Segment:
Luxury Mid-size SUV (Sport Utility Vehicle)
Target Audience:
Buyers seeking a premium, capable, and comfortable SUV with Mercedes-Benz engineering and refinement.
Key Competitors:
BMW X5 (E53), Audi allroad quattro, Volvo XC90 (later models), Lexus RX.
Unique Selling Points:
Robust construction, strong diesel engine torque, premium interior materials, advanced safety features for its time, genuine off-road capability (for an SUV of its era).
General Coverage:
Complete workshop repair and service procedures for Mercedes-Benz ML270 CDI (W163).
Specific Systems Covered:
Engine, Drivetrain (Transmission, Transfer Case, Axles), Suspension, Steering, Brakes, Fuel System, Cooling System, Exhaust System, Electrical System, Climate Control, Bodywork, Interior Trim, Diagnostic Procedures.
Type:
Workshop Repair Service Manual
Engine Mechanical:
Detailed procedures for engine overhaul, component replacement (pistons, rings, bearings, valves, camshafts, crankshaft), timing chain and belt service, cylinder head repair, lubrication system maintenance, cooling system service.
Engine Management:
Diagnosis and repair of engine control unit (ECU), fuel injection system (Common Rail Direct Injection - CDI), glow plug system, emissions control systems (EGR, DPF if applicable to specific model year), sensor testing and replacement.
Drivetrain:
Service and repair of the 5-speed automatic transmission (722.6), transfer case operation and repair, front and rear axle assembly, driveshafts, CV joints, propeller shafts.
Suspension And Steering:
Front and rear suspension component replacement (struts, shocks, control arms, ball joints, bushings), steering gear maintenance and repair, power steering system service, wheel alignment procedures and specifications.
Brakes:
Front and rear brake system service (disc brake pad and rotor replacement), caliper overhaul, brake fluid bleeding and replacement, Anti-lock Braking System (ABS) component testing and diagnosis.
Electrical System:
Wiring diagrams, fuse box layouts, battery service, alternator and starter motor testing, lighting system repair, power accessory troubleshooting, diagnostic connector (OBD-II) access and data interpretation.
Climate Control:
Air conditioning system service, refrigerant charging, heater core and evaporator diagnosis, blower motor and control panel repair.
Maintenance:
Scheduled maintenance intervals, oil and filter changes, air filter replacement, fuel filter replacement, coolant flush and replacement, spark plug replacement (if applicable, though diesel), brake fluid replacement, transmission fluid and filter service.
Troubleshooting:
Diagnostic flowcharts for common issues, symptom-based troubleshooting guides, fault code interpretation, electrical system diagnostics.
Repair:
Step-by-step repair instructions for virtually all mechanical and electrical components, including engine rebuilds, transmission overhauls, suspension and brake component replacement, body panel repair, interior trim removal and installation.
Specifications And Data:
Torque specifications for all fasteners, fluid capacities, component tolerances, diagnostic data, wiring schematics, lubrication charts.
Body And Interior:
Front bumper and fender removal, rear bumper and tailgate procedures, door panel removal, seat removal and installation, headliner repair, exterior trim replacement.
Diagnostics:
Utilizing diagnostic tools (e.g., XENTRY/DAS for later models, or generic OBD-II scanners) to read and interpret fault codes, monitor live data, and perform system tests.
Depth:
Comprehensive, covering everything from basic fluid checks and filter changes to full engine and transmission rebuilds. Detailed diagnostic procedures and component-level repair are included.
Wiring Diagrams:
Extensive and detailed wiring schematics for all electrical systems, crucial for diagnosing electrical faults.
Component Identification:
Clear identification of all components with corresponding part numbers or descriptions where applicable.
Front Impact Crash Test:
NHTSA: 4-star rating (driver and passenger) for 1999 models.
Side Impact Crash Test:
NHTSA: 5-star rating (front and rear passenger) for 1999 models.
Active Safety Systems:
Anti-lock Braking System (ABS), Electronic Stability Program (ESP), Traction Control System (ETS), Downhill Speed Regulation (DSR).
Airbags:
Front airbags (driver and passenger), optional side airbags.
Seatbelts:
Pretensioning seatbelts with force limiters, rear three-point seatbelts.
Oil Change Interval:
Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first, under normal driving conditions. Consult manual for severe service intervals.
Transmission Service Interval:
Typically every 60,000 km (37,000 miles) or 3-4 years for fluid and filter replacement. Check manual for specific recommendations.
Engine Oil Type:
Refer to Mercedes-Benz MB 229.3 or MB 229.5 specifications (e.g., SAE 5W-40 or 0W-40 synthetic diesel oil).
Transmission Fluid Type:
MB 236.10 specification Automatic Transmission Fluid (ATF) for 722.6 transmission (e.g., Shell ATF 134 or equivalent).
Coolant Type:
MB 325.0 specification (Glysantin G05 or equivalent HOAT coolant).
Common Problems Area:
Potential issues include ABS/ESP sensor failures, swirl flap actuator problems, rear main crankshaft seal leaks, transmission control module (TCM) issues, and rust on the chassis, especially around the wheel arches and sills.
Diesel Specific Issues:
Glow plug system faults, injector seal leaks, and turbocharger wear can occur with age and mileage.
Brand Legacy:
Mercedes-Benz, renowned for automotive engineering excellence, luxury, safety, and durability since its inception.
W163 Platform:
The W163 generation M-Class was Mercedes-Benz's first foray into the SUV market, launched in 1997 for the 1998 model year. The ML270 CDI was introduced later to offer a more fuel-efficient and torquey diesel option.
Manufacturing Location:
Tuscaloosa, Alabama, USA (for North American market), and Graz, Austria (for European and other markets via Magna Steyr).
