🏷️ Basic Information

Make:

Mercedes-Benz

Model:

ML320

Model Code:

W163

Generation:

First Generation

Production Years:

1997-2005

Chassis Code:

W163

👋 Introduction

Vehicle Class:

Luxury Mid-size SUV / Sport Utility Vehicle

Segment:

Premium SUV segment, competing with brands like BMW X5, Lexus RX, and Land Rover Discovery.

Key Competitors:

BMW X5 (E53), Lexus RX (XU10), Land Rover Discovery II, Jeep Grand Cherokee (WJ).

Offroad Capability:

Known for its blend of luxury and respectable off-road capability, especially with the 4MATIC all-wheel-drive system and available off-road packages (though often not heavily utilized by typical owners).

Luxury Appointments:

Typical Mercedes-Benz interior quality, comfort features, and advanced (for its time) technology.

Powertrain Options:

Primarily known for its smooth and powerful V6 engine, offering a refined driving experience.

Target Audience:

Service technicians, dealership repair shops, and knowledgeable DIY car owners undertaking maintenance and repairs.

📋 Manual Details

Primary Coverage:

Mercedes-Benz ML320 (W163) models

Year Coverage:

1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005

Estimated Pages:

Hundreds of pages (exact count not specified but implied to be comprehensive)

Type:

Factory Service Repair Manual

Language:

English

Format:

Download PDF

📖 Manual Coverage

Engine:

Comprehensive diagnosis, repair, overhaul, and specifications for all ML320 engines offered during the W163 generation (primarily M112 V6).

Transmission:

Detailed service and repair procedures for the automatic transmission (e.g., 722.6 NAG1), including hydraulic systems, electronic controls, and torque converter.

Drivetrain:

Front and rear axle assemblies, differential service, driveshafts, CV joints, and transfer case (4MATIC all-wheel drive system).

Brakes:

Front and rear brake system service, ABS, ESP (Electronic Stability Program), brake fluid flush, caliper and rotor replacement.

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, ball joints, bushings, and steering linkage.

Steering:

Power steering system diagnosis and repair, steering column, steering rack, and alignment procedures.

Electrical System:

Complete wiring diagrams, fuse and relay locations, charging system (alternator, battery), starting system, lighting, and accessory circuits.

Engine Management:

ECU/ECM operation, sensors (e.g., MAF, O2, crankshaft position), actuators, fuel injection, ignition system, and emission control systems (e.g., EGR, catalytic converter).

Climate Control:

HVAC system diagnosis and repair, A/C compressor, refrigerant system, heater core, blower motor, and climate control modules.

Bodywork:

Body panel removal and installation, door mechanisms, glass replacement, interior trim, and exterior moldings.

Safety Systems:

Airbag system diagnosis and components, seat belt mechanisms.

Maintenance:

Routine maintenance tasks such as oil changes, filter replacements, spark plug replacement, brake fluid changes, coolant flushes, and belt inspections.

Diagnostics:

Systematic troubleshooting guides, diagnostic trouble codes (DTCs) and their meanings, component testing procedures, and fault finding strategies.

Repair:

Step-by-step instructions for component removal, repair, and reinstallation for all major vehicle systems.

Overhaul:

Complete engine and transmission overhaul procedures, including disassembly, cleaning, inspection, and reassembly with torque specifications.

Replacements:

Detailed procedures for replacing common wear items like brake pads, rotors, belts, hoses, and suspension components.

Adjustments:

Procedures for adjusting critical systems like parking brake, door latches, and electronic control modules where applicable.

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems, facilitating accurate diagnosis of electrical faults.

Depth:

Expert-level diagnostic and repair information suitable for professional technicians and experienced DIY enthusiasts.

Detail Level:

Includes detailed torque specifications, special tool requirements, clearances, and critical tolerances for all repair procedures.

Diagnostic Tools:

References diagnostic procedures that would typically utilize Mercedes-Benz proprietary diagnostic tools (e.g., STAR Diagnosis), though general troubleshooting is also covered.

📊 Manual Specifications

Format:

PDF

Searchability:

Likely searchable text content within the PDF for efficient information retrieval.

Quality:

Assumed high-quality digital reproduction of original factory documentation.

Type:

Digital Download (PDF) - Not applicable for physical binding.

Type:

Not applicable for digital format.

⚙️ Engine Specifications

Engine Family:

M112

Engine Type:

SOHC V6 (90-degree bank angle)

Displacement:

3.2 Liters (3199 cc)

Bore X Stroke:

89.9 mm x 84.0 mm

Compression Ratio:

10.0:1

Horsepower Peak:

215 hp @ 5750 rpm (approx.)

Torque Peak:

229 lb-ft @ 3250 rpm (approx.)

Fuel Delivery:

Electronic Fuel Injection (EFI) with sequential port injection.

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

ECM Type:

ME 2.0 / ME 2.8 (depending on model year and specific variations)

Coolant Type:

MB Approved Antifreeze/Coolant (e.g., G48 or equivalent)

Coolant Capacity:

Approximately 9.0 - 10.0 Liters

🔧 Transmission

Type:

5-speed Automatic Transmission

Transmission Code:

722.6 (NAG1)

Electronic Control:

Electronically controlled with multiple shift modes (Comfort, Sport).

Transmission Fluid:

MB Approved ATF (e.g., ATF 3403-M115 or similar approved fluid)

Capacity:

Approximately 7.5 - 8.5 Liters for a fluid change (dry fill is higher)

📐 Dimensions

Length:

Approx. 4637 mm (182.6 in)

Width:

Approx. 1829 mm (72.0 in)

Height:

Approx. 1790 mm (70.5 in)

Wheelbase:

Approx. 2820 mm (111.0 in)

Curb Weight:

Approx. 4500-4800 lbs (2040-2180 kg), varies by configuration.

Cargo Volume:

Approx. 442-756 Liters (rear seats up/down), expandable significantly with seats folded.

🛡️ Safety Features

NHTSA Front Impact:

Not explicitly available for the entire production run; later models often had good ratings but predecessor data may vary. Early models focused on different safety standards.

IIHS Crash Test:

Generally performed well for its era, but specific ratings for all model years and test types may differ. (Refer to IIHS archives for specifics).

Airbags:

Front airbags, optional side airbags.

Seatbelts:

Pretensioning seatbelts, height-adjustable shoulder belts.

Esp:

Electronic Stability Program (ESP) standard on most models, often branded as ASR (Anti-Slip Regulation) in earlier years or integrated with ESP.

ABS:

Anti-lock Braking System (ABS) standard.

Traction Control:

ASR (Traction Control) integrated with the powertrain and braking systems.

💡 Technology Features

Audio System:

Premium audio systems available (e.g., Bose), CD players, cassette players (early models), radio with AM/FM.

Navigation:

Optional GPS navigation systems were available, often integrated into the dashboard display.

Parking Sensors:

Optional Parktronic parking assist system.

Cruise Control:

Standard cruise control system.

Bluetooth:

Not standard in early models; Bluetooth connectivity was introduced or became more common in later years or as an option.

🔧 Maintenance

Oil Change Interval:

Every 10,000 miles or 12 months, whichever comes first (depending on driving conditions and model year updates).

Transmission Fluid Change:

Recommended every 40,000-60,000 miles for optimal performance and longevity, though some sources suggest longer intervals. Manual provides specific guidance.

Spark Plugs:

Typically at 100,000 miles for iridium or platinum spark plugs (refer to manual for specific type and interval).

Coolant Flush:

Every 2-3 years or approximately 30,000 miles.

Engine Oil Viscosity:

Typically 0W-40 or 5W-40 synthetic oil meeting MB 229.5 specification.

Brake Fluid:

DOT 4 Plus (MB 331.0 specification).

Oil Cooler Seals:

Leaking oil cooler seals can lead to coolant and oil mixing (often referred to as 'chocolate milk' issue).

Transmission Conductor Plate:

Failure of the transmission conductor plate in the 722.6 transmission can cause shifting issues and limp-mode engagement.

Crankshaft Position Sensor:

Premature failure of the crankshaft position sensor can lead to intermittent stalling or no-start conditions.

Mass Air Flow Sensor:

MAF sensor can become dirty or fail, causing rough idling and poor performance.

Rust Issues:

Potential for rust on wheel wells, rocker panels, and tailgate, especially in areas with road salt.

Evaporative Emissions System:

Issues with the EVAP system, such as charcoal canister leaks or faulty purge valves, can trigger Check Engine Lights.

📚 Vehicle History

Manufacturer:

Mercedes-Benz, a German automotive manufacturer with a long history of luxury and engineering excellence.

Introduction Year:

1997 (as a 1998 model year in North America)

Development Purpose:

Mercedes-Benz's first entry into the burgeoning luxury SUV market, leveraging their engineering expertise for a vehicle with car-like comfort and off-road capability.

Facelift:

Received a significant facelift for the 2002 model year, introducing revised styling, updated interior, and powertrain enhancements.

Manufacturing Location:

Tuscaloosa, Alabama, USA (primary production facility for the W163 generation).

🏆 Awards & Recognition

Consumer Reports Rating:

Consumer Reports ratings varied over the years; early models often received average to below-average reliability scores, while later models saw improvements. The manual is crucial for addressing common issues and maintaining reliability.

Euro Ncap Rating:

Early models were tested, with results generally reflecting the safety standards of the late 1990s. Specific star ratings should be verified for individual model years.