1997 MERCEDES-BENZ ML500 oil

Air conditioning system
Workshop equipment
REMOVE/INSTALL DEFROSTER VENT FLAP ACTUATOR MOTOR FOR WINDSHIELD - AR83.30-P-2006GH
MODEL 163.113 /154 /174 #A as of 289565, 163.113 #X as of 754620, 163.128/157/175
4evacuate
Filling
5Supplement oil for refrigerant
compressor The exact quantity determined when
drained must be used.
6Fill air conditioning system *BF83.30-P-
1001-01B
Testing
7Inspect air conditioning system for leaks
with leak detector *WE58.40-
Z-1002-20A

8
Risk of accident. Accidents may result if
the vehicle starts off unintentionally with
the engine running. Risk of injury from
bruises and burns if you hold your hand
near engine when it is started or when it
is running. Check function of air
conditioningSecure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.
Run engine at idle speed for about 4
minutes and check all the component
functions which are of relevance for proper
operation of the air conditioning system.
AS00.00-Z-
0005-01A
NumberDesignationModel Series 163
BF83.30-P-1001-01BRefrigerantsFilling quantityg750
Specifications for Operating FluidsSheetBB00.40-P-0361-00A
WE58.40-Z-1002-20AAir conditioning leak detector
WE58.40-Z-1002-22AAir conditioning service station

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 189 © 2006 Mitchell Repair Information Company, LLC.

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.

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.

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.

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.

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
Saturday, October 02, 2010 3:23:18 PMPage 203 © 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.