1997 MERCEDES-BENZ ML320 engine

poisoning from swallowing
coolant.Wear protective gloves, protective
clothing and eye protection.
1Drain coolantEngine 111 in MODEL 163.AR20.00-P-
1142HG
Engines 112 /113 in MODEL 163.AR20.00-
P-1142HA
Engine 628.963 in MODEL 163.128.AR20.00-P-
1142HB
Engine 612.963 in MODEL 163.113.AR20.00-P-
1142M
2.1 Detach
brake line
from the
front end of
the radiator
Only required for right-hand steering.
3.1 Detach
ignition
cable from
the front end
of the
radiator
Only required on right-hand drive vehicles
with ENGINES 111 /112/113.
4Release coolant overflow from
battery shield
5Disconnect upper coolant hose
from the electric coolant pump Detach hose clamp from the upper
coolant hose.
6Unscrew nuts from expansion
reservoir at firewall
7Remove expansion reservoir from
the firewall and lay aside
8Disconnect coolant delivery/return
hoses for heat exchanger (17) Detach hose clamps from coolant
delivery/ return hoses for heat exchanger.
9Discharge air conditioning system
Installation: Evacuate air
conditioning, refill and check for proper
operation and leaktightness.AR83.30-
P-1760GH
10Unscrew self-locking nut (16) at
the expansion valve (15) Replace self-locking nut.
*BA83.30-
P-1003-01B
11
Detach low-pressure refrigerant
line (13) and high-pressure
refrigerant line (14) from expansion
valve (15)
Installation: Install new sealing rings
and moisten with compressor oil.
12Remove instrument panel carrier
(4) AR68.10-
P-1111GH

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 197 © 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.

Air conditioning system
Refrigerant compressor
Fig. 172: Identifying External Torx Set (001 589 76 09 00)
3.1Remove mass air flow sensor on left
behind the charge air cooler On Model 163.113 only: between the air
hose of the charge air cooler and engine.
4Discharge air conditioning system
Installation: Evacuate air conditioning,
refill and check for proper operation and
leaktightness.AR83.30-P-
1760GH
5
Unscrew screw (3) for refrigerant
line (6) to the expansion valve and
screw (4) for refrigerant line (5) from
the condenser at the fluid reservoir
(8)
*BA83.30-
P-1001-01B
6
Remove refrigerant line (5) from
condenser and refrigerant line (6) to
the expansion valve at the fluid
reservoir (8)
Installation: Install new sealing rings
and moisten with compressor oil.
7Release external Torx drive bolt (7)
at fluid reservoir clamp External torx setFig. 172
8Remove fluid reservoir (8) Installation: Note additional oil filling
capacity when replacing the fluid reservoir.*BF83.55-
P-1005-
01A
9Install in the reverse order
NumberDesignationModel Series 163
BA83.30-P-1001-01BHexagon bolt securing refrigerant line to fluid reservoirNM10
NumberDesignationRefrigerant
compressor 7SB16,
refrigerant R134a
in model 163
BF83.55-P-1005-
01AAdditional oil filling
capacity when
replacing fluid
reservoirCompressor oilcm3 10
Specifications for
Operating FluidsSheetBB00.40-P-0362-
00A

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 213 © 2006 Mitchell Repair Information Company, LLC.

Notes on handling refrigerant
R134aAll models fitted with air conditioning
AH83.30-
N-0003-
01A
1.1
Remove
additional
fan (M4)

Models 163.136 /154/157 /172 with air
conditioning or for USA Tempmatic, code
580.AR83.30-
P-5600GH
2.1Remove intercooler Only models 163.113/ 128.
Model 163.113AR09.41-P-
6817MM
Model 163.128AR09.41-P-
6817CD
3Discharge air conditioning system
Installation: Evacuate, refill air
conditioning system and check for proper
operation and tightness.AR83.30-
P-1760GH
4.1Detach lower engine compartment
panelingModel 163.172/174/175AR61.20-
P-1105GH
4.2Remove noise encapsulation Removal: Only remove front part.
Model 163.113/128AR94.30-P-
5400GH
5.1Remove air guide Only if present Located at front
crossmember, in center behind front bumper.
6Unscrew bolts at bottom of
electric fan or fan shroud. Also remove sheet metal nuts.
7Remove attachment parts (20) and
rubber shock absorber(21) Removal: Lower attaching parts and
damper rubber.
Installation: Replace attaching parts.

8Unscrew screw (2) for refrigerant
line at fluid reservoir
*BA83.30-
P-1001-
01B
9Detach refrigerant line from fluid
reservoir Installation: Replace sealing rings and
moisten with compressor oil.
10Unscrew screw (6) for refrigerant
line at condenser(5)
*BA83.30-
P-1002-
01B
11Detach refrigerant line from
condenser (5) Installation: Replace sealing rings and
moisten with compressor oil.
12Detach rubber seal (4) from
radiator (7)
13Remove screws (3)
14.1Remove attachment parts (20) and
rubber shock absorber(21)Model 163.113/128
Upper attaching parts and damper rubber.
Installation: Replace attaching parts.


2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 215 © 2006 Mitchell Repair Information Company, LLC.

Remove/install

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

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
Procedures if air conditioning system
is damaged or leakingAll models
AH83.30-
N-0004-
01A

Protect air conditioning circuit and
components from moisture when
carrying out repair work
All models fitted with air conditioning
AH83.30-
N-0005-
01A
Notes on handling refrigerant R134aAll models fitted with air conditioning
AH83.30-
N-0003-
01A
1Drain coolant J Engine 112, 113.AR20.00-P-
1142HA
Engine 111.AR20.00-P-
1142HG
Engine 612.963.AR20.00-P-
1142M
2Unscrew coolant compensating
reservoir (1) on firewall Lay compensating reservoir to one side.
3Disconnect coolant delivery/return
hoses for heat exchanger (2) Remove hose clamps from coolant hoses.
4Discharge air conditioning system
Installation: Evacuate air conditioning,
refill and check for proper operation and
leaktightness.AR83.30-P-
1760GH
5Remove cover on expansion valve
(4)
6Remove nut (3) on expansion valve
(4) Replace self-locking nut.
*BA83.30-
P-1003-01B
7Disconnect refrigerant lines from
expansion valve Installation: Install new sealing rings
and moisten with compressor oil.

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:19 PMPage 220 © 2006 Mitchell Repair Information Company, LLC.

Fig. 183: Identifying Sun Sensor And Connector
Fig. 184: Identifying Longitudinal Wedge (115 589 03 59 00)

REMOVE AND INSTALL REFRIGERANT COMPRESSOR - AR83.55-P-5300GH
ENGINE 112 in MODEL 163 with CODE (580) Air conditioning or Tempmatic for USA

Remove/install
1Pull sun sensor (B32) upwards out of the
instrument panel Do not damage sun sensor and
instrument panel.
Installation wedgeFig.
184
2Disconnect plug (1) from sun sensor (B32)
3Install in the reverse order

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:19 PMPage 227 © 2006 Mitchell Repair Information Company, LLC.

AC compressor
Refrigerant compressor
2Remove poly V-belt AR13.22-P-
1202B
3
Unscrew hexagon socket head screw
(1) securing low-pressure refrigerant
line (2) to refrigerant compressor (6) Detach low-pressure refrigerant line (2)
from refrigerant compressor (6).
Installation: Install new sealing rings
and moisten with compressor oil.
*BA83.55-
P-1002-01A
4
Unscrew hexagon socket head screw
(3) securing high-pressure refrigerant
line (4) to refrigerant compressor (6)
*BA83.55-
P-1002-01A
5
Detach refrigerant compressor
connector (A9x1) at refrigerant
compressor (6) Installation: Install new sealing rings
and moisten with compressor oil.
6
Unscrew external Torx drive bolt (5)
from refrigerant compressor (6) at
crankcase
External torx setFig. 172
7Remove refrigerant compressor (6)
from below Installation: Note additional oil filling
capacity when replacing the fluid reservoir.*BF83.55-
P-1005-01A
8Install in the reverse order
9Remove receiver/drier
The fluid reservoir must be replaced
every time after the refrigerant compressor
is removed and installed.AR83.30-P-
6520GH

Installation: Note additional oil filling
capacity when replacing the refrigerant
compressor.*BF83.55-
P-1008-01A
NumberDesignationEngines 111.977,112.942,
112.970,113.942/ 965/981
in MODEL 163
BA83.55-P-1002-01ABolt of refrigerant lines to
AC compressorNM20
NumberDesignationRefrigerant
compressor 7SB16,
refrigerant R134a
in model 163
BF83.55-P-1005-
01AAdditional oil filling
capacity when
replacing fluid
reservoirCompressor oilcm3 10
Specifications for
Operating FluidsSheetBB00.40-P-0362-
00A

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:19 PMPage 229 © 2006 Mitchell Repair Information Company, LLC.

AD54.30-P-6000-42GH
IC test of electrical system coolant level

indicator
Model 163 as of 3.98

t
A

Scope of test

Measuring instrument/

Test connection
Operation/Requirement

Specified value
D

Possible cause/Remedy

1.0
Coolant level indicator

electronic switch (S41)

Model 163 as of 3.98

1
w

S41

BL
2

Ignition:
OFF

Disconnect coupling at S41,

connect Ohm decade

device,

set 70 k
W,

Start engine,

wait for up to 1min

Set 30 k
W

wait for up to 1min

Low ECL

indicator lamp

(A1e11)

illuminated

A1e11 goes out

Values in order:

D
Coolant level indicator
electronic switch (S41)

Values not in order:

D
Cables to A1

D
A1

Copyright DaimlerChrysler AG 05.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
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