Segment:
Luxury Mid-size SUV
Key Competitors 2002:
BMW X5, Lexus RX300, Audi allroad quattro, Volvo XC90
SUV Attributes:
Luxurious interior, strong V8 engine, available 4MATIC all-wheel drive, advanced safety features, superior ride comfort for an SUV
Manual Value Proposition:
Official, factory-level repair information for accurate and efficient maintenance and repair
Coverage Scope:
Comprehensive service, repair, and diagnostics
Estimated Pages:
Extensive (exact count not specified, but typical for official workshop manuals)
Type:
Official Service & Repair Manual Software
Format:
Software (likely digital, searchable PDF or proprietary application)
Powertrain:
Engine, Fuel System, Exhaust System, Transmission, Drivetrain (4MATIC AWD)
Chassis:
Suspension (front and rear), Steering, Brakes (ABS, ESP), Wheels, Tires
Electrical:
12V Electrical System, Battery, Alternator, Starter, Lighting, Instruments, HVAC Controls, Body Electronics (Central Locking, Power Windows, Mirrors), SRS Airbag System
Body:
Body Panels, Doors, Roof, Bumpers, Exterior Trim, Interior Trim, Seats
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication
Diagnostics:
Troubleshooting guides, symptom analysis, diagnostic trouble codes (DTCs), OBD-II scanning procedures
Repair:
Component removal and installation, adjustments, calibration, rebuild procedures
Special Tools:
Identification and usage of Mercedes-Benz specific tools
Depth:
Detailed technical specifications, repair procedures, diagnostic strategies, and wiring diagrams
Configuration:
4.3L V8 SOHC (3 valves per cylinder)
Horsepower:
288 hp @ 5500-6000 rpm
Torque:
287 lb-ft @ 3500-4500 rpm
Induction:
Naturally Aspirated, Electronic Fuel Injection (EFI)
Fuel Type:
Premium Unleaded Gasoline (91+ Octane)
ECU Type:
Bosch ME 2.8 (or similar)
NHTSA Frontal Impact Driver:
5-Star
NHTSA Frontal Impact Passenger:
5-Star
IIHS Front Offset Crash Test:
Good (for its time)
Electronic Stability Program:
Standard (ESP)
Anti Lock Braking System:
Standard (ABS)
Traction Control:
Standard (ASR)
Airbags:
Frontal airbags (driver & passenger), front side-impact airbags
Seatbelts:
3-point inertia-reel seatbelts with front belt tensioners and force limiters
Audio System:
Bose premium sound system, optional COMAND navigation system with CD player and AM/FM radio
Cruise Control:
Standard electronic cruise control
Parking Assist:
Optional rear parking assist sensors
Phone Integration:
Optional factory-installed telephone system with car kit
Oil Change Interval:
Every 10,000 miles or 12 months, whichever comes first (using synthetic oil)
Major Service Interval:
Around 30,000, 60,000, 90,000, 120,000 miles (detailed in manual)
Engine Oil Type:
SAE 0W-40 Synthetic (MB 229.5)
Engine Oil Capacity:
8.5 US quarts (8.0 Liters)
Coolant Type:
Mercedes-Benz Approved Antifreeze/Coolant (e.g., G05 or equivalent)
Brake Fluid Type:
DOT 4 Plus (e.g., MB 331.0)
Power Steering Fluid Type:
MB 236.3 (ATF DEXRON II/III or equivalent)
Common W163 Issues:
O-ring failure in transmission cooler lines leading to ATF leaks, EGR valve clogging, mass airflow sensor (MAF) issues, ignition coil failures, rust on the tailgate and wheel arches, potential for SRS warning light due to faulty occupant classification system or seat occupancy sensor.
Mercedes Benz SUV History:
Pioneering luxury SUV manufacturer with models like the G-Class, establishing a reputation for robust engineering and luxury
W163 Generation:
First generation ML-Class, introduced in 1997; 2002 model year saw minor updates including the introduction of the ML500 with the M113 V8 engine
Manufacturing Location:
Tuscaloosa, Alabama, USA
Popular Mechanics Car Of The Year:
Recipient of the 2000 (for ML320) and potentially recognized for the ML series in other years by automotive publications (specific ML500 award for 2002 not prominently documented, but part of a lauded series).
Consumer Reports Reliability:
Varied over the W163 generation; specific 2002 ML500 reliability ratings depend on the report year, but generally noted as average to below average in earlier years, improving with updates.
