1997 MERCEDES-BENZ ML430 air filter

Fig. 73: Identifying Automatic Air Conditioning Box Function - Operating Condition Air Ducting Under
Heater Operation
Operating condition: HEATING Function
When in heating mode, the blower motor (5) draws in fresh air (A) to the automatic air conditioning box and
routes it through the multipurpose filter (3). The air cleaned by the multipurpose filter (3) is then routed to the
evaporator core (2) and dried there. The dried, cooled and filtered air (B) is then routed on through the heat
exchanger (1). This air conduction is controlled via the setting of the blending air flaps (6).
The dried, cooled and filtered air (B) is then heated up again in the hot heat exchanger (1). The warm air (C) is
routed via the air outlets (E, F, FR, M and S) into the vehicle interior.
The fresh air/recirculated air flap (4) is closed.
Operating condition: Air ducting in cooling mode

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:16 PMPage 91 © 2006 Mitchell Repair Information Company, LLC.

Fig. 74: Identifying Automatic Air Conditioning Box Function - Operating Condition Air Ducting In
Cooling Mode
Operating condition: cooling. Function
When in cooling mode, the blower motor (5) draws in fresh air (A) to the automatic air conditioning box and
routes it through the multipurpose filter (3). The air cleaned by the multipurpose filter (3) is then routed to the
evaporator core (2) and dried there. The dried, cooled and filtered air (B) is then routed around the heat
exchanger (1). This air conduction is controlled via the setting of the blending air flaps (6).
The dried, cooled and filtered air (B) is routed directly into the passenger compartment via the air outlets (E, F,
FR, M and S). The fresh air/recirculated air flap (4) is closed.
Operating condition: Air ducting in blending mode (hot/cold) closed-loop operation

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:16 PMPage 92 © 2006 Mitchell Repair Information Company, LLC.

Fig. 75: Identifying Automatic Air Conditioning Box Function - Operating Condition Air Ducting In
Blending Mode (Hot/Cold) Closed-Loop Operation
Operating condition: Blend air (warm/cold) Function
When in blending mode, the blower motor (5) draws in fresh air (A) to the automatic air conditioning box and
routes it through the multipurpose filter (3). The air cleaned by the multipurpose filter (3) is then routed to the
evaporator core (2) and dried there. Some of the dried, cooled and filtered air (B) is routed onwards by the heat
exchanger (1) and some is routed around the heat exchanger (1). This air conduction is controlled via the center
setting of the blending air flaps (6).
The dried, cooled and filtered air (B) which was routed through the heat exchanger (1) is then heated up again.
After passing through the blending air flaps (6) this heated air (C) is mixed up to form blend air (D) with the
dried, cooled and filtered air, which was routed around the heat exchanger (1). This blend air (D) is then routed
via the air outlets (E, F, FR, M and S) into the passenger compartment. The fresh air/recirculated air flap (4) is
closed.
Operating condition: Air ducting "recirculation air" in cooling mode

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:16 PMPage 93 © 2006 Mitchell Repair Information Company, LLC.

Fig. 76: Identifying Automatic Air Conditioning Box Function - Operating Condition Air Ducting
Recirculation Air In Cooling Mode
Operating condition: Cooling down "recirculation air" Function
In cooling mode with recirculated air, the blower motor (5) draws in recirculated air (A) from the passenger
compartment via the opened fresh air/recirculated air flap (4) into the automatic air-conditioning box and routes
it through the multipurpose filter (3). The air cleaned by the multipurpose filter (3) is then routed to the
evaporator core (2) and dried there. The dried, cooled and filtered air (B) is then routed around the heat
exchanger (1). This air conduction is controlled via the setting of the blend air flap (6).
The dried, cooled and filtered air (B) is routed directly into the passenger compartment via the air outlets (E, F,
FR, M and S). The supply of fresh-air is cut off by the fresh air/recirculation flap (4).
AUTOMATIC AIR CONDITIONING BOX, DESIGN - GF83.40-P-2105-04GI
The automatic air conditioning box consists of the following components
Air ducting flaps
Combination filter
Blower motor
Blower regulator
Evaporator
Heating system heat exchanger
Expansion valve

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:16 PMPage 94 © 2006 Mitchell Repair Information Company, LLC.

Fig. 82: Locating Evaporator
EVAPORATOR, LOCATION/PURPOSE/DESIGN/FUNCTION - GF83.40-P-2121GC
MODELS 163, up to 31.8.01, 168 with code (580) Air conditioning or Tempmatic for USA
MODELS 163 as of 1.9.01 with code (580a) Automatic air conditioning
FLUID RESERVOIR FUNCTION - GF83.40-P-2122-01GI
Function
The liquefied refrigerant enters the fluid reservoir under pressure and flows through a stainless-steel fabric layer
to the filter block. The filter block's pores are matched exactly to the molecular size of the refrigerant. Thus the
refrigerant can flow through the filter block.
All other matter, primarily water, is held back by this molecular filter and deposited. The cleansed refrigerant
then flows through a rising pipe to the expansion valve.
Evaporator,
locationModel 168GF83.40-P-2121-
02GC
Model 163GF83.40-P-2121-
02GH
Evaporator,
purposeThe evaporator is used to cool, dehumidify and clean the interior
air.
Evaporator,
designThe evaporator is a disk-type evaporator made of soldered
semicircular disks with louvered corrugated fins.
Evaporator,
function GF83.40-P-2121-
01GC

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:16 PMPage 102 © 2006 Mitchell Repair Information Company, LLC.

MODELS 163, up to 31.8.01, 168 with CODE (580) Air conditioning or Tempmatic for USA
MODEL 163 as of 1.9.01 with CODE (580a) Automatic air conditioning
FLUID RESERVOIR, LOCATION/PURPOSE/FUNCTION - GF83.40-P-2153GI
MODEL 163 (except 163.128) as of 1.9.01 with CODE (580a) Automatic air conditioning
Fig. 93: Identifying Fluid Reservoir

Condenser,
locationModel 168GF83.40-P-2120-
02GC
Model 163GF83.40-P-
2120-02GH
Condenser taskThe condenser ensures that the state of the refrigerant coming from
the compressor changes from gaseous to liquid.
Condenser
function GF83.40-P-
2120-01GC
Receiver positionThe fluid reservoir is located in the engine compartment on the
left front next to the condenser
Fluid reservoir,
purposeFiltering chemical and mechanical impurities out of the
refrigerant
Volume reservoir for the refrigerant


2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:16 PMPage 111 © 2006 Mitchell Repair Information Company, LLC.

function 2146GI
Blower motor,
location/purpose/design/function GF83.10-P-
2170GI
Blower regulator, location/purpose/function GF83.10-P-
2141GI
Rear blower motor, location/purpose/design/
function GF83.10-P-
2168GI
Rear electronic blower regulator, location/
purpose/function GF83.10-P-
2176GI
Combination filter, location/purpose/function GF83.10-P-
2128GI
Defroster vent flap actuator motor, location/
purpose/function GF83.10-P-
2175GI
Footwell flap actuator,
location/purpose/function GF83.10-P-
2132GI
Actuator motor, center nozzle flap, location/
purpose/function GF83.10-P-
2172GI
Actuator motor, rear shut-off flap, location/
purpose/function GF83.10-P-
2171GI
Actuator motor, rear air distribution flap,
location/purpose/function GF83.10-P-
2173GI
Heating system heat exchanger, location/
purpose/function GF83.20-P-
2108GC
Heating water circulation pump, location/
purpose/function GF83.20-P-
2109GI
Fresh air/recirculation flap, location/purpose/
function GF83.20-P-
2111GC
Fresh air/recirculation flap actuator, location/
purpose/function GF83.30-P-
2116GC
Blower switch,
location/purpose/design/function GF83.25-P-
2100GI
Blower button, location/purpose/functionRear ventilation operating moduleGF83.40-P-
2144GI
Air distribution switch,
location/purpose/design/ function GF83.25-P-
2101GI
Air distribution button,
location/purpose/functionRear ventilation operating moduleGF83.40-P-
2159GI
Temperature selector wheel, location/purpose/
design/function GF83.25-P-
2102GI
Defroster button, location/purpose/function GF83.40-P-
2139GI
Recirculating air push-button,
location/purpose/ function GF83.40-P-
2145GI
GF83.40-P-

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:16 PMPage 118 © 2006 Mitchell Repair Information Company, LLC.

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
Saturday, October 02, 2010 3:23:18 PMPage 200 © 2006 Mitchell Repair Information Company, LLC.