1997 MERCEDES-BENZ ML320 oil capacity

2
Remove covers at seat frame of 60% bench

seat

As of VIN A145273, X708319.

AR91.12-P-1100GH

Only remove the covers which are
identified in the document with A, D and E.

3
Fold 60% bench seat forward into footwell

As of VIN A145273, X708319. See

operator's manual.

4
Pull floor covering below rear seat mounting

bracket (1) of 60% seat forward

Ensure that the floor covering is not torn

when pulled forward.

As of VIN A145273, X708319.

5
Pull floor covering below front corner of trim

panel of C-pillar (2) forward

Ensure that the floor covering is not torn

when pulled forward.

As of VIN A145273, X708319.

6
Cut into floor covering directly behind seat

retaining cable (5)

Ensure that the wiring harness (4) is not

damaged when cutting into floor covering.

As of VIN A145273, X708319. broken line

marks cut-in.

7
Turn back floor covering to gain access to

cap (84)


Do not kink floor covering.

8
Remove cap (84)


Cap (84) is sealed in with body sealer.

Heat with hot air blower to make it easier to

remove.


Installation:
Replace cap and install with

new sealing compound.

9
Detach fuel feed line (90/12) and fuel return

line (90/11) and, if fitted, the fuel line at

connection (90/13)


Do not kink the fuel lines.


If no stationary heater is fitted to vehicle,

do not remove connection (90/13) otherwise

housing will be damaged.

*163589003700

10
Remove nut (89)

*163589010700


*BA47.20-P-1006-01B

11
Remove housing (3)

Fuel lever sensor and housing are a

single part and cannot be removed separately.


Installation:
Re-install nut (89) together

with seal (89/2).

Apply a thin film of oil to seal.

12
Install in the reverse order


Fuel pump

Number

Designation
Engine 612Engine 628

BA47.20-P-1006-01B
Union nut for fuel tank sensor on fuel

tank
Nm
6565


Fuel tank

Number

Designation
Models

163.113/
136/154/

172 up to

31.08.01
Model

163.113/
136/154/

172 as of

01.09.01


Model

163.157/

175
Model

163.128

BF47.10-P-1001-01A
Fuel tank capacity
Total capacity
Liter
728383

Reserve capacity
Liter
101212

Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2

2000-01 MANUAL A/C-HEATER SYSTEMS
ML 320, ML 430 & ML 55
SPECIFICATIONS
SPECIFICATIONS
DESCRIPTION & OPERATION
A/C CONTROL PANEL
The A/C control panel contains switches to control A/C functions such as blower motor speed, mode control,
i
n-vehicle temperature, A/C on/off, and fresh/recirculated air control. See Fig. 1.
ApplicationSpecification
Compressor TypeNippondenso 7SB16 7-Cyl.
Compressor Belt Tension(1)
Compressor Oil Capacity(2) 5.6-6.3 ozs.
Refrigerant (R-134a) Capacity26.4 ozs.
System Operating Pressures(3)
(1)Belt tension is automatically adjusted by belt tensioner.
(2)Use Densooil 8 (A 001 989 08 03).
(3)Information is not available from manufacturer.
WARNING:To avoid injury from Accidental air bag deployment, read and carefully
follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR
BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY article in
GENERAL SERVICING.

2001 Mercedes-Benz ML320
2000-01 MANUAL A/C-HEATER SYSTEMS ML 320, ML 430 & ML 55

2001 Mercedes-Benz ML320
2000-01 MANUAL A/C-HEATER SYSTEMS ML 320, ML 430 & ML 55
me
Saturday, October 02, 2010 3:25:10 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.
me
Saturday, October 02, 2010 3:25:13 PMPage 1 © 2006 Mitchell Repair Information Company, LLC.

A/C compressor
A/C compressor
CORRECTING OIL LEVEL IN AIR CONDITIONING AFTER REPLACING PARTS - AR83.30-P-5252E
MODEL 163 with CODE (580) Air conditioning or Tempmatic for USA
A/C compressor 7SB16
MODEL 202 with CODE (580) Air conditioning or Tempmatic for USA with CODE (581a) Air
conditioning (Automatic) A/C compressor ND6CA17, A/C compressor 7SB16
MODEL 208 with CODE (580) Air conditioning or Tempmatic for USA with CODE (581a) Air
1If loss of refrigerant is <
400 g (no leakage
detectable) do not add
compressor oil ?
Carry out leak-tightness
test refer to SI83/85
2If loss of refrigerant is >
400 g (leakage detectable)
fill with new compressor
oil, also ? *BF83.55-P-1009-01A

Replace fluid reservoir
Models 202, 208, 210AR83.30-P-6520E
Model 163AR83.30-P-6520GH
Models 215, 220AR83.30-P-6520M
NumberDesignationA/C
compressor
7SB16 in
models 140,
170, 202, 208,
210A/C
compressor
ND6CA17 in
model 202A/C
compressor
7SB16
Refrigerant
R134a in
model 163
BF83.55-P-
1009-01AAdditional oil
capacity when
leakage
detectedCompressor oilcm3202020
Specifications
for service
productsSheetBB00.40-P-
0362-00ABB00.40-P-
0362-00ABB00.40-P-
0362-00A
NumberDesignationA/C compressor
7SE16 in model
215A/C compressor
7SE16 in model
220
BF83.55-P-
1009-01AAdditional oil
capacity when
leakage detectedCompressor oilcm32020
Specifications for
service productsSheetBB00.40-P-
0362-00ABB00.40-P-
0362-00A

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 201 © 2006 Mitchell Repair Information Company, LLC.

CORRECTING OIL LEVEL IN AIR CONDITIONING AFTER SYSTEM SUDDENLY LOSES ALL REFRIGERANT - AR83.30-
P-5253E
MODEL 163 with CODE (580) Air conditioning or Tempmatic for USA A/C compressor 7SB16
MODEL 202 with CODE (580) Air conditioning or Tempmatic for USA with CODE (581a) Air
conditioning (Automatic) A/C compressor ND6CA17, A/C compressor 7SB16
MODEL 208 with CODE (580) Air conditioning or Tempmatic for USA with CODE (581a) Air
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
215220
BF83.55-P-
1003-01AAdditional oil quantity
when replacing condenserCompressor oilcm333
Specifications for
service productsSheetBB00.40-P-0362-
00ABB00.40-P-0362-
00A
BF83.55-P-
1004-01AAdditional oil capacity
when replacing evaporatorCompressor oilcm34040
Specifications for
service productsSheetBB00.40-P-0362-
00ABB00.40-P-0362-
00A
BF83.55-P-
1005-01AAdditional oil quantity
when replacing fluid
reservoirCompressor oilcm31010
Specifications for
service productsSheetBB00.40-P-0362-
00ABB00.40-P-0362-
00A
BF83.55-P-
1006-01AAdditional oil quantity
when replacing suction lineCompressor oilcm32020
Specifications for
service productsSheetBB00.40-P-0362-
00ABB00.40-P-0362-
00A
BF83.55-P-
1007-01AAdditional oil quantity
when replacing pressure
lineCompressor oilcm31010
Specifications for
service productsSheetBB00.40-P-0362-
00ABB00.40-P-0362-
00A
BF83.55-P-
1008-01AAdditional oil quantity
when replacing A/C
compressorCompressor oilcm32020
Specifications for
service productsSheetBB00.40-P-0362-
00ABB00.40-P-0362-
00A
BF83.55-P-
1010-01AAdditional oil quantity
when replacing evaporator,
rear air conditioningCompressor oilcm3-3
Specifications for
service productsSheetBB00.40-P-0362-
00ABB00.40-P-0362-
00A
BF83.55-P-
1011-01AAdditional oil quantity
when replacing rear air
conditioning linesCompressor oilcm3-20
Specifications for
service productsSheetBB00.40-P-0362-
00ABB00.40-P-0362-
00A
Correct oil level

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 204 © 2006 Mitchell Repair Information Company, LLC.

A/C compressor
A/C compressor
REMOVE AND INSTALL EXPANSION VALVE - AR83.30-P-5520GH
MODELS 163.113 /128 /136 /154 /157 /172 /174 /175 with CODE (580) Air conditioning or Tempmatic for
USA

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 defective component and fluid reservoirModels 202,
208, 210AR83.30-P-
6520E
Model 163AR83.30-P-
6520GH
Model 215,
220AR83.30-P-
6520M
2Additionally fill new compressor oil to specified oil capacity *BF83.55-P-
1002-01A
NumberDesignationA/C
compressor
7SB16
Refrigerant
R134a in
model 163A/C
compressor
7SB16 in
models 140,
170,202,208,
210A/C
compressor
ND6CA17 in
model 202
F83.55-P-
1002-01AAdditional oil
capacity after
sudden
emptying of
system (e.g.
ruptured line)Compressor oilcm3404040
Specifications
for service
productsSheetBB00.40-P-
0362-00ABB00.40-P-
0362-00ABB00.40-P-
0362-00A
NumberDesignationA/C compressor
7SE16 in model
215A/C compressor
7SE16 in model
220
BF83.55-P-
1002-01AAdditional oil
capacity after
sudden emptying
of system (e.g.
ruptured line)Compressor oilcm35050
Specifications for
service productsSheetBB00.40-P-
0362-00ABB00.40-P-
0362-00A

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 205 © 2006 Mitchell Repair Information Company, LLC.

Refrigerant compressor

Remove/Install

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. Contact with liquid
refrigerant may result in injury to the
skin and eyes.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
1Remove evaporator housing AR83.30-
P-5200GH
2Remove expansion valve
Installation: Replace sealing rings
between the expansion valve and
evaporator and moisten with compressor
oil.
AR83.30-
P-5520GH
3Disassemble AC housing AR83.30-
P-5201GH
4Remove evaporator (1) from AC
housing Observe oil filling capacity when
replacing the evaporator.

*BF83.55-
P-1004-
01A
5Remove evaporator temperature sensor
(B10/6) AR83.30-
P-8085GH
6Install in the reverse order
NumberDesignationRefrigerant
compressor 7SB16,
refrigerant R134a
in model 163
BF83.55-P-1004-
01AAdditional oil filling
capacity when
replacing evaporatorCompressor oilcm3 40
Specifications for
Service ProductsSheetBB00.40-P-0362-
00A

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 208 © 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.

Air conditioning system
Refrigerant compressor
REMOVE, INSTALL AIR CONDITIONING CONTROL MODULE - AR83.30-P-6600GH
MODELS 163.113/136/154/172/174 up to 31.8.01 with CODE (580) air conditioning or Tempmatic for
USA
15Remove capacitor (5) upward Installation: Note additional oil filling
capacity when replacing the condenser.*BF83.55-
P-1003-
01A
16Install in the reverse order
NumberDesignationModel 163
BA83.30-P-1001-01BHexagon bolt securing refrigerant line to fluid reservoirNm10
BA83.30-P-1002-01BHexagon bolt for refrigerant line to capacitorNm20
NumberDesignationRefrigerant
compressor 7SB16,
refrigerant R134a
in model 163
BF83.55-P-1003-
01AAdditional oil filling
capacity when
replacing condenserCompressor oilcm3 20
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 216 © 2006 Mitchell Repair Information Company, LLC.