Mercedes Benz ML320 ML350 ML500 Complete Workshop Service Repair Manual 1997 1998 1999 2000 2001 2002 2003 2004 2005

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: ML-Class Body Style: SUV (Sport Utility Vehicle) Generation: First Generation (W163) Codes Chassis Code: W163 👋 Introduction Market Position Segment: Luxury Mid-size SUV...

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标签: 1997 1998 1999 2000 2001 2002 2003 2004 2005 Car Cars Mercedes Mercedes Benz Misc ML320 ML350 ML500

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

ML-Class

Body Style:

SUV (Sport Utility Vehicle)

Generation:

First Generation (W163)

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Luxury Mid-size SUV (Sport Utility Vehicle)

Competitive Analysis

Key Competitors:

BMW X5, Lexus RX, Volvo XC90, Audi Allroad Quattro

Key Features

Brand Prestige:

Represents Mercedes-Benz's entry into the burgeoning SUV market with its characteristic luxury and engineering.

Platform Sharing:

Built on a unibody chassis, offering a more car-like ride compared to traditional body-on-frame SUVs of the era.

📋 Manual Details

Coverage Areas

Vehicle Years:

1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005

Covered Models:

ML320, ML350, ML500

Page Count

Estimated Pages:

Extensive (typically 1000+ pages for a complete workshop manual)

Manual Type

Type:

Workshop Service and Repair Manual

Language

Language:

English

Format

Format:

Digital Download (likely PDF)

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, repair, overhaul, timing, fuel injection, lubrication, cooling, emissions control

Transmission:

Automatic transmission repair, maintenance, diagnostics, fluid service, shift control

Drivetrain:

Four-wheel drive (4MATIC) system, differentials, drive shafts, CV joints

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, wheel alignment

Steering:

Power steering system, steering column, rack and pinion, steering linkage

Brakes:

Hydraulic system, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), brake discs, pads, calipers, lines, parking brake

Electrical:

Wiring diagrams, battery, charging system, starter, lighting, instrument cluster, body control module (BCM), fuse/relay locations

HVAC:

Heating, Ventilation, and Air Conditioning system diagnostics and repair, climate control module

Body:

Exterior panels, doors, windows, glass, sunroof, bumpers, interior trim, seats

Chassis:

Frame and body structural components, torque specifications for chassis fasteners

Safety Systems:

Airbag system (SRS), seat belt pre-tensioners, system diagnostics

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks, tune-ups

Troubleshooting:

Diagnostic charts, fault code interpretation, common problems and solutions

Repair:

Step-by-step repair instructions for all major components and systems

Overhaul:

Complete engine and transmission rebuild procedures

Installation:

Component replacement and installation guidance

Specifications:

Torque values, clearances, fluid capacities, electrical specifications

Wiring Diagrams:

Comprehensive electrical schematics for all systems

Technical Depth

Level:

Comprehensive; covers basic maintenance to full engine/transmission rebuilds and complex diagnostics

📊 Manual Specifications

File Format

Type:

Searchability:

Likely searchable text for efficient navigation

Print Quality

Quality:

High-resolution images and diagrams

Binding Type

Type:

Not applicable (digital download)

Paper Type

Type:

Not applicable (digital download)

⚙️ Engine Specifications

Primary Engine

Ml320 (1997-2002):

3.2L V6 (M112 E32)

Ml350 (2003-2005):

3.7L V6 (M112 E37)

Ml500 (2002-2005):

5.0L V8 (M113 E50)

Performance

Ml320 (Approximate):

215 hp @ 5750 rpm, 229 lb-ft @ 3250 rpm

Ml350 (Approximate):

232 hp @ 5750 rpm, 236 lb-ft @ 3500 rpm

Ml500 (Approximate):

288 hp @ 5600 rpm, 325 lb-ft @ 2800 rpm

Fuel System

Type:

Sequential Multi-Port Fuel Injection (MPI)

Engine Management

ECU Model:

ME 2.0 / ME 2.8 / ME 3.7 (depending on year and engine)

🔧 Transmission

Standard

Type:

5-speed automatic transmission (722.6 '5G-TRONIC')

Optional

Type:

N/A for these specific models/years

Features

Control:

Electronic control with multiple shift modes (Comfort/Standard/Manual)

Fluid Type

Specification:

MB Spec 236.10 (ATF 3403 M-115 or equivalent)

📐 Dimensions

Exterior

Length:

Approx. 187.4 inches

Width:

Approx. 71.5 inches

Height:

Approx. 67.1 inches

Wheelbase

Distance:

Approx. 111 inches

Weights

Curb Weight:

Approx. 4,400 - 4,700 lbs (depending on engine and options)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

5-Star (Model Year dependent, generally good for its time)

IIHS Side Impact:

Good (Model Year dependent)

Active Features

Stability Control:

Standard ESP (Electronic Stability Program)

Braking System:

Standard ABS (Anti-lock Braking System), Brake Assist (BAS)

Traction Control:

ASR (Acceleration Slip Regulation)

Passive Features

Airbags:

Front dual-stage airbags, optional side airbags

Seat Belts:

Pre-tensioners, force limiters

💡 Technology Features

Infotainment

System:

Optional COMAND (Cockpit Management and Navigation) system, premium sound systems available.

Features:

CD player, cassette player (early models), AM/FM radio, optional CD changer.

Driver Assistance

Systems:

Parktronic parking assist (optional), rain-sensing wipers (optional).

Connectivity

Features:

Early telematics systems (e.g., Tele Aid) available on some models.

🔧 Maintenance

Service Intervals

Oil Change:

Typically every 10,000 miles or 12 months (following Flexible Service System - ASSYST), but always consult manual for specifics.

Transmission Fluid:

Recommended service every 40,000-60,000 miles, depending on driving conditions.

Spark Plugs:

Long-life iridium spark plugs, typically replaced around 100,000 miles.

Fluid Specifications

Engine Oil:

SAE 0W-40 (MB Spec 229.5) or SAE 5W-40 (MB Spec 229.51 for diesel if applicable, though unlikely for these gas models)

Coolant:

MB Spec 325.0 or 326.0 (Antifreeze/Coolant concentrate, typically silicate-free)

Known Issues

Common Problems:

Mass airflow sensor (MAF) issues, "Check Engine" light, transmission conductor plate failures, rear main seal leaks, blower motor resistor failure, rust on tailgate and wheel arches.

📚 Vehicle History

Brand Heritage

Legacy:

Mercedes-Benz has a long history of engineering excellence, luxury, and automotive innovation.

Model Evolution

Launch Year:

Introduced in 1997 (as a 1998 model in North America) to compete in the growing luxury SUV market.

Updates:

Received a significant facelift and powertrain updates for the 2002 model year, including the introduction of the ML500 and ML350 (replacing ML320 in some markets/years).

Production

Manufacturing Location:

Tuscaloosa, Alabama, USA

🏆 Awards & Recognition

Recognitions

Automotive Journalism:

Often recognized by automotive publications for its luxury, refinement, and off-road capability (relative to competitors).

Ratings

Safety Awards:

Achieved good safety ratings from organizations like NHTSA and IIHS during its production run.