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Mercedes-BENZ ML500 EXCLUSIVE GAS 2002-2003 Service Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: ML500 Exclusive Year: 2002-2003 Powertrain Type: Gasoline Codes Chassis Code: W163 👋 Introduction Market Position Segment: Mid-size Luxury SUV (Sport Utility Vehicle) Positioning:...
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Mercedes-BENZ ML500 EXCLUSIVE GAS 2002-2003 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
ML500 Exclusive
Year:
2002-2003
Powertrain Type:
Gasoline
Codes
Chassis Code:
W163
👋 Introduction
Market Position
Segment:
Mid-size Luxury SUV (Sport Utility Vehicle)
Positioning:
Positioned as a premium, capable, and luxurious SUV offering a blend of on-road refinement and off-road capability, reflecting Mercedes-Benz's brand heritage.
Competitive Analysis
Key Competitors:
BMW X5 (E53), Lexus RX (XU30), Porsche Cayenne (955), Volvo XC90, Audi Allroad Quattro
Key Features
Distinctive Features:
Powerful V8 engine, standard 4MATIC all-wheel drive, luxurious interior appointments, advanced safety features for its time, excellent build quality.
📋 Manual Details
Coverage Areas
Market Focus:
North America (implied by 'GAS' designation and typical sales markets for ML-Class)
Vehicle Variant Coverage:
ML500 Exclusive trim level
Page Count
Estimated Page Count:
1500-2000 (typical for comprehensive factory-level service manuals of this era)
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical (M113 V8), fuel system, ignition system, emissions control, cooling system, lubrication system
Transmission:
5G-TRONIC automatic transmission (722.6 series)
Drivetrain:
All-wheel drive (4MATIC), differentials, drive shafts, axles, transfer case
Suspension:
Front independent suspension, rear multi-link suspension, shock absorbers, springs, control arms, bushings
Brakes:
Hydraulic system, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), brake calipers, rotors, pads, lines, parking brake
Steering:
Power steering system, steering column, steering gear/rack and pinion
Electrical:
12V electrical system, battery, alternator, starter, fuse box, wiring diagrams, lighting systems, instrumentation, power accessories
Body:
Body panels, doors, hood, tailgate, interior trim, glass, seals, bumpers
HVAC:
Heating, ventilation, air conditioning, climate control system, components (compressor, evaporator, heater core)
Comfort Features:
Power seats, sunroof, door locks, windows, mirrors
Diagnostics:
On-board diagnostics (OBD-II), fault code retrieval and interpretation, diagnostic trouble codes (DTCs)
Procedures Included
Routine Maintenance:
Oil and filter changes, fluid level checks and top-offs, tire rotation, air filter replacement, spark plug replacement
Component Replacement:
Brake pads and rotors, belts, hoses, battery, alternator, starter motor, suspension components, exhaust system components
Major Repairs:
Engine rebuilds, transmission overhauls, driveline component repair
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues
Special Tools:
Identification and use of Mercedes-Benz specific tools required for certain procedures
Technical Depth
Level Of Detail:
Comprehensive factory-level repair procedures, detailed specifications, diagnostic flowcharts, and wiring schematics
📊 Manual Specifications
File Format
PDF Quality:
High-resolution scans or digitally created, with searchable text where possible
Printable:
Designed to be printable, with clear formatting for individual pages
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M113
Engine Type:
V8, SOHC (Single Overhead Camshaft), 3 valves per cylinder (2 intake, 1 exhaust) with Variable Valve Timing (VVT)
Displacement:
4966 cc (5.0 Liters)
Bore X Stroke:
97.0 mm x 84.0 mm
Compression Ratio:
9.5:1
Performance
Horsepower:
292 hp @ 5500 rpm (approx.)
Torque:
306 lb-ft @ 3500 rpm (approx.)
Fuel System
Fuel Delivery:
Sequential Multi-port Fuel Injection (SFI)
Recommended Fuel:
Premium Unleaded Gasoline (91 octane or higher)
Other
Engine Management System:
ME 2.8 (Motronic Electronic Engine Control)
🔧 Transmission
Standard
Type:
5-speed Automatic Transmission
Transmission Code:
722.6 (NAG1 - Neue Automatik Getriebe Generation 1)
Optional
Availability:
Not Applicable for ML500 Exclusive in these model years; standard 5-speed automatic.
Features
Drivetrain Integration:
Electronically controlled, integrated with 4MATIC all-wheel-drive system.
Shift Modes:
Comfort (C) and Sport (S) modes
📐 Dimensions
Exterior
Length:
4637 mm (182.6 inches)
Width:
1897 mm (74.7 inches)
Height:
1829 mm (72.0 inches)
Wheelbase:
2820 mm (111.0 inches)
Weights
Curb Weight:
2070 kg (4564 lbs) (approx.)
Gross Vehicle Weight Rating:
2600 kg (5732 lbs) (approx.)
Cargo
Cargo Volume:
31.7 cu ft (seats up) / 74.5 cu ft (seats folded)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5-Star (for 2002 model year)
NHTSA Front Impact Passenger:
5-Star (for 2002 model year)
IIHS Frontal Offset:
Good (for 2002 model year)
Active Features
Electronic Stability Program:
Standard (ESP - Electronic Stability Program)
Antilock Brakes:
Standard (ABS - Anti-lock Braking System)
Traction Control:
Standard (ASR - Acceleration Slip Regulation, integrated with ESP)
Passive Features
Airbags:
Driver and front passenger airbags, front side-impact airbags, optional rear side-impact airbags
Seatbelts:
3-point seatbelts with pretensioners and force limiters
💡 Technology Features
Infotainment
Audio System:
Optional COMAND (Cockpit Management and Navigation) system, high-quality audio with CD player, optional CD changer.
Navigation:
Optional factory-integrated navigation system with CD-ROM based maps.
Driver Assistance
Cruise Control:
Standard cruise control with speed limiter.
Parking Assistance:
Optional Parktronic parking sensors (front and rear).
Connectivity
Phone Integration:
Optional integrated hands-free telephone system (often requires a specific car phone cradle or Bluetooth adapter for later retrofits).
🔧 Maintenance
Service Intervals
Oil Change:
Every 10,000 miles or 12 months, whichever comes first (using synthetic oil)
Major Service A:
Typically around 15,000-30,000 miles, including fluid checks, brake inspection, filter replacements
Major Service B:
Typically around 30,000-60,000 miles, including spark plug replacement, transmission fluid service (check manual for specific interval, often 60k-100k)
Fluid Specifications
Engine Oil:
Mobil 1 Synthetic 0W-40 (MB Approval 229.5)
Engine Oil Capacity:
8.5 Liters (approx. 9.0 US Quarts)
Coolant:
Mercedes-Benz Coolant/Antifreeze (MB 325.0 / 326.0, typically a silicate-free OAT formula), mix 50/50 with distilled water
Transmission Fluid:
Mercedes-Benz ATF (MB 236.10 or MB 236.12), e.g., Pentosin ATF1 or equivalent
Power Steering Fluid:
Mercedes-Benz Power Steering Fluid (MB 343.0 or MB 345.0)
Brake Fluid:
DOT 4 Plus (MB 331.0)
Known Issues
Common Problems:
Oil leaks from valve cover gaskets and oil cooler seals, ESP/BAS warning lights due to faulty brake light switch or ABS sensors, premature wear of suspension components (bushings, ball joints), potential for catalytic converter failure, electronic module failures (e.g., EIS - Electronic Ignition Switch).
Maintenance Tips:
Regularly inspect for oil leaks. Clean battery terminals and check charge. Listen for suspension noises indicating worn bushings. Ensure proper cooling system maintenance to prevent overheating.
📚 Vehicle History
Brand Heritage
Brand Reputation:
Mercedes-Benz is renowned for engineering excellence, luxury, safety, and durability, with a long history in automotive innovation.
Model Evolution
Generation:
First Generation (W163)
Introduction Year:
1997 (globally), 1998 (North America)
Facelift Year:
2001 (significant update for 2002 model year, including updated styling and powertrains)
Production
Production Location:
Tuscaloosa, Alabama, USA
Production Years:
1998-2005 (W163 generation)
🏆 Awards & Recognition
Recognitions
Safety Awards:
Achieved 5-star safety ratings in NHTSA frontal crash tests for the 2002 model year, indicating strong occupant protection.
Initial Reception:
Praised upon release for its luxury, V8 power, and on-road comfort, though criticized by some purists for not being as utilitarian as traditional SUVs.
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