Page 1753 of 4133

REMOVE/INSTALL XENON HEADLAMP CONTROL UNIT - AR82.10-P-4632GH 
MODEL 163.113 #X up to 754619, 163.113 /154 #A up to 289564, 163.172 with CODE (612) Xenon 
UV light, hot 
components on xenon 
headlamps and glass 
splinters when xenon 
bulbs burst 
Risk of poisoning 
through inhalation of 
mercury vapor and 
swallowing of or skin 
contact with toxic salts 
and mercury compoundsprotective gloves. Remove 
highly inflammable 
materials from the hazard 
area. Ensure that the 
workplace is sufficiently 
ventilated.
1Remove left front lamp 
unit (E1) or right front 
lamp unit (E2) AR82.10-P-4730GH
2Remove cover from rear 
of lamp unit  
3Turn left headlamp range 
adjustment motor 
(E1m1) or right 
headlamp range 
adjustment motor 
(E2m1) to right and 
remove from left front 
lamp unit (E1) or right 
front lamp unit (E2) Left side: 1/4 clockwise 
rotation. Right side: 1/4 
counterclockwise rotation. 
4Unhook adjusting 
support and remove left 
headlamp range 
adjustment motor 
(E1m1) or right 
headlamp range 
adjustment (E2m1)  
5Install in the reverse 
order  
6Set headlamps to zero 
position using STAR 
DIAGNOSIS  
7Inspect headlamp 
adjustment, correct if 
necessary.  
 Check and correct 
headlamp adjustment AP82.10-P-8260GH
 
2001 Mercedes-Benz ML320 
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis  
me  
Saturday, October 02, 2010 3:30:09 PMPage 258 © 2006 Mitchell Repair Information Company, LLC.  
     
        
        Page 1754 of 4133

headlamp unit  
MODEL 163.174 #A up to 289564  
Fig. 159: Identifying Xenon Headlamp Control Unit Components
 
  Remove/install  
 Risk of death caused by 
high voltage levels 
present at xenon 
headlamps. 
Risk of explosion/fire 
hazard through highly 
flammable material in 
the area of damaged 
xenon bulbs. 
Risk of injury through 
UV light, hot 
components on xenon 
headlamps and glass 
splinters when xenon 
bulbs burst. 
Risk of poisoning 
through inhalation of 
mercury vapor and Do not come into contact 
with parts that are under 
high voltage. Persons with 
active electronic implants 
(e.g. heart pacemakers) must 
never work on xenon 
headlamps. Switch off 
complete lighting system. 
Wear insulating safety 
shoes, safety glasses and 
protective gloves. Remove 
highly inflammable 
materials from the hazard 
area. Ensure that the 
workplace is sufficiently 
ventilated.AS82.10-Z-0001-01A
 
2001 Mercedes-Benz ML320 
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis  
me  
Saturday, October 02, 2010 3:30:09 PMPage 259 © 2006 Mitchell Repair Information Company, LLC.  
     
        
        Page 1755 of 4133

Fig. 160: Identifying Long Wedge (115 589 03 59 00) 
REMOVE/INSTALL XENON HEADLAMP CONTROL UNIT - AR82.10-P-4632GI 
MODEL 163.113 #X as of 754620, 163.113 /154 /174 #A as of 289565, 163.128/157/175  
swallowing of or skin 
contact with toxic salts 
and mercury compounds.
1Remove left front lamp 
unit (E1) or right front 
lamp unit (E2) AR82.10-P-4730GH
2Remove cover from rear 
of lamp unit  
3Detach plug (1, 2) on 
xenon headlamp control 
unit(E1n1, E2n1)Turn connector 1/4U turn 
counterclockwise. 
4Remove xenon headlamp 
control unit (E1n1, 
E2n1) Carefully press control 
unit off of mount using long 
wedge 
   Long wedgeFig. 155
5Install in the reverse 
order  
6Set headlamps to zero 
position using STAR 
DIAGNOSIS  
7Inspect headlamp 
adjustment, correct if 
necessary.  
 Check and correct 
headlamp adjustment AP82.10-P-8260GH
 
2001 Mercedes-Benz ML320 
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis  
me  
Saturday, October 02, 2010 3:30:09 PMPage 260 © 2006 Mitchell Repair Information Company, LLC.  
     
        
        Page 1756 of 4133

Fig. 161: Identifying Xenon Headlamp Control Unit Components 
  Remove/install  
 Risk of death caused by 
high voltage levels 
present at xenon 
headlamps. 
Risk of explosion/fire 
hazard through highly 
flammable material in the 
area of damaged xenon 
bulbs. 
Risk of injury through 
UV light, hot components 
on xenon headlamps and 
glass splinters when 
xenon bulbs burst. 
Risk of poisoning 
through inhalation of 
mercury vapor and 
swallowing of or skin 
contact with toxic salts 
and mercury compounds.Do not come into contact 
with parts that are under 
high voltage. Persons 
with active electronic 
implants (e.g. heart 
pacemakers) must never 
work on xenon 
headlamps. Switch off 
complete lighting system. 
Wear insulating safety 
shoes, safety glasses and 
protective gloves. 
Remove highly 
inflammable materials 
from the hazard area. 
Ensure that the 
workplace is sufficiently 
ventilated.AS82.10-Z-0001-01A
1Remove left front lamp 
unit (E1) or right front  AR82.10-P-4730GH
 
2001 Mercedes-Benz ML320 
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis  
me  
Saturday, October 02, 2010 3:30:09 PMPage 261 © 2006 Mitchell Repair Information Company, LLC.  
     
        
        Page 1757 of 4133
REMOVE/INSTALL TURN SIGNAL LAMPS - AR82.10-P-4725GH 
MODELS 163.113 /154 /174 #A as of 289565, 163.113 #X as of 754620, 163.128/157/175  
Turn signal lamp in exterior mirror  
Fig. 162: Identifying Turn Signal Lamp Components
 
lamp unit
2Place headlamp in 
inverted position on 
workbenchPlace on a soft base so 
that the headlamp lens is 
not scratched. 
3Remove bolts (1) 3 each. 
4Remove Xenon headlamp 
control unit Is unplugged 
automatically when 
removed. 
5Install in the reverse order  
6Set headlamps to zero 
position using STAR 
DIAGNOSIS  
7Inspect headlamp 
adjustment, correct if 
necessary.  
 Check and correct 
headlamp adjustment AP82.10-P-8260GH
  Remove/install  
1Remove exterior mirror  AR88.70-P-9040GI 
 
2001 Mercedes-Benz ML320 
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis  
me  
Saturday, October 02, 2010 3:30:09 PMPage 262 © 2006 Mitchell Repair Information Company, LLC.  
     
        
        Page 1758 of 4133
REMOVE/INSTALL HEADLAMP UNIT - AR82.10-P-4730GH 
MODEL 163.113 /128 /136 /154 /157 /172 /174 /175  
Fig. 163: Identifying Headlamp Unit Components
 
paneling (4)
2Unscrew screw (2) of turn 
signal lamp (3) in the 
exterior mirror paneling 
(4)  
3Remove turn signal lamp 
(3) from the exterior 
mirror paneling (4)  
4Install in the reverse order  
  Remove/Install  
1Open engine hood  
2Unlock cover (1) at the 
clip (arrow A) under the 
lamp unit and unhook Installation: Lock 
clip again. 
3Unscrew screw (2)  
4Unscrew nuts (3). Installation: Align 
the lamp unit so that the  
 
2001 Mercedes-Benz ML320 
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis  
me  
Saturday, October 02, 2010 3:30:09 PMPage 263 © 2006 Mitchell Repair Information Company, LLC.  
     
        
        Page 1759 of 4133

INSTALLING AUXILIARY CABLE HARNESS ON SIDE WALL TAILLAMP - AR82.10-P-4920-01GH 
Models 163.154/174 as of VINA289565 to VIN A371934, model 163.175 up to VIN A371934 with USA 
version code 494a  
1. Insert plug (1) of auxiliary cable harness (2) in socket (3) of side-marker lamp.  
2. Insert the plug on the other end of the wiring harness in the free connection pins in the opening (4) of the 
lamp support (5). 
 The brown line (ground) should be on the outside. Ensure that the plugs are completely pushed onto 
the connection pins. 
3. Seal the lines and opening (4) with a thermoplastic adhesive gun. 
 Give the adhesive sufficient time to dr
y before installing the taillamp.
distance of the cover to 
the bumper is even.
5Unhook left front 
headlamp unit (E1) or 
right front headlamp unit 
(E2) from the hole (arrow 
B) using drift (4) and pull 
forwards  
6Disconnect headlamp 
harness connector (X24)  
7Remove headlamp unit 
toward front  
8Install in the reverse order  
9Perform function check  
10Check and correct 
headlamp adjustment  
 Check and correct 
headlamp adjustment AP82.10-P-8260GH
 
2001 Mercedes-Benz ML320 
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis  
me  
Saturday, October 02, 2010 3:30:09 PMPage 264 © 2006 Mitchell Repair Information Company, LLC.  
     
        
        Page 1760 of 4133
Fig. 164: Identifying Auxiliary Cabl e Harness On Side Wall Taillamp 
REMOVE/INSTALL SIDE WALL TAILLAMP - AR82.10-P-4920GH 
MODEL 163   
Fig. 165: Identifying Side Wall Taillamp
 
  Remove/Install  
 
2001 Mercedes-Benz ML320 
1998-2005 ACCESSORIES & BODY, CAB Electr  ical System - Body - 163 Chassis  
me  
Saturday, October 02, 2010 3:30:09 PMPage 265 © 2006 Mitchell Repair Information Company, LLC.