.A120150
minA90120
Engine speedrpm25002500
RatioI=2.932.93
NumberDesignation
WH58.30-Z-1002-09AVolt-amp(s) tester with load resistance (no longer
available)

2001 Mercedes-Benz ML320
1998-2005 ENGINE Electrical System - Engine - 163 Chassis
me
Saturday, October 02, 2010 3:18:54 PMPage 59 © 2006 Mitchell Repair Information Company, LLC.

GENERAL NOTES: PASSENGER CARS - AH00.01-Z-0998AZ
MODEL all
Notes on TowingMODEL 461, 463AH00.60-P-0100-
02GA
Overall vehicle
Overall vehicleFG00AH00.00-Z-9999AZ
Engine
Complete engine,
crankcase ventilation,
cylinder head, crankcaseFG01AH01.00-Z-9999AZ
Crank assemblyFG03AH03.00-Z-9999AZ
Engine timingFG05AH05.00-Z-9999AZ
Mixture formationFG07AH07.00-Z-9999AZ
Air intake, superchargingFG09AH09.00-Z-9999AZ
Electrical system - engineFG15AH15.00-Z-9999AZ
Engine lubrication,
engine oil coolingFG18AH18.00-Z-9999AZ
Engine cooling systemFG20AH20.00-Z-9999AZ
Engine suspensionFG22AH22.00-Z-9999AZ
Throttle control, cruise
control systemFG30AH30.00-Z-9999AZ
Fuel systemFG47AH47.00-Z-9999AZ
Exhaust systemFG49AH49.00-Z-9999AZ
Chassis
Manual transmissionFG26AH26.00-Z-9999AZ
Automatic transmissionFG27AH27.00-Z-9999AZ
Frame, trailer operationFG31AH31.00-Z-9999AZ
SuspensionFG32AH32.00-Z-9999AZ
Rear axleFG35AH35.00-Z-9999AZ
Wheels, chassis
alignment checkFG40AH40.00-Z-9999AZ
Brakes - hydraulic and
mechanical systemsFG42AH42.00-Z-9999AZ
Brakes - pneumatic
system and auxiliary
brakesFG43AH43.00-Z-9999AZ
SteeringFG46AH46.00-Z-9999AZ
Electrical system,
equipment and
instrumentsFG54AH54.00-Z-9999AZ

2004 Mercedes-Benz ML350
1998-2005 GENINFO Overall vehicle - 163 Chassis
me
Saturday, October 02, 2010 3:47:44 PMPage 10 © 2006 Mitchell Repair Information Company, LLC.

NOTES ON HANDLING REFRIGERANT R134A - AH83.30-N-0003-01A
Air conditioning with refrigerant R134a
The refrigerant R134a is colorless and odorless.
At normal temperatures it is neither toxic nor flammable, and will not explode in the air, no matter what its
mixing ratio.
The R134a refrigerant may only be used in air conditioning systems for which R134a has been specifically
approved.
The refrigerant R134a must not be mixed with other refrigerants (e.g. R12).
The refrigerant R134a does not contain any chlorofluorocarbons (CFC). In contrast to other refrigerants (e.g.
R12) it is not hazardous to the environment at normal temperatures. The refrigerant R134a does not damage the
earth's ozone layer.
Despite these benefits, refrigerant R134a may only be extracted by experts with suitable extraction, recycling
and filling equipment that includes integral disposal and reprocessing capabilities.
CONDUCT IF AIR CONDITIONING SYSTEM IS DAMAGED OR LEAKING - AH83.30-N-0004-01A
All models
The air conditioning system should never be operated if it is damaged or when there is evidence of refrigerant
loss.
In the event that refrigerant is lost, lubrication can fail. This will lead to damage of the refrigerant compressor.
Evacuate damaged and/or leaking air conditioning refrigerant circuits as quickly as possible using extraction,
processing and recharging equipment with integral disposal and reprocessing capabilities.
PROTECT AIR CONDITIONING CIRCUIT AND COMPONENTS FROM MOISTURE WHEN CARRYING OUT REPAIR
WORK - AH83.30-N-0005-01A

Protect air conditioning circuit and
components from moisture when carrying
out repair work
MODEL 240AH83.30-P-
0005-01H

Protect air conditioning circuit and
components from moisture when carrying
out repair work
MODEL 164, 199, 203, 209, 251 ...AH83.30-P-
0005-01P

Protect air conditioning circuit and
components from moisture when carrying
out repair work
MODEL 199AH83.30-P-
0005-01SLR
Notes on removing and installing the air
conditioner housingMODEL 209, 463 ...AH83.30-P-
0006-01GM

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:14 PMPage 3 © 2006 Mitchell Repair Information Company, LLC.

ultimately cause the system to burst. For this reason, all welding and soldering operations on or near closed
air conditioning systems are prohibited. High pressure levels can combine with refrigerant vapors to produce a
mixture that is potentially explosive when exposed to atmospheric air.
Risk of poisoning
Refrigerant can decompose when overheated. The resulting substances are toxic and should never be inhaled.
Risk of injury
Refrigerant vapors are heavier than air; this means that escaping gases pose a risk of suffocation for anyone in a
work pit beneath the vehicle.
Contact with liquid refrigerant may cause chilblain-like damage to the skin (due to under-cooling).
Safety instructions/precautions
All welding, brazing and soldering operations on sealed air conditioning systems and in their
immediate vicinity are prohibited.
Never smoke when working with refrigerant, never expose refrigerant to open flames.
A piercing odor can indicate overheated refrigerant - never inhale these vapors. Leave closed rooms
immediately and ventilate thoroughly.
All refrigerant must be evacuated from the entire air conditioning system prior to doing any repair work
on the air conditioning circuit or components.
Because it poses a hazard to the atmosphere as well as to personal health and safety, discharging
refrigerant directly into the air is prohibited.
Suitable evacuation, treatment and charging devices equipped with integral disposal and treatment
facilities must be used for evacuating refrigerant.
Even after the system has been evacuated, residual pressure may still be present in the system when
loosening couplings. Therefore, loosen the couplings carefully, so that the pressure can dissipate slowly.
Avoid all contact with liquid refrigerant.
Always wear safety glasses and protective gloves when working with refrigerant.
First aid measures
In case of eye contact
Immediately flush with plenty of running water and consult a physician.
In case of skin contact
Consult a physician immediately in case of frostbite. In case of inhalation
of concentrated refrigerant, immediately take victim out into the fresh air and keep victim calm.

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 154 © 2006 Mitchell Repair Information Company, LLC.