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Mercedes-Benz ML320 ML350 ML500 2002 Repair Service Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: ML-Class Model Variant: ML320, ML350, ML500 Year: 2002 Codes Chassis Code: W163 👋 Introduction Market Position Vehicle Segment: Luxury Mid-size SUV (Sport Utility...
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Mercedes-Benz ML320 ML350 ML500 2002 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
ML-Class
Model Variant:
ML320, ML350, ML500
Year:
2002
Codes
Chassis Code:
W163
👋 Introduction
Market Position
Vehicle Segment:
Luxury Mid-size SUV (Sport Utility Vehicle).
Competitive Analysis
Key Competitors 2002:
BMW X5, Lexus RX300, Audi allroad quattro, Volvo XC90.
Key Features
Standard Drivetrain:
Rear-wheel drive (RWD) and optional 4MATIC all-wheel drive (AWD).
Body Style:
5-door SUV.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive repair and service for all factory specifications.
Page Count
Estimated Page Count:
Approx. 1500-2500 pages (typical for comprehensive factory service manuals).
Manual Type
Manual Type:
Factory Repair and Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, cylinder head, block, pistons, connecting rods, crankshaft, lubrication system, cooling system.
Engine Performance:
Fuel injection systems (MPI), ignition systems, emissions control systems, turbocharging (if applicable), engine management systems (ECU).
Transmission Automatic:
Transmission assembly/disassembly, torque converter, valve body, electronic controls, fluid specifications, troubleshooting.
Drivetrain:
Front and rear axle assemblies, differentials, driveshafts, CV joints, transfer case (4MATIC).
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment procedures.
Steering:
Power steering system, steering column, steering gear, tie rods, troubleshooting.
Brakes:
Hydraulic brake system, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), brake fluid specifications, disc/drum brake components, parking brake.
Electrical System:
Battery, charging system (alternator), starting system, lighting systems, power distribution, wiring diagrams, fuses, relays.
Body And Chassis:
Body construction, exterior panels, interior trim, doors, windows, latches, hinges, corrosion protection.
HVAC:
Heating, ventilation, and air conditioning (HVAC) system, refrigerant, compressor, evaporator, condenser, climate control unit.
Safety Systems:
Airbag system (SRS), seat belts, crash sensor location and replacement, diagnostics.
Infotainment And Electronics:
Audio system, navigation system, instrument cluster, control modules, CAN bus communication.
Procedures Included
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement.
Diagnostic Procedures:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs), wiring diagram interpretation.
Repair Procedures:
Detailed step-by-step instructions for component removal, installation, and adjustment.
Engine Repair:
Engine rebuild procedures, cylinder head gasket replacement, timing chain/belt service (if applicable), component overhaul.
Transmission Repair:
Automatic transmission overhaul, clutch replacement (if applicable), electronic control module (TCM) programming/replacement.
Brake System Repair:
Brake caliper replacement, rotor resurfacing/replacement, brake line repair, ABS/ESP component testing and replacement.
Electrical Diagnostics:
Component testing, circuit diagnosis using wiring diagrams, sensor testing, module troubleshooting.
HVAC Service:
Refrigerant recharge, leak detection, component replacement (compressor, evaporator), climate control system calibration.
Suspension And Steering Repair:
Component replacement (ball joints, tie rod ends), power steering pump replacement, suspension alignment procedures.
Technical Depth
Depth Of Information:
Factory-level technical detail, suitable for professional technicians and advanced DIY enthusiasts.
Diagnostic Tools Required:
References to specific Mercedes-Benz diagnostic equipment (e.g., STAR Diagnosis/XENTRY) and generic OBD-II scanners.
Specifications Detail:
Torque specifications, clearances, fluid types and capacities, electrical schematics, pressure specifications.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, designed for clear digital viewing and printing.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Searchability
Searchable Text:
Typically includes searchable text for quick information retrieval.
⚙️ Engine Specifications
Primary Engine Ml320
Engine Code:
M112
Engine Type:
3.2L SOHC V6 (Naturally Aspirated)
Horsepower Ml320:
215 hp @ 5750 rpm
Torque Ml320:
229 lb-ft @ 3000-4500 rpm
Primary Engine Ml350
Engine Code:
M112
Engine Type:
3.7L SOHC V6 (Naturally Aspirated)
Horsepower Ml350:
232 hp @ 5750 rpm
Torque Ml350:
258 lb-ft @ 3000-4500 rpm
Primary Engine Ml500
Engine Code:
M113
Engine Type:
5.0L SOHC V8 (Naturally Aspirated)
Horsepower Ml500:
288 hp @ 5500 rpm
Torque Ml500:
325 lb-ft @ 2700-3750 rpm
Performance
Engine Management:
ME 2.8 SFI (Sequential Fuel Injection).
Fuel System
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended).
Fuel Delivery:
Multi-port Fuel Injection (MPI).
🔧 Transmission
Standard
Transmission Type:
5-speed automatic with TouchShift manual shifting capability.
Optional
Drivetrain Options:
4MATIC All-Wheel Drive (AWD).
Features
Transmission Controller:
Electronic Transmission Control (ETC).
📐 Dimensions
Exterior
Length:
Approx. 180.0 inches
Width:
Approx. 71.5 inches
Height:
Approx. 68.0 inches
Wheelbase:
Approx. 111.0 inches
Weights
Curb Weight Ml320:
Approx. 4475 lbs
Curb Weight Ml500:
Approx. 4780 lbs
🛡️ Safety Features
Ratings
NHTSA Front Crash Rating:
5-Star (Driver and Passenger)
NHTSA Side Impact Rating:
4-Star (Front and Rear Passengers)
Active Features
Traction Control:
ASR (Acceleration Slip Regulation).
Stability Control:
ESP (Electronic Stability Program).
Braking Assist:
BAS (Brake Assist System).
Passive Features
Airbags:
Frontal airbags, side-impact airbags (front and rear optional).
Seat Belts:
3-point seat belts with pretensioners and force limiters.
💡 Technology Features
Infotainment
Audio System:
Optional Bose premium sound system.
Navigation:
Optional factory navigation system.
Driver Assistance
Parking Assist:
Optional front and rear Parktronic parking sensors.
Connectivity
Remote Key Fob:
Infrared remote key fob for central locking and ignition.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 miles or 12 months, whichever comes first (synthetic oil recommended).
Air Filter Replacement:
Every 30,000 miles or as needed based on driving conditions.
Cabin Filter Replacement:
Every 15,000 miles or annually.
Spark Plug Replacement:
Approx. 100,000 miles (Long-life spark plugs).
Fluid Specifications
Engine Oil Specification:
Mobil 1 0W-40 Synthetic (MB Approval 229.5).
Transmission Fluid Specification:
MB 236.10 Automatic Transmission Fluid (e.g., Mobil ATF 134).
Coolant Specification:
Mercedes-Benz Coolant Concentrate (Zerex G-05 or equivalent, mixed 50/50 with distilled water).
Brake Fluid Specification:
DOT 4.
Known Issues
Common Problem 1:
Mass Air Flow (MAF) sensor issues, leading to rough idle or poor performance.
Common Problem 2:
Cracked dashboard material due to UV exposure/age.
Common Problem 3:
Power steering pump leaks or failure.
Common Problem 4:
ABS/ESP sensor faults, often due to wheel speed sensor issues or wiring.
Common Problem 5:
Catalytic converter failure (more common with higher mileage).
Common Problem 6:
HVAC blower motor resistor failure, resulting in non-functional fan speeds.
📚 Vehicle History
Brand Heritage
Manufacturer History:
Mercedes-Benz, a global leader in luxury vehicle manufacturing with a long history of engineering excellence and innovation.
Model Evolution
W163 Generation:
First generation of the ML-Class, introduced in 1997 (as a 1998 model) and updated for 2002 with revised styling and powertrains.
Production
Manufacturing Location:
Tuscaloosa, Alabama, USA.
🏆 Awards & Recognition
Recognitions
Segment Awards:
Often lauded for its comfortable ride and robust build quality in the luxury SUV segment.
Ratings
Consumer Reports Rating:
Varies by specific model year and components, generally rated as average to good for reliability, with some common issues noted.
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