Mercedes ML320 ML350 1998-2005 Service Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: ML-Class Model Variant: ML320, ML350 Generation: First Generation (W163) Codes Chassis Code: W163 👋 Introduction Market Position Target Audience: DIY mechanics, independent repair...

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Type: Car

Vendor:

Sku: 264421

Tags: 1998 1999 2000 2001 2002 2003 2004 2005 400 Car Cars Mercedes ML320 ML350

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

ML-Class

Model Variant:

ML320, ML350

Generation:

First Generation (W163)

Codes

Chassis Code:

👋 Introduction

Market Position

Target Audience:

DIY mechanics, independent repair shops, and Mercedes-Benz enthusiasts.

Competitive Analysis

Value Proposition:

Provides professional-grade repair information equivalent to dealership-level manuals at a fraction of the cost, covering a vast range of topics.

Key Features

Comprehensiveness:

Over 5000 pages covering virtually every aspect of the vehicle's maintenance and repair.

Accessibility:

Works on all computers (PC & MAC) and allows for selective printing of specific pages.

Diagnostic Support:

Extensive coverage of trouble codes and diagnostic procedures.

📋 Manual Details

Coverage Areas

Years Covered:

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

Market Coverage:

North America (implied by model designations)

Page Count

Total Pages:

Over 5000

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Digital Format:

PDF (delivered as a ZIP archive)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine overhaul and rebuilding, timing belt replacement, engine performance tuning

Engine Management:

Trouble codes, computer diagnostic codes, firing orders

Fuel And Emissions:

Fuel system, emissions control systems

Drivetrain:

Transmission information, U-joint and CV-joint service procedures

Suspension And Steering:

Front end procedures and specifications, suspension system service

Brakes:

Brake system service and repair

Electrical System:

Wiring diagrams, troubleshooting and diagnostics of electrical components

Body And Chassis:

Sunroof service, exterior and interior components

HVAC:

Air conditioning service and capacities

Procedures Included

Maintenance:

Factory maintenance schedules and charts

Repair:

Detailed repair procedures for all covered systems

Diagnostics:

Troubleshooting and diagnostics, interpretation of computer diagnostic codes

Specifications:

Complete torque specifications, detailed specifications covered

Diagrams:

Serpentine belt routings with diagrams, complete wiring diagrams, hundreds of illustrations

Technical Depth

Depth:

Comprehensive: from basic maintenance to full engine and transmission overhauls, including advanced diagnostics and electrical schematics.

📊 Manual Specifications

File Format

Delivery Method:

Downloadable ZIP archive containing PDF files.

Software Requirement Windows:

WinZip (or compatible decompression software) required for Windows.

Software Requirement Mac:

Archive Utility (built-in OS X) or StuffIt Expander (free) recommended for Mac.

Print Quality

Scalability:

PDF format allows for zooming for detailed part views.

Printability:

Pages can be printed as needed, protecting the original digital file from grease.

Binding Type

Binding:

Digital (not applicable for printed book)

Paper Type

Paper Quality:

Digital (not applicable for printed book)

⚙️ Engine Specifications

Primary Engine Ml320

Engine Type:

V6 SOHC (M112 series)

Displacement Ml320:

3.2 Liters (3199 cc)

Bore X Stroke Ml320:

89.9 mm x 84.0 mm

Horsepower Ml320:

Approx. 215 hp @ 5750 rpm

Torque Ml320:

Approx. 229 lb-ft @ 3250 rpm

Primary Engine Ml350

Engine Type:

V6 SOHC (M112 series)

Displacement Ml350:

3.7 Liters (3724 cc)

Bore X Stroke Ml350:

97.0 mm x 82.9 mm

Horsepower Ml350:

Approx. 232 hp @ 5750 rpm

Torque Ml350:

Approx. 250 lb-ft @ 3250 rpm

Fuel System

Fuel Injection:

Sequential Electronic Fuel Injection (SEFI)

Timing

Timing Mechanism:

Single Overhead Camshafts (SOHC) per bank, driven by timing chain.

🔧 Transmission

Standard

Transmission Type Standard:

5-speed Automatic (722.6 series '5G-TRONIC')

Optional

Transmission Type Optional:

Not specified as optional, standard across W163 ML320/ML350.

Features

Transmission Control:

Electronically controlled with automatic shifting programs.

Fluid

Transmission Fluid Type:

Mercedes-Benz Specification MB 236.10 or MB 236.12 (ATF - Automatic Transmission Fluid).

📐 Dimensions

Exterior

Length:

Approx. 184.5 inches (4686 mm)

Width:

Approx. 71.6 inches (1819 mm)

Height:

Approx. 67.7 inches (1720 mm)

Wheelbase

Wheelbase:

Approx. 111.0 inches (2819 mm)

Weights

Curb Weight:

Approx. 4,400 - 4,700 lbs (2000 - 2130 kg) depending on configuration

Gross Vehicle Weight Rating:

Approx. 5,800 - 6,000 lbs (2630 - 2720 kg)

Cargo

Cargo Volume Behind Rear Seats:

Approx. 39.8 cubic feet (1127 liters)

Cargo Volume With Rear Seats Folded:

Approx. 77.4 cubic feet (2192 liters)

🛡️ Safety Features

Ratings

NHTSA Front Crash Rating:

4-star driver, 4-star passenger (for earlier models, later models may vary)

IIHS Front Crash Rating:

Good (for models equipped with side airbags)

Active Features

Traction Control:

Standard Electronic Traction System (ETS)

Stability Control:

Standard Electronic Stability Program (ESP) on most models.

Braking System:

Four-wheel Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Brake Assist (BAS)

Passive Features

Airbags:

Front airbags, optional side-impact airbags for front and rear occupants.

Seatbelts:

Three-point seatbelts with pretensioners and force limiters for all occupants.

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM stereo with CD player or optional Bose premium sound system. Available navigation system (COMAND).

Climate Control:

Standard manual or optional automatic climate control (THERMATIC/THERMOTRONIC).

Driver Assistance

Cruise Control:

Standard cruise control.

Parking Assistance:

Optional rear park assist sensors on later models.

Connectivity

Phone Integration:

Optional hands-free communication system with Bluetooth (availability varies by model year and options).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000 miles or 12 months, whichever comes first (refer to specific model year maintenance schedule in manual).

Transmission Fluid Service:

Recommended every 40,000 to 60,000 miles, or as per the service manual's specific guidance for the 722.6 transmission.

Spark Plug Replacement:

Typically around 100,000 miles for iridium spark plugs.

Fluid Specifications

Engine Oil Specification:

SAE 0W-40 or 5W-40 Synthetic Engine Oil meeting Mercedes-Benz Specification MB 229.5.

Coolant Specification:

Mercedes-Benz Specification MB 325.0 (Approved Antifreeze/Coolant - typically a silicate-free, ethylene glycol-based coolant).

Brake Fluid Specification:

DOT 4 Plus (SAE J1704) Hydraulic Brake Fluid.

Known Issues

Misfires And Ignition:

Can experience misfires due to faulty ignition coils, spark plugs, or mass airflow sensors.

Oil Leaks:

Common oil leaks can occur from valve cover gaskets, oil cooler seals, and crankcase seals.

Window Regulators:

Window regulator mechanisms are prone to failure, causing windows to drop unexpectedly.

ABS Esp Sensor Failure:

Wheel speed sensors for ABS and ESP can fail, triggering warning lights and affecting braking/stability control.

Transmission Harshness:

The 5G-TRONIC transmission can sometimes exhibit harsh shifting or delayed engagement, often related to valve body issues or fluid contamination.

📚 Vehicle History

Brand Heritage

Manufacturer Heritage:

Mercedes-Benz, a global leader in luxury and automotive engineering with a long history of innovation and quality since 1886.

Model Evolution

Introduction Of W163:

The W163 ML-Class was introduced in late 1997 for the 1998 model year as Mercedes-Benz's first entry into the luxury SUV market.

Facelift And Updates:

Received a significant facelift for the 2002 model year (W163.5), featuring revised exterior styling, interior upgrades, and powertrain enhancements, including the introduction of the ML350.

Production

Assembly Locations:

Primarily assembled in Tuscaloosa, Alabama, USA.

🏆 Awards & Recognition

Recognitions

Motor Trend SUV Of The Year:

While not winning this specific award for the ML320/ML350, the ML-Class generally received positive reviews upon its introduction, establishing Mercedes-Benz in the SUV segment.