Covered Models:
ML320, ML350, ML500
Production Years Covered:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Engine Codes Ml320:
M112 E32 (3.2L V6)
Engine Codes Ml350:
M112 E37 (3.7L V6 - later models), M111 E23 ML (2.3L Supercharged I4 - rare market specific)
Engine Codes Ml500:
M113 E50 (5.0L V8)
Segment:
Luxury Mid-size SUV
Target Audience:
Consumers seeking a blend of luxury, utility, and off-road capability from a premium European manufacturer.
Key Competitors:
BMW X5, Lexus RX series, Audi allroad/Q series, Volvo XC90, Land Rover Discovery
Powertrain Options:
Smooth and powerful V6 and V8 engines, paired with Mercedes-Benz's renowned automatic transmissions.
Drivetrain:
Standard 4MATIC all-wheel-drive system providing enhanced traction and stability.
Luxury Appointments:
High-quality interior materials, comfortable seating, advanced features for its era.
General Coverage:
Comprehensive service, repair, and maintenance
Specific Systems Coverage:
Engine mechanical, engine electrical, fuel system, emission control, transmission (automatic), drivetrain, suspension, steering, brakes, body electrical, body hardware, HVAC, interior, exterior trim, diagnostics, wiring diagrams
Estimated Page Count:
~2500+
Type:
Workshop Service Manual (WSM) / Service and Repair Manual
Source Type:
OEM or high-quality aftermarket equivalent, providing factory-level repair information.
Format:
Digital (likely PDF, often searchable)
Engine Systems:
M112 (V6) and M113 (V8) engine overhaul, component replacement, timing, diagnostics, lubrication, cooling, fuel delivery, ignition, emission controls (OBD-II)
Transmission Systems:
5G-TRONIC (722.6) automatic transmission service, repair, fluid changes, torque converter, valve body diagnostics
Drivetrain Systems:
All-Wheel Drive (4MATIC) system, transfer case, front and rear differentials, driveshafts, CV joints
Suspension Steering Brakes:
Independent front and rear suspension, coil springs, shock absorbers, control arms, ball joints, steering system components (rack and pinion), power steering system, ABS, ESP (Electronic Stability Program), brake pad/rotor replacement, brake caliper service, hydraulic system bleed
Electrical Body:
Battery, charging system, starter, lighting, instrument cluster, power accessories (windows, locks, mirrors, seats), SRS (Airbag) system, climate control (HVAC), infotainment, body control module (BCM), fuse/relay identification and troubleshooting, body panel removal/installation, door mechanisms, interior trim removal
Maintenance Procedures:
Oil and filter change, air filter replacement, cabin air filter replacement, fuel filter replacement, spark plug replacement, coolant flush and replacement, brake fluid flush, transmission fluid and filter change, differential fluid change, transfer case fluid change
Repair Procedures:
Engine component replacement (alternator, starter, water pump, etc.), fuel injector replacement, exhaust system repair, suspension component replacement, brake caliper rebuild/replacement, drive axle replacement, transmission overhaul, AC system recharge/repair, SRS component replacement, body panel repair/replacement
Diagnostic Procedures:
OBD-II code reading and interpretation, diagnostic trouble code (DTC) troubleshooting flowcharts, sensor testing, actuator testing, module programming (mention of STAR DIAGNOSIS system compatibility implied)
Depth:
Highly detailed, covering from routine maintenance to complete engine and transmission rebuilds. Includes specifications, tolerances, torque values, diagnostic procedures, and wiring diagrams.
Searchability:
Likely searchable text within PDF for quick information retrieval.
Printability:
Printable pages for workshop use.
Graphics Quality:
High-resolution diagrams and illustrations.
Physical Binding:
N/A (digital format assumed, but if printed, typically spiral-bound or perfect-bound for durability)
Physical Paper:
N/A (digital format assumed, but OEM manuals often use heavy-duty, gloss-coated paper)
Ml320 Engine:
3.2L SOHC V6 (M112 E32)
Ml320 Horsepower:
215 hp @ 5750 rpm
Ml320 Torque:
229 lb-ft @ 3000-4250 rpm
Ml350 Engine:
3.7L SOHC V6 (M112 E37) - typically 2003-2005 models
Ml350 Horsepower:
232 hp @ 5750 rpm
Ml350 Torque:
258 lb-ft @ 3000-4500 rpm
Ml500 Engine:
5.0L SOHC V8 (M113 E50)
Ml500 Horsepower:
288 hp @ 5500 rpm
Ml500 Torque:
325 lb-ft @ 2700-4500 rpm
Engine Technology:
Single Overhead Camshaft (SOHC), 3 valves per cylinder (M112), 2 valves per cylinder (M113), aluminum block and heads, Sequential Multi-Port Fuel Injection (MPFI)
Fuel Type:
Premium Unleaded Gasoline (91 AKI or higher recommended)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Length:
Approx. 185.4 - 187.2 inches
Width:
Approx. 71.8 inches
Height:
Approx. 70.2 - 70.7 inches
Wheelbase:
Approx. 111.0 inches
Ground Clearance:
Approx. 8.0 - 8.4 inches (depending on suspension/tire)
Seating Capacity:
5 passengers (optional 3rd-row seating for 7 passengers available on some models/trims)
Cargo Volume Behind Rear Seat:
Approx. 39.5 cubic feet
Cargo Volume With Rear Seat Folded:
Approx. 73.2 cubic feet
Curb Weight Ml320:
Approx. 4600 - 4800 lbs
Curb Weight Ml350:
Approx. 4700 - 4900 lbs
Curb Weight Ml500:
Approx. 4850 - 5050 lbs
Towing Capacity:
Up to 5000 lbs (with optional trailer hitch and specific configuration)
NHTSA Front Impact Driver:
Likely 4 Stars (1997-2000 models, varies by year)
NHTSA Front Impact Passenger:
Likely 4 Stars (1997-2000 models, varies by year)
IIHS Front Offset:
Acceptable (for tested models, varies by year)
Esp:
Standard Electronic Stability Program (ESP) on most models/years
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Standard Acceleration Slip Regulation (ASR)
Airbags:
Front airbags, side airbags (standard on later models, optional earlier)
Seatbelts:
3-point seat belts with pretensioners
Head Unit:
Factory AM/FM/CD player, optional navigation system (COMAND 2.0/2.5), optional CD changer.
Speaker System:
Premium sound system options available (e.g., Bose).
Cruise Control:
Standard cruise control.
Parking Assistance:
Optional rear parking sensors (Parktronic) on some models.
Bluetooth:
Not natively integrated in early models; aftermarket solutions common.
Auxiliary Input:
Optional, or available via aftermarket adapters.
Oil Change Interval:
Typically every 10,000 miles or 12 months, whichever comes first, using synthetic oil.
Transmission Fluid Service:
Recommended every 50,000 - 60,000 miles (fluid and filter change).
Coolant Replacement:
Every 2 years or 30,000 miles for initial change, then every 2 years thereafter with appropriate coolant.
Spark Plug Replacement:
ML320/ML350 (M112): Approx. 100,000 miles; ML500 (M113): Approx. 100,000 miles (iridium plugs).
Engine Oil Spec:
MB 229.1 or MB 229.5 (API SN or newer) 5W-40 or 0W-40 synthetic recommended
Transmission Fluid Spec:
MB 236.10 or MB 236.12 (ATF 3403-M115 / NAG2 FLC)
Coolant Spec:
MB 325.0 / 326.0 (Antifreeze/Coolant based on Ethylene Glycol)
Power Steering Fluid:
MB 236.3 (ATF Dexron III compatible)
Common Problems Overview:
Common issues for this generation can include electronic component failures (e.g., ABS module, blower motor resistor), rust on body panels (especially wheel wells and rocker panels), interior component wear (e.g., seat leather, headliner), and occasional transmission or differential leaks.
ABS Esp Module Failure:
The ABS/ESP control module is a known failure point, leading to warning lights and system malfunction.
Blower Motor Resistor:
The blower motor resistor can fail, causing the HVAC fan to only work at the highest setting or not at all.
Rust Prone Areas:
Rear wheel arches, front fender liners, rocker panels, and the rear hatch area are susceptible to corrosion.
Oil Cooler Seals:
Leaking oil cooler seals can lead to oil in the coolant, or vice-versa, requiring replacement of seals or the entire cooler assembly.
Transfer Case Actuator:
The actuator for the 4MATIC transfer case can fail, leading to AWD system faults.
Mercedes Benz Legacy:
Pioneering automotive manufacturer with a long history of engineering excellence, safety, and luxury.
W163 Introduction:
Introduced in 1997 as Mercedes-Benz's first entry into the burgeoning SUV market, positioned as a premium, capable, and luxurious vehicle.
Facelift Update:
Received a significant facelift for the 2002 model year, including updated styling, interior refinements, and powertrain enhancements (e.g., introduction of the ML350).
Manufacturing Locations:
Primarily produced at the Mercedes-Benz Tuscaloosa Plant in Alabama, USA.
Generation Codes:
W163 generation.
