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Mercedes Benz ML320 W163 1998-2005 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: ML320 Chassis Code: W163 Model Years Covered: 1998-2005 Codes Engine Code: M112 E32 (3.2L V6) 👋 Introduction Market Position Segment: Luxury Mid-size SUV...
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Mercedes Benz ML320 W163 1998-2005 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
ML320
Chassis Code:
W163
Model Years Covered:
1998-2005
Codes
Engine Code:
M112 E32 (3.2L V6)
👋 Introduction
Market Position
Segment:
Luxury Mid-size SUV (Sport Utility Vehicle)
Target Audience:
Individuals seeking a premium, comfortable, and capable SUV with Mercedes-Benz engineering and luxury.
Competitive Analysis
Competitors:
BMW X5, Audi Q7, Lexus RX, Volvo XC90, Land Rover Discovery
Key Features
Powertrain:
3.2L V6 engine, 5-speed automatic transmission, standard 4MATIC all-wheel drive
Comfort And Luxury:
Leather upholstery, premium sound system, climate control, comfortable seating for up to seven (optional third row)
Off Road Capability:
Slightly higher ground clearance, available off-road package (though primarily focused on on-road comfort)
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Language:
English
Format:
Digital (likely PDF)
Page Count
Page Count:
> 2800
File Size Mb:
129
📖 Manual Coverage
Systems Covered
Engine:
3.2L 6-cylinder (M112 E32) - complete overhaul, diagnostics, tuning, emissions
Transmission:
Automatic Transmission (e.g., 5G-TRONIC 722.6) - overhaul, diagnostics, fluid service, electronic control
Drivetrain:
All-Wheel Drive (4MATIC), differentials (front, center, rear), drive shafts, CV joints
Suspension:
Independent front and rear suspension, struts, shocks, springs, control arms, bushings, anti-roll bars, self-leveling suspension (if equipped)
Brakes:
Hydraulic braking system, ABS, EBD, brake calipers, rotors, pads, lines, master cylinder, parking brake
Steering:
Power steering system, steering gear, tie rods, power steering pump, fluid service
Electrical:
Battery, charging system (alternator), starter, ignition system, lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, multiplexing systems
Climate Control:
HVAC system, A/C compressor, refrigerant, blower motor, evaporator, heater core, climate control modules
Body And Interior:
Body panels, doors, windows, sunroof, seats, upholstery, trim, dashboard, interior components, exterior trim
Safety Systems:
Airbags, seat belts, SRS module, anti-theft systems
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements (oil, air, cabin, fuel), spark plug replacement, fluid checks and top-offs
Diagnostics:
Troubleshooting common faults, identifying symptoms, diagnostic trouble codes (DTCs), using diagnostic tools (e.g., STAR Diagnosis)
Repair:
Component removal and installation, component rebuilding, leak diagnosis and repair, sensor replacement, module calibration
Overhaul:
Complete engine and transmission rebuild procedures
Specifications:
Torque specifications, clearances, timing procedures, fluid capacities, electrical component testing
Wiring Diagrams:
Comprehensive electrical schematics for all systems
Technical Depth
Depth:
Comprehensive - from basic maintenance and routine checks to advanced diagnostics, component overhaul, and full vehicle repair. Suitable for professional mechanics and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format) - typically, allowing for searchability and printability.
Print Quality
Print Quality:
Expected to be high, with clear diagrams, illustrations, and text, suitable for printing individual sections or the entire manual.
Binding Type
Binding Type:
Digital format implies no physical binding; however, if a printed version were available, it would typically be professionally bound (e.g., comb binding, spiral binding, or perfect binding) for durability in a workshop environment.
Paper Type
Paper Type:
Not applicable for digital format. If printed, it would likely be on durable paper stock suitable for workshop use.
⚙️ Engine Specifications
Primary Engine
Engine Type:
V6 SOHC (Single Overhead Camshaft)
Displacement:
3.2 Liters (3199 cc)
Bore X Stroke:
89.9 mm x 84.0 mm
Compression Ratio:
10.0:1
Power Output:
Approx. 215 hp @ 5750 rpm
Torque Output:
Approx. 228 lb-ft @ 3250-4500 rpm
Performance
0 To 60 Mph:
Approx. 8.5 - 9.0 seconds
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Fuel Tank Capacity:
Approx. 22.7 gallons (86 liters)
🔧 Transmission
Standard
Type:
5-speed Automatic (5G-TRONIC 722.6)
Features:
Electronic control, TouchShift manual shifting mode
Optional
Optional Transmissions:
Not applicable for the ML320 W163 with the 3.2L V6 in this generation.
Features
Transmission Fluid Type:
MB Specification 236.10 or 236.14 Automatic Transmission Fluid (ATF)
📐 Dimensions
Exterior
Length:
Approx. 181.6 inches (4613 mm)
Width:
Approx. 71.6 inches (1819 mm)
Height:
Approx. 66.9 inches (1700 mm)
Wheelbase:
Approx. 111 inches (2820 mm)
Ground Clearance:
Approx. 8.0 inches (203 mm)
Weights
Curb Weight:
Approx. 4450 - 4600 lbs (2018 - 2087 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 5800 - 6000 lbs (2630 - 2722 kg)
Cargo
Cargo Volume Behind Rear Seats:
Approx. 39.5 cu ft (1118 liters)
Cargo Volume With Rear Seats Folded:
Approx. 75.1 cu ft (2127 liters)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
4 Stars (for models prior to the 2003 facelift)
NHTSA Frontal Impact Passenger:
4 Stars (for models prior to the 2003 facelift)
NHTSA Side Impact Front Passenger:
4 Stars
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Standard Electronic Traction System (ETS) or ASR (Acceleration Slip Regulation)
Stability Control:
Available Electronic Stability Program (ESP) on later models or optional.
Passive Features
Airbags:
Driver and front passenger airbags, optional side airbags
Seat Belts:
3-point seat belts with pretensioners and load limiters
Rollover Protection:
Structural design considerations for SUV rollover resistance, although specific ratings vary by year and testing methodology.
💡 Technology Features
Infotainment
Audio System:
Bose premium sound system often standard or optional, with CD player, AM/FM radio, and auxiliary input.
Navigation:
Optional factory navigation system, typically with a CD-ROM based map database.
Driver Assistance
Parking Sensors:
Available front and rear PARKTRONIC parking assist sensors on higher trims or as an option.
Connectivity
Telematics:
Optional tele Aid emergency calling system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 miles (16,000 km) or 12 months, whichever comes first, using synthetic oil.
Air Filter Replacement:
Every 20,000 - 30,000 miles (32,000 - 48,000 km)
Cabin Air Filter Replacement:
Annually or every 10,000 - 15,000 miles (16,000 - 24,000 km)
Transmission Fluid Service:
Every 30,000 - 40,000 miles (48,000 - 64,000 km), often including filter replacement.
Spark Plug Replacement:
Approx. 100,000 miles (160,000 km) with iridium spark plugs.
Fluid Specifications
Engine Oil Type:
SAE 0W-30 or 0W-40 Synthetic Engine Oil meeting MB-Approval 229.5
Engine Oil Capacity:
Approx. 8.5 US quarts (8.0 liters)
Coolant Type:
Mercedes-Benz approved Antifreeze/Coolant (e.g., G05 or G48) at a 50/50 mixture with distilled water.
Brake Fluid Type:
DOT 4 Plus Brake Fluid
Known Issues
Icm Module Failure:
The Ignition Control Module (ICM) is a known failure point, causing intermittent or no-start conditions.
ABS Esp Sensor Failure:
Wheel speed sensors for the ABS and ESP systems can fail, leading to warning lights and loss of ABS/ESP function.
Biodegradable Wiring Harness:
Early models experienced issues with the insulation on wiring harnesses degrading, leading to short circuits and electrical problems.
Rear Main Seal Leaks:
Common to experience oil leaks from the rear main crankshaft seal.
Catalytic Converter Failure:
Catalytic converters can fail prematurely due to various engine issues or age.
📚 Vehicle History
Brand Heritage
Heritage:
Mercedes-Benz has a long-standing reputation for luxury, engineering, and automotive innovation, established in the early 20th century. This heritage brings a commitment to quality and refinement to their SUV offerings.
Model Evolution
First Generation W163:
Introduced in 1997 for the 1998 model year, the W163 marked Mercedes-Benz's entry into the premium SUV segment. It was designed to blend luxury car comfort with the versatility of an SUV. Key updates occurred with a facelift in 2001, introducing revised styling and enhanced features.
Production
Manufacturing Locations:
Primarily produced at the Tuscaloosa, Alabama, USA, plant, which was a significant investment for Daimler-Benz.
Production Years:
1998-2005
🏆 Awards & Recognition
Recognitions
Type:
As a luxury SUV, the ML320 W163 was generally well-received for its comfort and brand prestige. Specific awards might include 'Best Luxury SUV' or similar accolades from automotive publications during its production run, though detailed award tracking for this specific model year range can be extensive and vary by region.
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