Segment:
Luxury Mid-size SUV
Target Audience:
Owners seeking to perform their own maintenance and repairs, saving on dealership labor costs. Enthusiasts and independent repair shops.
Competitors:
BMW X5, Lexus RX300/RX330, Audi allroad, Volvo XC90, Land Rover Discovery.
Nvh Levels:
Known for excellent Noise, Vibration, and Harshness (NVH) control due to its robust construction and advanced engineering.
Off Road Capability:
While marketed as a luxury SUV, it possessed genuine off-road capabilities with optional 4MATIC all-wheel drive and available low-range gearing on some models.
Build Quality:
Typical Mercedes-Benz build quality, emphasizing durability and premium materials.
Engine Variants:
All gasoline and diesel variants offered for the ML320 in the specified years.
Transmission Variants:
All automatic transmission variants offered for the ML320 in the specified years.
Body Styles:
All body styles offered for the ML320 in the specified years (primarily SUV).
Estimated Page Count:
1500+
Type:
Factory Service Manual / Repair Manual
Format:
Digital (Likely PDF, potentially e-book)
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine electrical, transmission (automatic), transfer case, drive axles, differentials.
Chassis:
Suspension (front and rear), steering system, braking system (including ABS and ESP), wheels and tires.
Electrical:
Body electrical systems, lighting, instruments and indicators, climate control system, infotainment system, power accessories (windows, locks, seats), starter, alternator, battery, wiring diagrams, fuse/relay locations.
Body:
Exterior body panels, interior trim, doors, hood, tailgate, bumpers, glass, body sealing.
Maintenance:
Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid, differential fluid), filter replacements, spark plug replacement, belt inspection/replacement, brake pad/rotor replacement.
Repair:
Engine overhaul, transmission repair, suspension component replacement, brake caliper/line repair, steering rack replacement, electrical component diagnosis and replacement, body panel repair and replacement.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, fault code interpretation (OBD-II), specific diagnostic procedures for various systems.
Depth:
Comprehensive, covering from basic maintenance tasks to complex component overhauls and diagnostics. Includes detailed specifications, torque values, and step-by-step instructions.
Engine Code Primary:
M112 (3.2L V6 SOHC)
Engine Type:
Naturally Aspirated V6, SOHC, 18 Valves
Displacement:
3199 cc (3.2 Liters)
Bore X Stroke:
89.9 mm x 84.0 mm
Compression Ratio:
10.0:1
Horsepower Peak Early Models:
215 hp @ 5750 RPM
Torque Peak Early Models:
229 lb-ft @ 3000-4500 RPM
Horsepower Peak Later Models:
218 hp @ 5700 RPM (slight variation)
Torque Peak Later Models:
232 lb-ft @ 3000-4750 RPM (slight variation)
Fuel Delivery:
Sequential Multi-Point Fuel Injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (91 Octane or higher recommended)
Ignition System:
Distributorless Electronic Ignition (EIS) with coil-on-plug technology.
Ml320 Diesel Option:
Yes, a 3.2L Inline 5-cylinder Turbocharged Diesel (OM612) was available in some markets, producing around 163 hp and 258 lb-ft of torque.
Transmission Type:
5-Speed Automatic Transmission (5G-TRONIC)
Transmission Features:
Electronically controlled, adaptive shift points, torque converter lock-up.
Transfer Case:
Standard 4MATIC All-Wheel Drive system (full-time) with a single-speed transfer case. Some earlier models may have had a two-speed transfer case with a locking center differential, offering a low-range gear for off-road use.
Transmission Fluid Type:
MB Spec 236.10 or 236.12 Automatic Transmission Fluid (e.g., ATF 3403-M 115 or equivalent).
Transmission Fluid Capacity:
Approx. 8.0-9.0 Liters (Varies with torque converter drain).
Length:
Approx. 4637 mm (182.6 in)
Width:
Approx. 1840 mm (72.4 in)
Height:
Approx. 1717 mm (67.6 in)
Wheelbase:
Approx. 2820 mm (111.0 in)
Ground Clearance:
Approx. 8.1 inches (206 mm), can vary with suspension options.
Cargo Volume Rear Seats Up:
Approx. 39.5 cu ft (1118 liters)
Cargo Volume Rear Seats Down:
Approx. 78.5 cu ft (2223 liters)
Curb Weight Approx:
4,400 - 4,600 lbs (2000 - 2100 kg)
Towing Capacity Max:
Up to 5,000 lbs (2,268 kg) when properly equipped.
NHTSA Front Impact Driver:
5 Stars (1998-2005 models generally performed well in frontal impacts).
NHTSA Front Impact Passenger:
5 Stars (1998-2005 models generally performed well in frontal impacts).
IIHS Front Offset Test:
Good (for models tested in the early years of this generation, improvements made in later iterations).
Traction Control:
Standard Electronic Traction System (ETS) on all models, often integrated with ABS.
Stability Control:
Standard Electronic Stability Program (ESP) on later models within this range.
ABS:
Standard Anti-lock Braking System (ABS).
All Wheel Drive:
Standard 4MATIC all-wheel drive system for enhanced traction.
Airbags Front:
Dual front SRS airbags (driver and passenger).
Airbags Side:
Optional or standard front and rear side curtain airbags (availability varied by year and trim).
Seatbelts:
3-point seat belts with pretensioners and force limiters for all seating positions.
Audio System:
Various Mercedes-Benz COMAND (Cockpit Management and Navigation) or Audio systems with CD player, AM/FM radio. Optional navigation system and premium sound systems (e.g., Bose).
Climate Control:
Automatic Climate Control (Thermatic) or optional dual-zone Thermatronic climate control systems.
Cruise Control:
Standard cruise control.
Parking Assistance:
Optional front and rear parking sensors (Parktronic) on some models.
Pre Wiring:
Pre-wiring for telephone and CD changer on many models. The manual covers installation and diagnosis of these features.
Oil Change Interval:
Approximately every 10,000 miles or 12 months, whichever comes first, using synthetic oil. (Refer to manual for exact conditions).
Engine Air Filter Replacement:
Every 30,000 miles or as needed, inspect more frequently.
Cabin Air Filter Replacement:
Every 15,000-20,000 miles or annually.
Spark Plug Replacement:
Around 100,000 miles for iridium-tipped plugs (check specific plug type).
Transmission Fluid Flush:
Recommended every 50,000-60,000 miles (or as per specific service bulletins).
Engine Oil Type:
SAE 0W-40 or 5W-40 Synthetic Engine Oil meeting MB 229.5 Specification.
Engine Oil Capacity:
Approx. 8.0 Liters (6.7 US Quarts).
Coolant Type:
Mercedes-Benz approved Antifreeze/Coolant (e.g., MB Spec 325.0 or 326.0), typically a silicate-free, phosphate-free formulation, often blue or green.
Coolant Capacity:
Approx. 9.5 Liters (10.0 US Quarts).
Brake Fluid Type:
DOT 4 Plus (or MB Spec 331.0).
Power Steering Fluid Type:
MB Spec 236.3 Hydraulic Fluid or Pentosin CHF 11 S (check specific model year recommendations).
Interior Plastic Degradation:
Some interior plastics can become sticky or degrade due to heat exposure over time. The manual provides guidance on cleaning and potential replacement.
Mass Air Flow Sensor:
MAF sensors can become dirty or fail, leading to rough idling and poor performance. Cleaning or replacement procedures are covered.
Oil Cooler Seals:
Leaking oil cooler seals can cause oil to mix with coolant. The manual details the replacement process.
ABS Esp Module:
The ABS/ESP control module can fail, leading to warning lights. Diagnostic procedures are included.
Rear Main Seal Leak:
Potential for rear main crankshaft seal leaks, particularly on higher mileage vehicles. Repair involves engine/transmission removal.
Mercedes Benz Legacy:
Mercedes-Benz has a long history of engineering excellence, safety, and luxury, established in the early 20th century.
W163 Introduction:
The W163 generation M-Class was introduced in 1997 (for the 1998 model year) as Mercedes-Benz's first entry into the SUV market, aiming to compete with established luxury SUVs.
Design Philosophy:
Designed with a blend of luxury comfort, on-road manners, and some off-road capability, produced initially at the Tuscaloosa, Alabama plant.
Facelift Refresh:
The W163 received a significant facelift for the 2002 model year, featuring updated styling, interior enhancements, and revised powertrains.
Manufacturing Location:
Tuscaloosa, Alabama, USA.
Generation End:
This generation was succeeded by the W164 M-Class for the 2006 model year.
Motor Trend SUV Of The Year:
The M-Class (W163) was named MotorTrend's SUV of the Year for 1998.
Consumer Reports Ratings:
Consumer Reports ratings varied throughout the model run, with early models showing some reliability concerns that improved in later years. The manual provides valuable insight for maintaining these vehicles.
