2002 Mercedes M-Class (W163) Service and Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: M-Class Model Code: W163 Year: 2002 Generation Generation Name: First Generation (W163) Generation Years: 1997-2005 Codes Chassis Code: W163 👋 Introduction Market Position...

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标签: 2002 Car Cars M Class Mercedes W163

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

M-Class

Model Code:

Year:

Generation

Generation Name:

First Generation (W163)

Generation Years:

1997-2005

Codes

Chassis Code:

👋 Introduction

Market Position

Target Audience:

Mercedes-Benz M-Class (W163) owners and independent repair shops

Competitive Analysis

Advantage:

Provides dealership-level technical information, eliminating reliance on generic guides

Key Features

Convenience:

Single, easy-to-use PDF manual, eliminating the need to flip through multiple books

Organization:

Print-on-demand functionality for specific sections and diagrams

📋 Manual Details

Coverage Areas

Coverage Scope:

All Models & All Repairs A-Z

Page Count

Estimated Page Count:

Extensive (Implied by comprehensive coverage)

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Digital Access:

Downloadable

📖 Manual Coverage

Systems Covered

Engine:

Complete service, diagnosis, and repair

Control System:

Engine, transmission, chassis, and body electronics

Mechanical:

All major mechanical components

Fuel Service:

Fuel system diagnosis, repair, and specifications

Emission Control:

Emission control system diagnosis and repair

Cooling System:

Cooling system maintenance and repair

Lubrication System:

Lubrication system maintenance and specifications

Ignition Starting Charging:

Ignition, starting, and charging system diagnosis and repair

Transmission Auto:

Automatic transmission service, diagnosis, and repair

Transmission Manual:

Manual transmission service, diagnosis, and repair

Drivetrain Transfer:

Transfer case, propeller shaft, and drive shaft service

Drivetrain Differential:

Differential service and repair

Suspension:

Axle, suspension, and wheel bearing service

Brakes:

Brake system control, repair, and specifications

Steering:

Steering column, power steering, and alignment

HVAC:

Air conditioning system diagnosis and repair

Safety Srs:

Supplemental Restraint System (SRS) diagnosis and repair

Restraint Systems:

Seat belts and associated systems

Security:

Engine immobilizer and door lock systems

Cruise Control:

Cruise control system diagnosis and repair

Wipers Washers:

Wiper and washer system maintenance and repair

Instrumentation:

Instrument panel, meters, and gauges

Audio Visual:

Audio and visual system diagnosis and repair

Horns:

Horn system operation and repair

Glass Mirrors:

Windshield, glass, and mirror service

Bodywork Interior:

Exterior and interior trim, seating, and body panels

Electrical Systems:

Comprehensive electrical system diagnosis and repair

Communication Networks:

Multiplex/CAN communication system diagnosis

Procedures Included

Maintenance Procedures:

Scheduled maintenance, fluid changes, filter replacements

Troubleshooting Guides:

Diagnostic procedures for common and uncommon issues

Repair Instructions:

Step-by-step repair procedures for all covered systems

Diagnostic Procedures:

Detailed diagnostic routines and fault code explanations

Wiring Schematics:

Complete electrical wiring diagrams for all systems

Illustrations Diagrams:

High-quality illustrations and diagrams for visual guidance

Technical Depth

Depth Of Coverage:

Factory-level detail, suitable for professional technicians and advanced DIYers

Information Source:

Exact same manual used by dealership technicians

📊 Manual Specifications

File Format

Compatibility:

Windows (Vista32/64, XP, ME, 98, NT, 2000) and Mac compatible

Software Requirements:

Adobe PDF Reader and Winzip (free)

Print Quality

Printability:

All pages are printable

Image Scaling:

Images can be blown up and printed in enlarged copies

Binding Type

Binding Method:

Digital (PDF) - no physical binding

Paper Type

Paper Quality:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Options 2002:

ML320 (3.7L V6), ML350 (3.7L V6 - often synonymous with ML320 in some markets), ML500 (5.0L V8)

Performance

Ml320 Horsepower Approx:

215 hp @ 5500 rpm (M112 V6)

Ml320 Torque Approx:

229 lb-ft @ 3750 rpm (M112 V6)

Ml500 Horsepower Approx:

288 hp @ 5500 rpm (M113 V8)

Ml500 Torque Approx:

325 lb-ft @ 3250 rpm (M113 V8)

Fuel System

Fuel Injection:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

🔧 Transmission

Standard

Standard Transmission:

5-speed Automatic Transmission (5G-TRONIC)

Optional

Optional Transmission:

N/A for 2002 M-Class (W163)

Features

Transmission Features:

TouchShift (allows manual selection of gears), electronically controlled

📐 Dimensions

Exterior

Length:

Approx. 189.2 inches (4806 mm)

Width:

Approx. 73.2 inches (1859 mm)

Height:

Approx. 67.7 inches (1720 mm)

Weights

Curb Weight Ml320:

Approx. 4400 lbs (2000 kg)

Curb Weight Ml500:

Approx. 4600 lbs (2090 kg)

🛡️ Safety Features

Ratings

NHTSA Front Crash Test Driver:

5 Stars (for models equipped with side airbags)

NHTSA Front Crash Test Passenger:

5 Stars (for models equipped with side airbags)

NHTSA Side Impact Driver:

4 Stars

NHTSA Side Impact Rear Passenger:

4 Stars

Active Features

Active Safety Features:

Anti-lock Braking System (ABS), Electronic Stability Program (ESP), Traction Control System (ASR)

Passive Features

Passive Safety Features:

Front airbags, side airbags (optional), front seatbelt pretensioners, rear child seat anchors (LATCH)

💡 Technology Features

Infotainment

Infotainment System:

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

Driver Assistance

Driver Assistance Features:

Optional Parktronic parking assist system

Connectivity

Connectivity Features:

Optional voice control system (Linguatronic)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000 miles or 12 months, whichever comes first (refer to manual for exact specifications)

Transmission Fluid Change:

Recommended every 60,000 miles or as per service schedule (refer to manual)

Fluid Specifications

Engine Oil Specification:

MB 229.5 (e.g., Mobil 1 0W-40 Synthetic) or similar approved specifications

Transmission Fluid Specification:

MB 236.12 or MB 236.14 Automatic Transmission Fluid (ATF)

Coolant Specification:

Mercedes-Benz Approved Antifreeze/Coolant (e.g., G05 or similar)

Known Issues

Common Issues Potential:

Mass airflow sensor (MAF) issues, ignition coil failures, front axle ball joint wear, crank position sensor failures, rust on body panels, electronic module failures

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Germany

Model Evolution

W163 Introduction:

Introduced in 1997 as Mercedes-Benz's first entry into the SUV market

W163 Facelift:

Received a minor facelift for the 2002 model year, including updated styling and features

Production

Production Locations:

Tuscaloosa, Alabama, USA; Rastatt, Germany

🏆 Awards & Recognition

Recognitions

Award Type:

MotorTrend SUV of the Year

Award Year: