MERCEDES-BENZ ML430 1997 Complete Repair Manual

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
Saturday, October 02, 2010 3:30:14 PMPage 466 © 2006 Mitchell Repair Information Company, LLC.

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

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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.

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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.

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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.

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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

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Page 1969 of 4133


AR82.10-P-5103GI
Remove/install fog lamp
27.2.01

MODELS
163.113 /154 #A as of 289565,

163.113 /154 #X as of 754620,

163.128 /157 /175

P82.10-2778-06

1
Lever

2
Fog lamp

3
Electrical connector

4
Grommets


Remove/install

1
Press lever (1) to release the fog lamp (2)

Pulling hook

*140589023300

2
Disconnect fog lamp (2) from front bumper

Exercise caution when pulling at the

edges of the fog lamp.


Installation:
First notch in the fog lamp at

the edges. Ensure that the lever (1) securely

holds the fog lamp in place.

Pulling hook

*140589023300

3
Disconnect electrical connector (3) from fog

lamp

4
Pull off grommets (4)


Installation:
Ensure that the grommets

are installed loosely and without kinks.

5
Install in the reverse order

6
Check fog lamp adjustment and adjust if

necessary

e

Check and correct headlamp adjustment

AP82.10-P-8260GH

Pulling hooks
140 589 02 33 00

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Page 1970 of 4133


AP82.10-P-8260GH
Check and correct headlamp adjustment
2.7.97

MODEL
163

a=Marking for low beams

b=Marking for high beams

c=Marking for fog lamps

P82.10-0212-02


Check

1
Drive vehicle to level surface
The vehicle level must not change when the

brakes are applied.

Vehicle must be in ready-for-the-road

condition (unladen weight, fuel tank full or

proper additional weight).

Correctly adjust tire pressure.

Load driver's seat with 75 kg or a person

(except USA)

2
Align headlamp adjustment tester to vehicle

and adjust height according to marking in lens

Follow the operating instructions for

headlamp beam setting equipment exactly

*WH58.30-Z-1002-09A


Danger!

Risk of accident
from vehicle starting off by

itself when engine running.
Risk of injury


suffered in the form of bruises or burns to the

hands when reaching in while the engine

cranks or runs
Secure vehicle to prevent it from moving off

by itself.

Wear closed and close-fitting work clothes.

Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

3
Run engine and switch on low beam

4
Check headlamp range control for proper

function
(except USA)


The light beams from both headlamps should

change uniformly

5
Set headlamp range control switch to position 0

6
Check low beams
Adjust if necessary (except USA)

AP82.10-P-8260-01A


Due to the common reflector unit, the low

beams, high beams and fog lamps are

adjusted simultaneously.

US version:
#

See "Owner's Manual"

7
Check high beam adjustment

AP82.10-P-8260-02A

8
Check fog lamps

AP82.10-P-8260-04A

Commercially available tools
(see Workshop Equipment Manual)

Number

Designation
Make (e.g.)
Order number

Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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