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1998 ML320
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Discussion Starter · #1 ·
I have a 1998 ML320 with manual controls for cabin temperature, that is I don't select a temperature. My problem is my A/C works intermittently, and my mechanic tells me he doesn't know what else to do since it is cooling properly when he has assessed it. I've reviewed multiple posts on A/C issues on MBWorld, but did not find others reporting intermittent issues like mine.

The technician says he has "hooked it up to the computer" and it checks fine, has checked freon level, etc.

The problem has only been noticed since the arrival of Spring. This ML 320 had its compressor replaced about two years ago. I was told at the time that there was an issue with the fuse box that commonly occurs as a result of the compressor failure, but they were able to repair the fuse box rather than replace it. Two years ago, I was told if future issues with the A/C cropped up that they might have to replace it. I may need to remind them of that. I wonder if that is my next step, but hate to start shot-gunning replacement parts without a best guess at the cause.

On some trips it works immediately on starting the vehicle and continues to work for the duration, which is typically 10 miles to work or back. On other trips, it does not cool at all, and I don't feel the compressor cycling when I am at stop lights. On some trips it doesn't come on initially, but does start cooling abruptly after driving a few miles. I can tell immediately when it starts running by temperature and humidity of the conditioned air, and feeling the compressor cycling.

Could this be due to borderline freon level causing the system to only intermittently allow the compressor to run? But, they've told me the freon pressure was tested and is fine. Is it an intermittent electrical connection that is causing the compressor not to cycle?

When the compressor was replaced two years ago, they put fluorescent dye in the AC system to help find leaks future leaks. Last fall I was beginning to notice the AC not cooling as well as it had earlier in the year, but it would cool every time it was turned on. I took the truck into the shop last January to get the A/C working for the coming heat, and they found that the A/C condenser was leaking. They also found the radiator was leaking. The A/C condenser, receiver/dryer, an A/C pressure line, and radiator were replaced per the parts list. I don't know if the AC worked after these repairs as it was a cold time in winter, and I didn't have a need to run it for a while. Then with the increasing number of warm days, I noticed the A/C was only working intermittently.

I planned to take it in for the intermittent AC, but before I could, a new issue arose with the air duct motor that controls the outside air/heat mixing door. I had that replaced, and that control is working well now. While there for the mixing door issue, I asked them to check the AC. They said they could not replicate an intermittent lack of A/C, but on the trip home my wife said it would not come on. It worked the next 4 drive, then did not come on, and works intermittently as described above since then.

There are no other shops for import repair here in Tupelo, MS, and I believe the technician is competent and knowledgable, having worked on MBs for 20 years. What should I ask the technician to do/check next to troubleshoot the intermittent issue?

Thanks for your assistance,

Justin
 

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2000 ML320 (x2)
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614 Posts
If the blend motor has already been replaced, Id gather more information.

If I had to guess, Id say electrical, non condensibles in the system, bad pressure sensors or or stuck expansion valve. Pretty broad though, eh?

Id start by seeing when the fans come on. Do the come on with ac not working? (If they do, they will shut off after a while. After sitting for a time, can you feel the compressor kick on when the ac is started but not working?
 

· Outstanding Contributor
2006 ML500 2002 ML320
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The actuation of the A/C compressor is not fuse or relay related. The power to the compressor comes directly from the AAM and is unfused.

The only thing that is fuse box related with the A/C system was that fuse #44 , which controls the Aux. Fans, would blow. Since the system works on and off and there is no overheating, fuse #44 cannot be blown.

But the prongs on fuse 44 could be heat corroded because of the high amperage draw and if the fuse prongs do not make constant contact inside the fuse box the fans will shut down and then the compressor will shut down.

Remove it and if the prongs are blackened, get an emery board from your wife and clean the prongs with the smooth side of the emery board. Then insert and withdraw the fuse repeatedly in an attempt to clean the contacts inside the fuse slots.

The next thing to do is check fuse #41 to see if it is blown or not. If it is blown you probably have a seized Coolant Circ. Pump. Fuse 41 also controls the small blower fan in the fuse box which is responsible for cooling the fuse box modules therein.

If fuse 41 is not blown you must still check the Coolant Cir. Pump. With a cold eng. and with the key in pos. #2 , feel with your hand that it is working.

The next step is to check the small blower motor in the fuse box. Remove both plastic covers to the fuse box and then the three additional screws and pull the fuse module up and out of the fuse box and turn it upside down onto a folded towel.

Then locate the blower motor and see if it is operating, which it probably isn't.

Whatever component is not working must be replaced.

It is expected that you conduct these procedures and not your mechanic because you must know what is operating or not.

Post back with results.
 

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1998 ML320
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16 Posts
Discussion Starter · #4 ·
If the blend motor has already been replaced, Id gather more information.

If I had to guess, Id say electrical, non condensibles in the system, bad pressure sensors or or stuck expansion valve. Pretty broad though, eh?

Id start by seeing when the fans come on. Do the come on with ac not working? (If they do, they will shut off after a while. After sitting for a time, can you feel the compressor kick on when the ac is started but not working?
Thanks.

Just knowing the possibilities and their relative likelihood is helpful to pass on to my technician so he can troubleshoot.

I'll have to observe for the AC condenser fan operation.

I cannot feel the compressor cycle on and off when the AC is not working, but can when it is running.

Best.

Justin
 

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1998 ML320
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16 Posts
Discussion Starter · #5 ·
The actuation of the A/C compressor is not fuse or relay related. The power to the compressor comes directly from the AAM and is unfused.

The only thing that is fuse box related with the A/C system was that fuse #44 , which controls the Aux. Fans, would blow. Since the system works on and off and there is no overheating, fuse #44 cannot be blown.

But the prongs on fuse 44 could be heat corroded because of the high amperage draw and if the fuse prongs do not make constant contact inside the fuse box the fans will shut down and then the compressor will shut down.

Remove it and if the prongs are blackened, get an emery board from your wife and clean the prongs with the smooth side of the emery board. Then insert and withdraw the fuse repeatedly in an attempt to clean the contacts inside the fuse slots.

The next thing to do is check fuse #41 to see if it is blown or not. If it is blown you probably have a seized Coolant Circ. Pump. Fuse 41 also controls the small blower fan in the fuse box which is responsible for cooling the fuse box modules therein.

If fuse 41 is not blown you must still check the Coolant Cir. Pump. With a cold eng. and with the key in pos. #2 , feel with your hand that it is working.

The next step is to check the small blower motor in the fuse box. Remove both plastic covers to the fuse box and then the three additional screws and pull the fuse module up and out of the fuse box and turn it upside down onto a folded towel.

Then locate the blower motor and see if it is operating, which it probably isn't.

Whatever component is not working must be replaced.

It is expected that you conduct these procedures and not your mechanic because you must know what is operating or not.

Post back with results.
Thank you 43sqd for your knowledge and very detailed recommendations. I will work through the items and report back.

Best,
Justin
 

· Registered
1998 ML320
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16 Posts
Discussion Starter · #6 ·
43sqd-

I checked both fuse #44 and fuse #41 . Both are intact with perfectly clean contacts.

You next asked me to check the coolant circulating pump. Thus far this week, for 5 trips to work and 5 trips home, the air conditioning has worked perfectly. It is in the mid 80s today. I have not checked to see if the coolant circulating pump is is working with my hand, as requested, because there have been no problems with A/C operation, and I presume that the A/C would not work adequately at the time if the circulating pump was not working at the time. Is this correct?

If so, next time I have an intermittent failure of operation I will check it. The good news for checking this pump manually is that that the engine should be cool. As best I can recall, the system doesn't stop working during a trip. It seems only to not work on some trips from start up to completion, or it doesn't work for the first 4-5 miles, and then suddenly starts working.

Thanks for your assistance,

Justin
 

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No, the AC will work fine on a 1998 with a bad aux pump. A failed aux pump burned up the AAC board on later MLs that had the auto temp controls.
 

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1998 ML320
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16 Posts
Discussion Starter · #8 ·
Intermittent AC function

43sqd and Noodles:

This morning I was able to complete the recommendations that 43sqd provided in troubleshooting the intermittent air conditioning function.

fuse #44 : intact, clean contacts. The auxiliary fans cycle off and on when A/C is on

fuse #41 : intact, clean contacts.

auxillary coolant circulating pump: With key in position #2 and engine cold, I cannot feel that it is running nor hear any function with a stethoscope coming from the pump.

fuse box blower: with engine cold and key in position #2 , I cannot feel that the motor is running nor hear it with a stethescope. Does this fan run at all times with key in position #2 or is it on a thermostat?

I recall hearing fluid movement sounds from the engine compartment after shut down, but not recently. I read today that the auxiliary coolant pump protects the engine from hot spots after shut down and circulates coolant to the heater core for more rapid cabin heat after start up. How does the auxiliary coolant pump and inoperative fuse box blower relate to my intermittent air conditioning function (doesn't work sometimes from start up to shut down, other times doesn't work for 5 miles then suddenly works, most often working immediately on start up for the whole trip)?

Noodles indicates above that the AAC board could be damaged with failure of an auxiliary coolant pump in later MLs than mine with auto temperature controls. What is the mechanism for an engine coolant motor failure causing electrical system damage, overemperature of the electronics by heat radiated directly from the engine?

Should my auxilary engine coolant pump be replaced to reduce the chance of hot spots in the engine after shut down?

Thanks for your assistance,

Justin
 

· Outstanding Contributor
2006 ML500 2002 ML320
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17,942 Posts
Justin, the Coolant Cir. Pump must be replace because its function is now non existent. It's as simple as that.

The small blower motor in the fuse box provides cooling to the fuse box and all the modules in the fuse box. If that does not operate, the modules heat up and the AAM (which turns on the compressor) is very susceptible to intermittent operation if it isn't cooled properly. It is a known issue on this forum.

So, all in all, this might correct your problem or it might not. But regardless, they must be replaced any how.

There will be no burnt board as that is only for 2002+ models.
 

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Discussion Starter · #13 ·
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