Page 3449 of 4133

 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.  
     
        
        Page 3450 of 4133

Fig. 166: Identifying Expansion Valve Components 
   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 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
1Discharge air conditioning system Installation: Evacuate air conditioning, refill 
and check for proper operation and leaktightness.AR83.30-P-
1760GH
2Unscrew expansion reservoir nuts (1) Lay compensating reservoir to one side. 
 
2001 Mercedes-Benz ML320 
1998-2005 HVAC Climate Control - 163 Chassis  
me  
Saturday, October 02, 2010 3:23:18 PMPage 206 © 2006 Mitchell Repair Information Company, LLC.  
     
        
        Page 3451 of 4133
 Air conditioning system 
REMOVE/INSTALL EVAPORATOR - AR83.30-P-5540GH 
MODEL 163 with CODE (580) Air conditioning or Tempmatic for USA  
Fig. 167: Identifying Evaporator Temperature Sensor Components
3Detach piping bracket (4) from 
expansion valve (6) Installation: Install new self-locking nut (3). 
   *BA83.30-
P-1003-01B
4Detach piping fastening clamps (5) 
from firewall  
5Pull both pipes out of the expansion 
valve (6) Press pipes to the side. 
6Unscrew bolts (7) from expansion 
valve (6) *BA83.30-
P-1004-01B
7Remove expansion valve (6) Installation: Install new sealing rings and 
moisten with compressor oil. 
8Install in the reverse order  
NumberDesignationModel Series 163
BA83.30-P-1003-01BNut to pipeline on expansion valveNM10
BA83.30-P-1004-01BBolt, expansion valve to evaporator coreNM10
 
2001 Mercedes-Benz ML320 
1998-2005 HVAC Climate Control - 163 Chassis  
me  
Saturday, October 02, 2010 3:23:18 PMPage 207 © 2006 Mitchell Repair Information Company, LLC.  
     
        
        Page 3452 of 4133

 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.  
     
        
        Page 3453 of 4133
REMOVE/INSTALL AIR CONDITIONING BLOWER MOTOR - AR83.30-P-5560GH
MODEL 163.113 /128 /136 /154 /157 /172 /174 /175 with CODE (580) Air conditioning or Tempmatic for 
USA  
Fig. 168: Identifying Air Conditioning Blower Motor Components
 
REMOVE/INSTALL BLOWER MOTOR IN REAR - AR83.30-P-5565GH 
MODEL 163.113 /154 /174 #A as of 289565, 163.113 #X as of 754620, 163.128/157/175  
 
 Remove/Install  
1Remove cover (1) under the instrument 
panel (right) Up to VIN A145272, 
X708318.AR68.10-P-
1520GH 
   As of VIN A145273, 
X708319.AR68.10-P-
1520GI 
2Unscrew bolt (2) from blower motor (M2)  
3Disconnect connector from blower motor 
(M2)  
4Remove blower motor (M2) from AC 
housing (3)  
5Install in the reverse order  
 
2001 Mercedes-Benz ML320 
1998-2005 HVAC Climate Control - 163 Chassis  
me  
Saturday, October 02, 2010 3:23:18 PMPage 209 © 2006 Mitchell Repair Information Company, LLC.  
     
        
        Page 3454 of 4133
Fig. 169: Identifying Rear Blower Motor Components 
REMOVE/INSTALL AUXILIARY FAN - AR83.30-P-5600GH 
MODEL 163.136 /154 /157 /172 with CODE (580) Air conditioning or Tempmatic for USA
 
 Remove/install  
1Remove center console AR68.20-P-
2000GH 
2Disconnect rear blower 
motor connector (1, 2)  
3Remove screws (3)  
4Pull out rear blower motor 
(M2/1) to the rear Installation: Ensure that the rear blower 
motor (M2/1) is connected to the air duct 
correctly (4).
 
5Install in the reverse order  
 
2001 Mercedes-Benz ML320 
1998-2005 HVAC Climate Control - 163 Chassis  
me  
Saturday, October 02, 2010 3:23:18 PMPage 210 © 2006 Mitchell Repair Information Company, LLC.  
     
        
        Page 3455 of 4133
Fig. 170: Identifying Auxiliary Fan Components 
REMOVE AND INSTALL RECEIVER/DRIER - AR83.30-P-6520GH 
MODELS 163.113/136/ /154 /157 /172 /174 /175 with CODE (580) Air conditioning or Tempmatic for 
USA  
 
 Remove/install  
1Remove upper frame cross member 
(1) AR62.30-P-
2300GH 
2Unscrew bolts (2) for auxiliary fan 
(M4) at radiator  
3Disconnect additional fan connector 
(M4x1)  
4
Unclip electric cable for outside 
temperature sensor at auxiliary fan 
(M4)
  
5Pull out auxiliary fan (M4) upward
 Installation: Insert additional fan in 
the lower guides first pay attention to 
correct seating.
 
6Install in the reverse order  
 
2001 Mercedes-Benz ML320 
1998-2005 HVAC Climate Control - 163 Chassis  
me  
Saturday, October 02, 2010 3:23:18 PMPage 211 © 2006 Mitchell Repair Information Company, LLC.  
     
        
        Page 3456 of 4133

Fig. 171: Identifying Receiver/Drier Components 
 
 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 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
1Remove upper frame cross member AR62.30-P-
2300GH 
2.1Remove charge air cooler On Model 163.113 only.AR09.41-P-
6817MM
 
2001 Mercedes-Benz ML320 
1998-2005 HVAC Climate Control - 163 Chassis  
me  
Saturday, October 02, 2010 3:23:18 PMPage 212 © 2006 Mitchell Repair Information Company, LLC.