Installing larger washer fluid reservoir - SM82.35-P-0002GH

MODELS 163.113/136/154/172 

with 5 I container 

The 5 I washer fluid reservoir has been replaced by a 7.6 I container. If a 5 l container is replaced, then the following modifications must be made.

This modification should ONLY be performed following a customer complaint. 

Fig 1: Identifying Larger Washer Fluid Reservoir Components

Fig 2: Larger Washer Fluid Reservoir Component Locations

	Remove
1	Remove radiator crossmember		AR62.30-P-2300GH
2	Drain the washer fluid reservoir		Figure
3	Remove container (1)	Detach hoses and connectors. Remove screws (2) and disconnect from lower grommets.
4	Loosen air conditioning hose (3) from clip (4)
5	Detach cooling module (10) from lower grommets
	Convert
6	Press 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.
7	Cut out holes (6) of template
8	Using the holes (7), position the template on the left inner fender and fasten in place with adhesive tape
9	Center punch body at bore (8)
10	Remove template (5).
11	Ø=19 mm bore hole at punch mark		*WH58.30-Z-1003-34A
12	Deburr hole
13	Clean, prime and paint hole
	Install
14	Mount clip (9) into hole
15	Installing 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  .
16	Mount cooling module (10) in grommets again
17	Fasten AC system hose (3) onto clip (4) again
18	Install radiator crossmember again		AR62.30-P-2300GH
19	Fill washer fluid reservoir

Fig 3: Identifying Hand pump (210 589 00 71 00)