liquid MERCEDES-BENZ ML320 1997 Complete Owner's Guide

If the victim's breathing is shallow, or the individual has stopped breathing altogether, tilt the head back
and administer artificial resuscitation. Call a doctor.
In case of ingestion
Consult a physician immediately.
SAFETY INFORMATION: CLIMATE CONTROL - AS83.00-Z-9999ZZ
MODEL all
TROUBLE DIAGNOSIS
AIR CONDITIONING SOMETIMES DOES NOT WORK - AF83.30-P-6000B
MODEL 124, 126, 129, 140, 163, 168, 170, 201, 202, 208, 210
Modification notes

Risk of explosion. Explosions may result when performing
welding or soldering work on a closed air conditioning system.
Risk of poisoning. Poisoning may result from inhaling
overheated refrigerant vapors. Risk of injury. Contact with
liquid refrigerant may result in injury to the skin and eyes.
MODEL 240AS83.00-P-
0001-01H
Risk of death caused by contact with current conducting parts
when repairing parts of the external power supplyMODEL 639, 903 ...
AS83.00-
Z-0002-
01A

Risk of explosion caused by welding or soldering work on
closed air conditioning system. Risk of poisoning caused by
inhaling overheated refrigerant vapors. Risk of injury to skin
and eyes caused by contact with liquid refrigerant.
MODEL all
AS83.00-
Z-0001-
01A
Hazard from contact with parts conducting high voltages.
MODEL all with CODE
(H25) Eberspacher D 30
W with CODE (H26)
Webasto DW 300AS83.70-
Z-0001-
01A

Risk of explosion caused by fuel vapors igniting, risk of
poisoning caused by inhaling combustible gases and risk of
injury caused by burns during and after operation of heater unitMODEL all with heater,
additional heating or
stationary heatingAS83.70-
Z-0002-
01A

Risk of explosion from liquefied petroleum gas flowing out
and from fuel vapors. Risk of poisoning from inhaling
combustion gases.
BODY 940, 972 ...
AS83.70-
Z-0004-
01A
Risk of poisoning due to inhalation of heater exhaust gases
MODELS 901, 902, 903,
904, 905 for underfloor
heatersAS83.70-
Z-0005-
01A
1.9.99Supersedes STIP 83.30-007 dated 15.8.97

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:17 PMPage 155 © 2006 Mitchell Repair Information Company, LLC.

Fig. 157: Checking Draining, Evacuating And Refilling Air Conditioning Function
Draining

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
1
Connect the connector (blue) (3) of the
filling unit (1) to the Schrader valve of
the high-pressure line and the connector
(red) (2) to the Schrader valve of the
suction line.
During all steps, the operating instructions
for the particular filling unit must be
followed.

*WE58.40-
Z-1002-22A
2Discharge air conditioning system
3
Drain separated oil for refrigerant
compressor out of the inspection glass for
the filling unit and determine the quantity
exactly
Drained quantity must be replaced by fresh
oil for refrigerant compressor.
Evacuate
Clean air conditioning system and

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 188 © 2006 Mitchell Repair Information Company, LLC.

Fig. 164: Identifying Evaporator Housing Components (2 Of 2)

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
Risk of injury to skin and eyes
suffering scalding from contact
with hot coolant spray. Risk of
Do not open cooling system unless
coolant temperature is below 90°C. Open
cap slowly and release the pressure. Do
not pour coolant into beverage bottles.
AS20.00-Z-
0001-01A

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 196 © 2006 Mitchell Repair Information Company, LLC.

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
me
Saturday, October 02, 2010 3:23:18 PMPage 199 © 2006 Mitchell Repair Information Company, LLC.

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.

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.

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.

INSTALL/REMOVE CONDENSER - AR83.30-P-6540GH
MODELS 163.113 /128 /136 /154 /157 /172 /174 /175 with CODE (580) Air conditioning or Tempmatic for
USA
Illustrated on model 163.154
Fig. 173: Identifying Condenser Components


Remove/Install

Risk of explosion caused by
welding or soldering work on
closed air conditioning system.
Risk of poisoning caused by
inhaling overheated refrigerant
vapors. Risk of injury to skin and
eyes caused by contact with liquid
refrigerant.Never perform welding work on or near a
closed air conditioning system. No smoking
or open flames. Wear safety glasses 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
Conduct 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

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:18 PMPage 214 © 2006 Mitchell Repair Information Company, LLC.

REMOVE/INSTALL OUTSIDE AIR TEMPERATURE SENSOR - AR83.30-P-8086GH
MODELS 163.113 #A up to 289564, 163.154 #A as of 145272 up to 289564, 163.172 #A as of 145272,
163.174 #A up to 289564, 163.113 #X up to 754619, 163.136 #X as of 708319, 163.154 #X as of 708319 up
to 754619, 163.172 #X as of 708319 with CODE (580) Air conditioning or Tempmatic for USA
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
2Disassemble AC housing AR83.30-
P-5201GH
3Unclip evaporator temperature sensor
(B10/6) from evaporator (1)
4Install in the reverse order

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:19 PMPage 218 © 2006 Mitchell Repair Information Company, LLC.

Remove/install

Risk of injury to skin and eyes
suffering scalding from contact with
hot coolant spray. Risk of poisoning
from swallowing coolant.
Do not open cooling system unless coolant
temperature is below 90°C. Open cap slowly
and release the pressure. Do not pour
coolant into beverage bottles.
Wear protective gloves, protective clothing
and eye protection.
AS20.00-Z-
0001-01A

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
1Drain coolant J Engine 112, 113.AR20.00-P-
1142HA
Engine 111.AR20.00-P-
1142HG
Engine 612.963.AR20.00-P-
1142M
2Unscrew coolant compensating
reservoir (1) on firewall Lay compensating reservoir to one side.
3Disconnect coolant delivery/return
hoses for heat exchanger (2) Remove hose clamps from coolant hoses.
4Discharge air conditioning system
Installation: Evacuate air conditioning,
refill and check for proper operation and
leaktightness.AR83.30-P-
1760GH
5Remove cover on expansion valve
(4)
6Remove nut (3) on expansion valve
(4) Replace self-locking nut.
*BA83.30-
P-1003-01B
7Disconnect refrigerant lines from
expansion valve Installation: Install new sealing rings
and moisten with compressor oil.

2001 Mercedes-Benz ML320
1998-2005 HVAC Climate Control - 163 Chassis
me
Saturday, October 02, 2010 3:23:19 PMPage 220 © 2006 Mitchell Repair Information Company, LLC.