Segment:
Luxury Mid-size SUV
Key Competitors:
BMW X5 (E53), Lexus RX (RX300/330), Porsche Cayenne (955), Land Rover Discovery
Vehicle Strengths:
Comfortable ride, premium interior, robust 4MATIC all-wheel-drive system, strong brand reputation for luxury and engineering.
Years Covered:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Type:
Workshop Repair and Service Manual
Powertrain:
Engine, Transmission, Drivetrain (4MATIC All-Wheel Drive)
Chassis:
Suspension, Steering, Brakes, Wheels and Tires
Electrical:
Engine Control Module (ECM), Body Control Module (BCM), Lighting, Instruments and Displays, Audio System, Climate Control, Power Accessories
Body:
Body Panels, Doors, Windows, Seats, Interior Trim, Exterior Trim
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel lines, injectors.
Exhaust System:
Exhaust manifolds, catalytic converter, mufflers, exhaust pipes.
Cooling System:
Radiator, water pump, thermostat, cooling fans, coolant hoses.
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks and Replacements, Tune-ups
Repair:
Engine Overhaul, Transmission Repair, Brake System Overhaul, Suspension Component Replacement, Electrical Component Diagnosis and Repair
Troubleshooting:
Diagnostic Trouble Codes (DTCs), Symptom-based Troubleshooting Guides, Electrical Schematics
Diagnostics:
On-Board Diagnostics (OBD-II) system, diagnostic trouble code retrieval and interpretation, component testing procedures.
Replacement:
Component replacement procedures for all major mechanical and electrical systems.
Adjustment:
Wheel alignment specifications, steering system adjustments, parking brake adjustments.
Depth:
Comprehensive: From basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and electrical system tracing.
Electrical Schematics:
Detailed wiring diagrams for all electrical systems, including power distribution, grounds, and component connections.
Torque Specifications:
Comprehensive list of torque specifications for all fasteners, critical for engine, chassis, and drivetrain assembly.
Engine Type:
M112 E32 - V6, SOHC, 18-valve (3 valves per cylinder)
Displacement:
3.2 Liters (3199 cc)
Bore X Stroke:
89.9 mm x 84.0 mm
Compression Ratio:
10.0:1
Horsepower:
215 hp @ 5,750 rpm
Torque:
227 lb-ft (308 Nm) @ 3,250 rpm
Fuel Delivery:
Sequential Multi-port Fuel Injection (SFI)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Transmission Type:
5-Speed Automatic Transmission (722.6 '5G-TRONIC')
Optional Transmissions:
N/A for ML320 during this period
Drive System:
4MATIC All-Wheel Drive (Permanently Engaged)
Transmission Fluid Type:
MB 236.10 (or equivalent, e.g., Pentosin ATF1)
Length:
Approx. 188.5 inches (4,788 mm)
Width:
Approx. 74.9 inches (1,903 mm)
Height:
Approx. 66.7 inches (1,694 mm)
Wheelbase:
Approx. 111.0 inches (2,820 mm)
Curb Weight:
Approx. 4,500 - 4,700 lbs (2,041 - 2,132 kg)
Towing Capacity:
Up to 5,000 lbs (2,268 kg)
Seating Capacity:
5 or 7 (optional third-row seating)
NHTSA Front Impact Driver:
4 Stars (1997-2001 models)
NHTSA Front Impact Passenger:
4 Stars (1997-2001 models)
Traction Control:
Standard (ASR - Automatic Slip Regulation)
Stability Control:
Standard (ESP - Electronic Stability Program)
Airbags:
Frontal airbags, optional side airbags
Seatbelts:
3-point inertia-reel seatbelts with pretensioners
Audio System:
Factory AM/FM/CD player, optional Bose sound system, optional navigation system (COMAND 2.0/2.5).
Climate Control:
Automatic Climate Control (often dual-zone) with pollen filter.
Parking Assist:
Optional rear park assist sensors (Parktronic).
Prewiring:
Optional telephone pre-wiring and CD changer pre-wiring.
Oil Change Interval:
Every 10,000 miles or 12 months (whichever comes first), using synthetic oil.
Air Filter Replacement:
Every 30,000 miles or 24 months.
Cabin Air Filter Replacement:
Every 15,000 miles or 12 months.
Transmission Fluid Service:
Every 60,000 miles or 48 months (recommended service, often debated).
Engine Oil Type:
Mobil 1 0W-40 Synthetic (or equivalent meeting MB-Approval 229.5)
Engine Oil Capacity:
Approx. 8.5 quarts (8.0 Liters) with filter change
Coolant Type:
MB 325.0 (or equivalent, typically a 50/50 mix of antifreeze and distilled water, e.g., Zerex G-05)
Common Failures:
Mass Air Flow (MAF) sensor failure, ignition coil failure, crank position sensor failure, radiator support issues (plastic breaking), HVAC blower motor resistor failure, rust on rear hatch and rocker panels, O2 sensor failures.
Maintenance Notes:
Regularly check for oil leaks from the valve covers and oil filter housing. Ensure the drain holes in the cowl area are clear to prevent water ingress into the HVAC system.
Manufacturer Reputation:
Mercedes-Benz: Renowned for luxury, engineering excellence, and robust build quality since its inception.
First Generation:
The W163 generation ML-Class was introduced in 1997 as Mercedes-Benz's first entry into the popular SUV segment. It was designed to blend luxury car comfort with off-road capability.
Facelift:
A significant facelift occurred for the 2002 model year, introducing updated styling, improved interior materials, and enhanced powertrain options.
Manufacturing Plant:
Tuscaloosa, Alabama, USA
