Model Designation Internal:
W163
Product Name:
Mercedes Benz M Class ML320 ML350 ML430 ML500 M55 Complete Workshop Service Repair Manual 1997-2005
Production Years Covered:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Vehicle Class:
Luxury SUV
Key Selling Points Of Vehicle:
Off-road capability, luxury appointments, powerful engines, robust build quality
Competitors Era:
BMW X5, Lexus RX, Land Rover Discovery, Volvo XC90
Value Proposition:
Empowers owners to perform their own repairs, saving significant costs on dealership labor.
User Friendliness:
Easy-to-follow step-by-step instructions and illustrations
Accessibility:
Downloadable to PC, Mac, tablets, and smartphones
Market Segment:
North America, Europe, Global
Model Variants Covered:
ML320, ML350, ML430, ML500, ML55 AMG
Engine Variants Covered:
All engine types for specified models
Trim Levels Covered:
All trim levels
Transmission Types Covered:
All transmission types (e.g., Automatic)
Estimated Page Count:
Detailed, likely exceeding 1000 pages
Type:
Complete Workshop Service Repair Manual
Digital Format:
Downloadable PDF
Powertrain:
Engine mechanical, lubrication, cooling, fuel, exhaust, ignition, emissions control, engine management (ECU/DME)
Transmission Drivetrain:
Automatic transmission (e.g., 5G-TRONIC 722.6), transfer case, drive axles, differentials, prop shafts, CV joints
Chassis Suspension:
Front and rear suspension components, steering system, wheels, tires, wheel alignment
Brakes:
Brake system hydraulics, ABS, ASR, ESP, brake pad and rotor replacement, parking brake
Electrical:
Battery, charging system, starter, lighting (interior/exterior), instrument cluster, body control module (BCM), power windows, mirrors, seats, door locks, wipers, horns
HVAC:
Heating, ventilation, air conditioning (manual and automatic climate control), refrigerant handling
Body:
Body construction, exterior panels, interior trim, doors, hood, tailgate, glass, seals, chassis components
Comfort Convenience:
Seats (manual/power), sunroof, audio system, navigation system (if equipped), remote keyless entry
Maintenance:
Routine maintenance schedules, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement
Repair:
Component removal and installation, troubleshooting guides, diagnostic procedures, component testing, adjustment procedures
Diagnostics:
Troubleshooting charts, symptom-based diagnostics, common fault codes (OBD-II), electrical system diagnostics
Disassembly Assembly:
Step-by-step instructions for complete disassembly and reassembly of major components and systems
Depth:
Comprehensive, covering all aspects from basic maintenance to in-depth engine and transmission overhauls
Diagnostic Level:
Advanced diagnostics, including electrical schematics and component testing procedures
Repair Level:
Full repair procedures, including engine rebuild, transmission overhaul, and structural repairs
Engine Ml320:
3.2L M112 E32 V6 (SOHC 18V)
Engine Ml350:
3.7L M112 E37 V6 (SOHC 18V) - Primarily post-2003
Engine Ml430:
4.3L M113 E43 V8 (SOHC 24V)
Engine Ml500:
5.0L M113 E50 V8 (SOHC 24V) - Primarily post-2002
Engine Ml55 Amg:
5.4L M113 E55 V8 (SOHC 24V) - AMG tuned
Ml320 Horsepower:
Approx. 215-218 hp @ 5750 rpm
Ml320 Torque:
Approx. 229-232 lb-ft @ 3000-4500 rpm
Ml430 Horsepower:
Approx. 268 hp @ 5500 rpm
Ml430 Torque:
Approx. 284 lb-ft @ 3000-4500 rpm
Ml500 Horsepower:
Approx. 292 hp @ 5600 rpm
Ml500 Torque:
Approx. 339 lb-ft @ 2800-4500 rpm
Ml55 Amg Horsepower:
Approx. 349 hp @ 5500 rpm
Ml55 Amg Torque:
Approx. 376 lb-ft @ 3000-4250 rpm
Fuel Type:
Premium Unleaded Gasoline
Injection System:
Electronic Fuel Injection (EFI)
Coolant Type:
MB Approved Antifreeze/Coolant (e.g., ZEREX G-05 or equivalent)
Type:
5-speed automatic transmission (722.6 '5G-TRONIC')
Type:
N/A (Automatic standard across all models)
Drive System:
4MATIC All-Wheel Drive (AWD)
Transmission Fluid Type:
MB Approved ATF (e.g., Shell ATF 134 or equivalent)
Transfer Case:
Integrated with AWD system, often with low-range gearing option for ML models
NHTSA Front Impact Driver:
Good (for models tested during the period)
NHTSA Front Impact Passenger:
Good (for models tested during the period)
Stability Control:
Electronic Stability Program (ESP) standard on most models
Traction Control:
All-Season Traction Control (ASR) standard
Antilock Brakes:
Anti-lock Braking System (ABS) standard
Airbags Front:
Dual front airbags
Airbags Side:
Optional side-impact airbags
Seatbelts:
Three-point seat belts with pretensioners
Audio System Options:
Factory-installed AM/FM stereo with CD player, optional Bose sound system.
Navigation:
Optional factory navigation system (COMAND 2.0/2.5).
Parking Sensors:
Optional Parktronic parking assist system.
Cruise Control:
Standard cruise control system.
Bluetooth:
Optional Bluetooth phone integration (e.g., UHI interface).
Oil Change Interval:
Every 10,000 miles or 12 months, whichever comes first (using synthetic oil).
Transmission Fluid Service:
Recommended at 40,000-60,000 miles (check manual for specific model year recommendations).
Coolant Flush:
Typically every 30,000-50,000 miles or 2-3 years.
Engine Oil Spec:
API SM or higher, ACEA A3/B4, SAE 0W-40 or 5W-40 synthetic (check owner's manual for exact MB approval number).
Power Steering Fluid:
MB Approved Hydraulic Fluid (e.g., CHF 11 S or equivalent, specific to model)
Common Problem Interior Plastics:
Deterioration of interior plastic trim and soft-touch surfaces due to age and UV exposure.
Common Problem ABS Esp Sensors:
Failure of ABS/ESP sensors or control modules, leading to warning lights and system malfunction.
Common Problem Cooling System:
Leaking coolant hoses, radiator, or water pump; potential for head gasket issues on some V6 engines.
Common Problem Transmission:
Transmission fluid leaks, 'limp mode' activation, or shifting issues, often related to the conductor plate or valve body.
Common Problem Window Regulators:
Window regulator failure, causing windows to drop into the door panels.
Brand Legacy:
Mercedes-Benz, established reputation for luxury, engineering, and durability.
First Generation W163:
Introduced in 1997 as Mercedes-Benz's first entry into the SUV market, blending luxury car comfort with off-road capability.
Mid-Cycle Refresh:
Facelifted for the 2002 model year, featuring updated styling, interior refinements, and engine enhancements.
Manufacturing Location:
Tuscaloosa, Alabama, USA
