Segment:
Luxury Mid-size SUV (Sport Utility Vehicle)
Target Audience:
Owners seeking detailed self-maintenance or repair guidance, independent workshops, and professional Mercedes-Benz technicians.
Competitors:
Competed against vehicles like the BMW X5 (E53), Lexus RX300, Audi allroad quattro, and Volvo XC90 in its segment.
Premium SUV:
Offered a blend of Mercedes-Benz luxury, refinement, and off-road capability, distinguishing itself from more utilitarian SUVs.
Drivetrain Technology:
Standard 4MATIC all-wheel-drive system provided excellent traction and stability in various conditions.
Primary Use:
To provide comprehensive service and repair information essential for maintaining and fixing the Mercedes-Benz ML-Class (W163) for the 1997 model year.
Vehicle Systems:
Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Bodywork, Interior, Emissions Control, Diagnostics
Estimated Pages:
Over 1500 (typical for comprehensive workshop manuals)
Type:
Repair Service Manual / Workshop Manual
Powertrain:
Detailed coverage of ML320 (M112 E32 V6), ML350 (M112 E37 V6 - though less common for '97 MY, often associated with later models or specific markets, assuming '97 models may have had earlier V8 or specific configurations), ML500 (M113 E50 V8) engines. Includes engine mechanicals, cooling, lubrication, fuel delivery, ignition, and emissions control systems.
Drivetrain:
Comprehensive coverage of the 4MATIC all-wheel-drive system, including transfer case, front and rear axles, drive shafts, and differentials. Includes service procedures for the 5-speed automatic transmission (722.6 '7G-TRONIC' family, though specific designation for this year might be 5G-TRONIC variant).
Suspension Steering:
Front independent suspension (double wishbone), rear multi-link suspension. Coverage includes shock absorbers, springs, control arms, bushings, and steering system components (rack and pinion, power steering hydraulics).
Brakes:
Front and rear disc brakes, including ABS (Anti-lock Braking System) and ESP (Electronic Stability Program) components. Details on brake pad replacement, rotor servicing, hydraulic system bleeding, and component diagnostics.
Electrical Electronics:
Extensive coverage of the vehicle's electrical system, including battery, charging system (alternator), starter motor, lighting, fuses, relays, wiring diagrams for all circuits, ECUs (Engine Control Units), SRS (Supplemental Restraint System/Airbags), and body control modules.
Maintenance:
Scheduled maintenance tasks such as oil and filter changes, air filter replacement, spark plug replacement, coolant flushing, brake fluid changes, and differential fluid changes. Includes interval recommendations.
Troubleshooting:
Diagnostic procedures for common and uncommon faults. Includes symptom-based troubleshooting guides, fault code interpretation (OBD-II), and step-by-step diagnostic routines for various systems.
Repair:
Detailed, step-by-step repair instructions for all major vehicle components, including engine overhaul, transmission service, suspension and steering component replacement, brake system repairs, electrical component replacement, and body panel repair.
Diagnostics:
Includes information on using diagnostic tools, understanding sensor data, and performing functional tests on various electronic modules and mechanical systems.
Depth:
Comprehensive: designed for professional technicians, covering everything from basic fluid changes and adjustments to complete engine and transmission rebuilds, including detailed torque specifications, tolerances, and schematics.
Quality:
High-resolution PDF, typically including searchable text for easy navigation and printing.
Printability:
Designed to be printable, allowing users to create physical copies of specific sections or the entire manual.
Binding For Print:
N/A (Digital Download - PDF)
Paper For Print:
N/A (Digital Download - PDF)
Ml320 Engine:
M112 E32 V6, SOHC, 18 valves
Ml500 Engine:
M113 E50 V8, SOHC, 24 valves
Ml320 Horsepower:
215 hp @ 5500 rpm (approx.)
Ml320 Torque:
229 lb-ft @ 3000-4400 rpm (approx.)
Ml500 Horsepower:
292 hp @ 5500 rpm (approx.)
Ml500 Torque:
339 lb-ft @ 3250 rpm (approx.)
Injection Type:
Sequential Multi-port Fuel Injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Ml320 Displacement:
3.2 Liters (3199 cc)
Ml500 Displacement:
5.0 Liters (4966 cc)
Transmission Type:
5-speed Automatic Transmission (likely variant of 722.6 '5G-TRONIC' family)
Optional Transmissions:
N/A (only automatic transmission offered for this generation ML-Class)
Drivetrain Integration:
Electronically controlled, integrated with 4MATIC AWD system.
Transmission Fluid:
Mercedes-Benz Automatic Transmission Fluid (ATF) specification 236.10 or equivalent (e.g., Mobil ATF 134, Pentosin ATF1)
Fluid Capacity Approx:
8.0 - 9.0 Liters (for complete drain and fill, including torque converter)
Length:
Approx. 4637 mm (182.6 in)
Width:
Approx. 1820 mm (71.7 in) (excluding mirrors)
Height:
Approx. 1717 mm (67.6 in)
Wheelbase:
Approx. 2830 mm (111.4 in)
Curb Weight Ml320 Approx:
Approx. 2070 kg (4564 lbs)
Curb Weight Ml500 Approx:
Approx. 2180 kg (4806 lbs)
Cargo Volume Seats Up:
Approx. 0.78 cubic meters (27.5 cu ft)
Cargo Volume Seats Down:
Approx. 1.93 cubic meters (68.1 cu ft)
NHTSA Front Crash Test:
Not explicitly rated by NHTSA for this specific year/model in all categories, but typical for luxury SUVs of the era. Likely performed well in internal testing.
Esp:
Standard Electronic Stability Program (ESP) for enhanced vehicle control.
ABS:
Standard Anti-lock Braking System (ABS) on all wheels.
Airbags:
Frontal airbags for driver and front passenger, side airbags (optional or standard depending on market/trim).
Seat Belts:
Three-point inertia-reel seat belts with pre-tensioners and force limiters.
Rollover Protection:
Advanced body structure designed to resist rollover, often supplemented by roll-bar reinforcement within the pillars.
Audio System:
Premium sound systems often available, including CD players and radio. Navigation systems were also optional.
Cruise Control:
Standard cruise control with electronic speed regulation.
Parking Assist:
Parking sensors were optional on some models.
Phone Integration:
Optional integrated hands-free telephone system available on some trims.
Hill Descent Control:
Downhill Speed Control (DSC) system was available for controlled descents on steep gradients.
Oil Change Interval:
Typically every 10,000 miles (16,000 km) or 12 months, whichever comes first, using synthetic oil.
Transmission Fluid Change:
Recommended every 30,000 - 60,000 miles (48,000 - 96,000 km), or as specified by the vehicle's service indicator. Early and consistent fluid changes are crucial for the longevity of the 722.6 transmission.
Coolant Change:
Every 2 years or 30,000 miles (48,000 km), using a Mercedes-Benz approved coolant.
Engine Oil Spec:
Mercedes-Benz MB 229.1 or MB 229.5 (for full synthetic)
Power Steering Fluid:
Pentosin CHF 11 S or equivalent Mercedes-Benz specification.
Common Problems Early W163:
Mass Air Flow (MAF) sensor issues, ignition coil failures (on V6/V8 engines), power steering hose leaks, tailgate struts failing, rust on body panels (especially wheel arches and sills), and HVAC blower motor resistor failures.
Transmission Issues:
Potential for valve body issues or conductor plate failure in the automatic transmission, leading to shifting problems.
Electronics Reliability:
Some early electronic module failures or sensor inaccuracies can occur, necessitating diagnostic checks.
Manufacturer Legacy:
Mercedes-Benz, a brand synonymous with engineering excellence, luxury, and automotive innovation since its inception.
First Generation:
The W163 ML-Class was Mercedes-Benz's first entry into the burgeoning luxury SUV market, launched in late 1997 for the 1998 model year in North America. This 1997 manual covers the very first iteration of this model.
Manufacturing Plant:
Primarily manufactured in Tuscaloosa, Alabama, USA, a dedicated plant for the M-Class production.
Production Period:
1997-2005 (for W163 generation)
Automotive Journal Awards:
The ML-Class received various accolades upon its introduction and throughout its first generation, often praised for its blend of luxury, performance, and utility.
Initial Reception:
Generally positive reviews for its refinement and capability, though some critics noted a ride that was firmer than expected for a luxury vehicle.
