Segment:
Luxury Mid-size SUV
Target Audience:
Owners seeking to perform maintenance and repairs themselves, independent repair shops, automotive enthusiasts.
Key Competitors:
BMW X5 (E53), Lexus RX (XU10), Audi allroad quattro, Volvo XC90.
Vehicle Selling Points:
German engineering, premium interior, advanced safety features, powerful engine options, available 4MATIC all-wheel drive, robust construction.
Benefits To Owner:
Cost savings on maintenance and repairs, deeper understanding of vehicle systems, improved troubleshooting capabilities, extended vehicle lifespan.
Scope Of Manual:
This manual provides in-depth guidance for routine maintenance, troubleshooting, and extensive repairs, enabling owners and technicians to maintain the vehicle to factory specifications.
Years Covered:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Model Variants Covered:
ML320, ML350, ML500
Page Count:
Estimates vary, but typically comprehensive service manuals for this era are between 1500-3000 pages.
Manual Type:
Full Service and Repair Manual
Format:
Digital (likely PDF, as per typical online sales)
Powertrain:
Engine mechanical, engine electrical, fuel system, lubrication, cooling, exhaust, ignition, starting, charging, transmission (automatic), transfer case, drivetrain components (front/rear axles, driveshafts, differentials).
Chassis:
Suspension (front and rear independent), steering system, braking system (ABS, EBD, ESP components), wheels and tires.
Body And Interior:
Body structure, exterior panels, doors, windows, glass, interior trim, seats, HVAC system, climate control, body electrical (lighting, wipers, mirrors, door locks, power accessories).
Electrical And Electronics:
Wiring diagrams, fuse box locations, relay assignments, instrument cluster, diagnostic trouble codes (DTCs) and troubleshooting, CAN bus systems, SRS (Supplemental Restraint System) / Airbag systems, ECU (Engine Control Unit) and module identification.
Diagnostics:
OBD-II diagnostics, specific Mercedes-Benz diagnostic codes, troubleshooting flowcharts for various systems.
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and changes, tune-ups, brake servicing, tire rotation and balancing.
Repair And Overhaul:
Engine disassembly and reassembly, cylinder head service, piston and connecting rod installation, crankshaft bearing replacement, transmission overhaul, differential repair, suspension component replacement, brake caliper and rotor service, steering rack replacement.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts, electrical system diagnostics, engine performance diagnosis, transmission shifting problems.
Special Tools And Techniques:
Identification of specialized tools required for specific repairs, torque specifications for critical fasteners, special alignment procedures.
Emission Systems:
Inspection and repair of emissions control components, catalytic converter system, EGR (Exhaust Gas Recirculation) if applicable.
Depth Of Coverage:
Comprehensive, covering everything from basic fluid changes and inspections to complete engine, transmission, and chassis overhauls. Includes detailed diagnostic procedures and component testing.
Wiring Diagrams:
Detailed electrical wiring diagrams for all major systems, including power distribution, lighting, engine control, and body electronics.
Ml320 Engine:
3.2L M112 E32 V6 (Naturally Aspirated)
Ml350 Engine:
3.7L M112 E37 V6 (Naturally Aspirated)
Ml500 Engine:
5.0L M113 E50 V8 (Naturally Aspirated)
Ml320 Horsepower:
215 hp @ 5750 rpm
Ml320 Torque:
229 lb-ft @ 3250 rpm
Ml350 Horsepower:
232 hp @ 5750 rpm (Later models)
Ml350 Torque:
258 lb-ft @ 3250 rpm (Later models)
Ml500 Horsepower:
288 hp @ 5250 rpm
Ml500 Torque:
325 lb-ft @ 2700 rpm
Fuel Injection:
Sequential Multi-Port Fuel Injection (MPI)
Recommended Fuel:
Premium Unleaded Gasoline (91+ Octane)
NHTSA Front Impact Rating:
4-star driver, 4-star passenger (for 2004 model year, typical for the generation).
IIHS Side Impact Rating:
Good (for models equipped with side airbags, typically later models).
Stability Control:
Electronic Stability Program (ESP) - Standard
Traction Control:
4-ETS (Electronic Traction System) - Standard
Braking System:
Anti-lock Braking System (ABS) with Electronic Brake-force Distribution (EBD).
Airbags:
Front airbags, side airbags (optional/standard depending on year/trim), front and rear head curtain airbags (optional on later models).
Seatbelts:
Pre-tensioning front seatbelts, three-point rear seatbelts.
Oil Change Interval:
Typically every 7,500 - 10,000 miles or 12 months, whichever comes first (depending on driving conditions and oil type used, refer to specific manual recommendations).
Transmission Fluid Change:
Recommended every 40,000 - 60,000 miles (refer to manual for specific fluid and procedure).
Coolant Change:
Typically every 30,000 - 50,000 miles or 2-3 years.
Engine Oil Type:
Mobil 1 Synthetic 0W-40 (MB 229.5 specification) is commonly recommended.
Transmission Fluid Type:
MB 236.10 (e.g., ATF 4134).
Coolant Type:
Mercedes-Benz approved G05 (HOAT) coolant or equivalent, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 (or DOT 3 if specified for certain components).
Common Problems:
Cracked dashboard (plastic degradation), 'Check Engine' light due to faulty Mass Air Flow (MAF) sensors or O2 sensors, ignition coil failures, transmission conductor plate issues, rust in wheel wells and rocker panels, SRS warning light (seat occupancy sensor or wiring).
Maintenance Recommendations:
Regular inspection for oil leaks, checking and topping up all fluid levels, monitoring for any unusual noises or warning lights, timely replacement of wear items like brake pads and rotors.
Mercedes-Benz SUV History:
Mercedes-Benz has a long history of producing robust and luxurious vehicles. The ML-Class was their first foray into the mid-size luxury SUV segment.
W163 Introduction:
Introduced in 1997 as the M-Class (later ML-Class), it was designed to compete in the growing SUV market, combining utility with Mercedes-Benz luxury and engineering.
W163 Facelift:
Received a significant facelift for the 2002 model year, with updated styling, interior enhancements, and improved powertrain options (introducing the ML350 and ML500).
Manufacturing Location:
Tuscaloosa, Alabama, USA.
