Page 3441 of 4133

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  
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        Page 3442 of 4133

 Air conditioning system 
DISASSEMBLING, ASSEMBLING A/C HOUSING - AR83.30-P-5201GH 
MODEL 163 with CODE (580) Air conditioning or, in USA, Tempmatic A/C 
13Unclip ETC control module 
(N15/3)  
14Detach connector from blend air 
flap actuator (M16/8)  
15Detach connector from recirculated 
air flap actuator motor (M39)  
16Detach evaporator temperature 
sensor connector (B10/6x1)  
17Detach blower motor series resistor 
connector (6)  
18Detach blower motor connector (5)  
19.1Remove air conditioning control 
module (N19) Only up to 31.08.01.AR83.30-
P-6600GH
20Unclip cable set at evaporator 
housing Installation: Ensure correct routing of 
cable set. 
21Remove sound deadener (2)  
22Detach water drain hose from AC 
housing lower side(1)  
23Remove AC housing (1) Unclip evaporator housing from air 
distributor and remove upward. 
24Install in the reverse order  
25Inspect cooling system for leaks AR20.00-
P-1010HA 
NumberDesignationModel Series 163
BA83.30-P-1003-01BNut to pipeline on expansion valveNM10
 
2001 Mercedes-Benz ML320 
1998-2005 HVAC Climate Control - 163 Chassis  
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        Page 3443 of 4133

Fig. 165: Identifying A/C Housing Components 
 
 Disassembly, assembly  
 
Explosion hazard due to welding or 
brazing work on the closed air 
conditioning system. Poisoning hazard
from inhaling overheated refrigerant 
vapors. Injury hazard from eye or skin 
contact with liquid refrigerant.Never perform welding or brazing work on the 
closed air conditioning system or in its vicinity. 
Smoking and open fire is prohibited. Wear 
protective goggles and protective gloves, only 
work in well ventilated rooms. Perform repair 
work on air conditioning circuit only if system is 
discharged.
AS83.00-
Z-0001-
01A
 Action to be taken in the event air 
conditioning is damaged or leaks 
AH83.30-
N-0004-
01A
 
Protect air conditioning circuit and 
components from moisture during 
repair work
All models with air conditioning
AH83.30-
N-0005-
01A
 Notes on handling R134a refrigerantAll models with R134a refrigerant
AH83.30-
N-0003-
01A
1Remove A/C housing AR83.30-
P-5200GH
2Remove heat exchanger (1) from heater 
housing AR83.20-
P-3400GH
 
2001 Mercedes-Benz ML320 
1998-2005 HVAC Climate Control - 163 Chassis  
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        Page 3444 of 4133

CORRECTING OIL LEVEL IN AIR CONDITIONING FOLLOWING REPAIR OR SLOW REFRIGERANT LOSS - AR83.30-P-
5251E 
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  
3Remove air mixture flap actuator 
(M16/8) AR83.30-
P-2010GH
4Unscrew screws (2) from upper section 
of A/C housing (3)  
5Remove upper section of A/C housing 
(3) Replace gasket between firewall and A/C 
housing 
6Remove dust filter (7) from bottom 
section of A/C housing (5)  
7Remove evaporator (6) AR83.30-
P-5540GH
8Remove evaporator temperature sensor 
(B10/4) AR83.30-
P-8085GH
9Remove blower motor (M2) AR83.30-
P-5560GH
10Reinstall in opposite order  
 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)  
 
2001 Mercedes-Benz ML320 
1998-2005 HVAC Climate Control - 163 Chassis  
me  
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        Page 3445 of 4133

 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  
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        Page 3446 of 4133

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  
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        Page 3447 of 4133

 A/C compressor 
models 140, 
170, 202, 208, 
210Refrigerant 
R134a in 
model 163model 202
BF83.55-P-
1003-01AAdditional oil 
quantity when 
replacing 
condenserCompressor oilcm3202020
Specifications 
for service 
productsSheetBB00.40-P-
0362-00ABB00.40-P-
0362-00ABB00.40-P-
0362-00A
BF83.55-P-
1004-01AAdditional oil 
quantity when 
replacing 
evaporatorCompressor oilcm3404040
Specifications 
for service 
productsSheetBB00.40-P-
0362-00ABB00.40-P-
0362-00ABB00.40-P-
0362-00A
BF83.55-P-
1005-01AAdditional oil 
quantity when 
replacing fluid 
reservoirCompressor oilcm3101010
Specifications 
for service 
productsSheetBB00.40-P-
0362-00ABB00.40-P-
0362-00ABB00.40-P-
0362-00A
BF83.55-P-
1006-01AAdditional oil 
quantity when 
replacing 
suction lineCompressor oilcm3202020
Specifications 
for service 
productsSheetBB00.40-P-
0362-00ABB00.40-P-
0362-00ABB00.40-P-
0362-00A
BF83.55-P-
1007-01AAdditional oil 
quantity when 
replacing 
pressure lineCompressor oilcm3202020
Specifications 
for service 
productsSheetBB00.40-P-
0362-00ABB00.40-P-
0362-00ABB00.40-P-
0362-00A
BF83.55-P-
1008-01AAdditional oil 
quantity when 
replacing A/C 
compressorCompressor oilcm3202020
Specifications 
for service 
productsSheetBB00.40-P-
0362-00ABB00.40-P-
0362-00ABB00.40-P-
0362-00A
BF83.55-P-
1010-01AAdditional oil 
quantity when 
replacing 
evaporator, 
rear air 
conditioningCompressor oilcm3---
Specifications 
for service 
productsSheet---
BF83.55-P-
1011-01AAdditional oil 
quantity when 
replacing rear 
air 
conditioning 
linesCompressor oilcm3---
Specifications 
for service 
productsSheet---
NumberDesignationA/C compressor 
7SE16 in model A/C compressor 
7SE16 in model 
 
2001 Mercedes-Benz ML320 
1998-2005 HVAC Climate Control - 163 Chassis  
me  
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        Page 3448 of 4133

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.