🏷️ Basic Information

Make:

Mercedes-Benz

Model:

M-Class

Chassis Code:

W163

Generation:

First Generation

Product Type:

Workshop Service Repair Manual

👋 Introduction

Market Segment:

Luxury Mid-Size SUV

Competitors:

BMW X5 (E53), Lexus RX (XU10), Porsche Cayenne (first generation, launched 2002), Land Rover Discovery Series II, Audi allroad quattro

Usp:

Offers luxury, off-road capability (with optional 4MATIC), advanced safety features, and robust build quality, representing Mercedes-Benz's entry into the burgeoning SUV market.

📋 Manual Details

Covered Years:

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

Model Variants Covered:

All M-Class (W163) models, engines, trims, and transmission types

Delivery Method:

Downloadable

File Format:

PDF (Requires Adobe Reader)

Compatibility:

All PC & MAC Computers, tablets, smartphones

Language:

English (Assumed, typical for workshop manuals of this era)

Manual Type:

Comprehensive Workshop Service Repair Manual

Estimated Page Count:

Extensive, covering all procedures A-Z (specific count not provided but implied to be substantial)

📖 Manual Coverage

Systems Covered:

Engine mechanical, engine electrical, fuel system, ignition system, cooling system, exhaust system, lubrication system, powertrain control module (PCM), transmission (automatic and manual), drivetrain, chassis, suspension (front and rear), steering, braking system (including ABS/ESP), body electrical, HVAC, climate control, interior components, exterior body panels, safety systems (airbags, seatbelts), diagnostic procedures, and troubleshooting

Procedures Included:

Routine maintenance, scheduled servicing, component diagnostics, repair procedures, disassembly and reassembly of all major systems, electrical troubleshooting, wiring diagrams, specifications, torque values, special tool requirements, adjustments, replacement procedures, and preventative maintenance

Technical Depth:

In-depth, step-by-step instructions with illustrative pictures for all service and repair jobs, suitable for both professional mechanics and DIY enthusiasts

📊 Manual Specifications

Print Quality:

High-quality (as stated in description), printable pages

Searchability:

Likely searchable text within PDF (standard for professional manuals)

Binding Type:

N/A (Digital Download - Printable)

Paper Type:

N/A (Digital Download - Printable)

⚙️ Engine Specifications

Engine Code Example:

M111 E23 (2.3L Inline-4 Supercharged)

Engine Displacement Example:

2.3 Liters (2295 cc)

Engine Configuration Example:

Inline-4, Supercharged

Horsepower Example:

194 hp @ 5300 rpm

Torque Example:

200 lb-ft (270 Nm) @ 2500 rpm

Engine Code Example:

M112 E32 (3.2L V6)

Engine Displacement Example:

3.2 Liters (3199 cc)

Engine Configuration Example:

V6

Horsepower Example:

215 hp @ 5750 rpm

Torque Example:

229 lb-ft (310 Nm) @ 3000-4250 rpm

Engine Code Example:

M112 E43 (4.3L V8)

Engine Displacement Example:

4.3 Liters (4300 cc)

Engine Configuration Example:

V8

Horsepower Example:

275 hp @ 5750 rpm

Torque Example:

284 lb-ft (385 Nm) @ 3250 rpm

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type Required:

Unleaded Gasoline (Premium recommended for most engines)

🔧 Transmission

Transmission Type:

5-Speed Automatic (5G-TRONIC)

Transmission Type:

Optional Manual Transmission (less common, typically for base models)

Drivetrain:

Rear-Wheel Drive (RWD) standard, 4MATIC All-Wheel Drive (AWD) optional

📐 Dimensions

Length Mm:

4518 mm (approx.)

Width Mm:

1839 mm (approx.)

Height Mm:

1757 mm (approx.)

Wheelbase Mm:

2820 mm (approx.)

Curb Weight Kg Min:

1920 kg (approx. for 2.3L)

Cargo Volume Liters Behind Rear Seats:

633 Liters (approx.)

Cargo Volume Liters With Rear Seats Folded:

2020 Liters (approx.)

🛡️ Safety Features

NHTSA Front Impact Rating Driver:

5-Star (for models tested)

NHTSA Front Impact Rating Passenger:

5-Star (for models tested)

IIHS Side Impact Rating:

Good (for models tested with side airbags)

Stability Control:

Electronic Stability Program (ESP) standard on most models

Traction Control:

All-Season Traction Control (ASTC)

Airbags:

Front airbags, optional side airbags

Seatbelts:

3-point inertia-reel seatbelts with pretensioners and belt force limiters

💡 Technology Features

Infotainment System:

Optional COMAND (Cockpit Management and Navigation) system with CD player, radio, and optional navigation.

Cruise Control:

Standard cruise control functionality.

Parking Assistance:

Optional Parktronic parking sensors.

Connectivity Features:

Early models may have integrated phone systems (optional); later models may feature more advanced audio system connectivity (e.g., auxiliary inputs).

🔧 Maintenance

Oil Change Interval:

Typically every 10,000 miles (16,000 km) or 12 months, whichever comes first (check manual for specific engine)

Air Filter Replacement:

Every 30,000 miles (48,000 km) or as needed based on driving conditions

Coolant Flush Interval:

Every 3 years or 60,000 miles (96,000 km)

Engine Oil Type Example:

Mobil 1 Synthetic 0W-40 (API SM or newer, MB-Approval 229.5)

Transmission Fluid Type Example:

ATF Dexron III or equivalent (MB-Approval 236.10 for 5G-TRONIC)

Coolant Type:

Mercedes-Benz Approved Antifreeze/Coolant (e.g., G05 or G48 formulation, blue/green color)

Brake Fluid Type:

DOT 4 (MB-Approval 331.0)

Common Issue 1:

Mass Air Flow (MAF) sensor failure leading to rough idling or poor performance.

Common Issue 2:

Cracked dashboard material due to sun exposure and aging.

Common Issue 3:

Oil leaks from valve cover gaskets or crankcase seals.

Common Issue 4:

ABS/ESP module failures, often indicated by warning lights.

Common Issue 5:

Rust issues, particularly around wheel wells and door sills, especially in areas with road salt.

📚 Vehicle History

Brand Focus:

Luxury automobiles, engineering excellence, safety innovation

W163 Introduction:

Launched in 1997 (for the 1998 model year) as Mercedes-Benz's first SUV.

Mid Cycle Refresh:

Received a significant facelift for the 2002 model year, featuring updated styling, interior refinements, and new powertrain options.

Manufacturing Location:

Tuscaloosa, Alabama, USA

W163 Production Span:

1997-2005

🏆 Awards & Recognition

Award Example:

Often recognized for its safety and luxury in its class during its production years.

Safety Ratings:

Achieved good safety ratings from IIHS and NHTSA for its era, contributing to Mercedes-Benz's reputation.