MERCEDES-BENZ ML430 1997 Complete Repair Manual

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

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1998-2005 HVAC Climate Control - 163 Chassis
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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

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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

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1998-2005 HVAC Climate Control - 163 Chassis
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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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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

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1998-2005 HVAC Climate Control - 163 Chassis
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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.

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
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Saturday, October 02, 2010 3:23:18 PMPage 206 © 2006 Mitchell Repair Information Company, LLC.