Page 1961 of 4133

LARGER 
CONTAINER FOR 
WINDSHIELD 
WASHER SYSTEM
 Remove  
1Remove radiator 
crossmember AR62.30-P-2300GH 
2Drain the washer fluid 
reservoir Fig. 189
3Remove container (1) Detach hoses and 
connectors. Remove 
screws (2) and disconnect 
from lower grommets. 
4Loosen air conditioning 
hose (3) from clip (4)  
5Detach cooling module 
(10) from lower 
grommets  
 Convert   
6Press out template (5) and 
set to correct dimension 
(a, b) Determine actual 
dimension (a) from 
drawing. Divide target 
dimension (a) by 
determined actual 
dimension (a) and copy 
template with 
corresponding factor to 
original size. 
 Check dimensions for 
both axes. 
7Cut out holes (6) of 
template  
8Using the holes (7), 
position the template on 
the left inner fender and 
fasten in place with 
adhesive tape  
9Center punch body at 
bore (8)  
10Remove template (5).  
11Ø=19 mm bore hole at 
punch mark *WH58.30-Z-1003-34A
12Deburr hole  
 
2001 Mercedes-Benz ML320 
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis  
me  
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        Page 1962 of 4133

Fig. 412: Identifying Hand pump (210 589 00 71 00) 
Commercially available tools 
Parts ordering notes 
13Clean, prime and paint 
hole  
 Install   
14Mount clip (9) into hole  
15Installing larger washer 
fluid reservoir Have someone assist 
you in lifting the cooling 
module. Make sure that 
the container is 
positioned correctly in 
the grommets and that the 
clip is properly seated. 
Fasten inner side of 
container using screws 
(2). Tighten hoses and 
connectors again. Level 
sensor is not required . 
16Mount cooling module 
(10) in grommets again  
17Fasten AC system hose 
(3) onto clip (4) again  
18Install radiator 
crossmember again AR62.30-P-2300GH 
19Fill washer fluid reservoir  
NumberDesignation
WH58.30-Z-1003-34AStep drill bit dia. 16-30.5 mm
Part no.DesignationQuantity
000 986 06 50Priming pin1
163 860 11 60Washer fluid reservoir, 2 pumps 
with level sensor1
 
2001 Mercedes-Benz ML320 
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis  
me  
Saturday, October 02, 2010 3:30:14 PMPage 467 © 2006 Mitchell Repair Information Company, LLC.  
     
        
        Page 1963 of 4133
163 869 00 14Clip1
 
2001 Mercedes-Benz ML320 
1998-2005 ACCESSORIES & BODY, CAB Electrical System - Body - 163 Chassis  
me  
Saturday, October 02, 2010 3:30:14 PMPage 468 © 2006 Mitchell Repair Information Company, LLC.  
     
        
        Page 1964 of 4133
 AR61.20-P-1105GH
Remove/install bottom engine compartment paneling
22.6.00
MODEL 
163.172 with ENGINE 113.942
MODEL 
 163.174 with ENGINE 113.981
MODEL 
 163.175 with ENGINE 113.965
P61.20-2017-12
1
Engine compartment paneling
2
 Grub screw
3
 Plastic clips
 
Remove/Install
1
Remove grub screws (2) of plastic clips (3)
 6 grub screws pins.
 
Installation:
  Check grub screws, replace 
if necessary.
2
Pull out plastic clips (3)
 
Installation:
  Check plastic clips, replace 
if necessary.
3
Remove engine compartment panel (1)
 
Installation:
  Ensure that engine 
compartment panel is positioned correctly.
4
Install in the reverse order
Copyright DaimlerChrysler AG  20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1 
     
        
        Page 1965 of 4133

 AR88.30-P-2000-01GH
Remove brush guard
Modification notes
10.8.01
Value modified from 25 Nm to 49 Nm
Value modified in BA88.30-P-1003-01A for 
model 163 up to 31.8.01
*BA88.30-P-1003-01A
 
Detachable body components, underride guard
Number
Designation
Model 163 
up to 
31.8.01
BA88.30-P-1002-01A
Nut, spacer tube on brush guard
Nm
86
BA88.30-P-1003-01A
Screw, mount on brush guard
Nm
49
BA88.30-P-1011-01A
Bolt, underride guard to brush guard
Nm
25
BA88.30-P-1015-01A
Nut, underride guard to bracket
Nm
49
BA88.30-P-1016-01A
Bolt, front section of underride guard to rear 
section of underride guard
Nm
49
P88.30-2150-06
1.1
 Remove screws (1) and nuts (2) from 
underride guard (3) at bottom of vehicle 
 .
 Only if available.
2
 Remove screw for brush guard (4) from 
inner mount at bottom (5) 
 
3
 Remove nut for spacer tube (6) 
 
4
Remove spacer sleeve (7) from spacer 
tube nut (6).
5
 Remove brush guard (8) toward front.
 Carefully move out brush guard so that 
paint is not damaged.
Copyright DaimlerChrysler AG  20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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        Page 1966 of 4133
 AR88.30-P-2000-01GI
Remove brush guard
 
Detachable body components, underride guard
Number
Designation
Model 
163 
as of 
1.9.01
BA88.30-P-1003-01A
Screw of mount on brush guard
Nm
25
BA88.30-P-1015-01A
Nut of underride guard to bracket
Nm
49
BA88.30-P-1016-01A
Bolt of front section of underride guard to rear 
section of underride guard
Nm
49
P88.30-2153-06
1.1
 Remove screws (1) and nuts (2) of 
underride guard (3) on bottom side of 
vehicle 
.
 Only if available.
2
 Remove screws (4) of bracket on brush 
guard 
.
3
 Remove screws (6) of bracket on brush 
guard behind grommets (7). 
.
4
 Remove brush guard (8).
 Do not damage paintwork.
Copyright DaimlerChrysler AG  20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1 
     
        
        Page 1967 of 4133
 AR88.30-P-2000-01GI
Remove brush guard
 
Detachable body components, underride guard
Number
Designation
Model 
163 
as of 
1.9.01
BA88.30-P-1003-01A
Screw of mount on brush guard
Nm
25
BA88.30-P-1015-01A
Nut of underride guard to bracket
Nm
49
BA88.30-P-1016-01A
Bolt of front section of underride guard to rear 
section of underride guard
Nm
49
P88.30-2153-06
1.1
 Remove screws (1) and nuts (2) of 
underride guard (3) on bottom side of 
vehicle 
.
 Only if available.
2
 Remove screws (4) of bracket on brush 
guard 
.
3
 Remove screws (6) of bracket on brush 
guard behind grommets (7). 
.
4
 Remove brush guard (8).
 Do not damage paintwork.
Copyright DaimlerChrysler AG  20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1 
     
        
        Page 1968 of 4133
 AP82.10-P-8260-04A
Set or inspect fog lamps
P82.10-0205-01
1
The light-dark boundary must be as horizontal as possible at the height of the appropriate 
dividing line (4), correct if necessary.
2
 For model 140 sedan as of approx. 03.94, 168 and 202: Check seat of bulb.
P82.10-3633-01
Model 163.113 /154 #A as of 289565, 
163.113 #X as of 754620, 
163.128 /154 /157 /175 except CODE (U49) Styling package
Arrow:
 Position of adjusting screw
Copyright DaimlerChrysler AG  20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1