Positioning:
The Mercedes-Benz ML-Class (W163) was a pioneering luxury mid-size SUV that blended Mercedes-Benz's renowned comfort and build quality with off-road capability.
Competitors:
Competed against luxury SUVs like the BMW X5, Lexus RX, and Land Rover Discovery during its production run.
Features:
Offered a comfortable ride, premium interior, powerful engine options, and the advanced 4MATIC all-wheel-drive system.
Vehicle Models Covered:
Mercedes-Benz ML320, ML350, ML500
Vehicle Years Covered:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Type:
Repair Service Manual
Engine:
Detailed diagnostics, repair procedures, component overviews for M112 (3.2L V6, 3.7L V6) and M113 (5.0L V8) engines. Includes timing system, lubrication, cooling, fuel injection, ignition.
Transmission:
Repair and maintenance for 722.6 NAG1 (5-speed automatic) transmission. Includes fluid service, electronic controls, torque converter, valve body.
Drivetrain:
Front and rear differentials, transfer case (4MATIC all-wheel drive system), drive shafts, CV joints. Lubrication and repair procedures.
Suspension:
Independent front and rear suspension, shock absorbers, springs, control arms, sway bars, power steering system.
Brakes:
Front and rear disc brakes, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), brake fluid service, caliper and rotor replacement.
Electrical System:
Battery, charging system, starter, lighting, wiring diagrams, fuse box locations, ECU/ECM diagnosis, body control modules.
HVAC:
Air conditioning system, heater core, blower motor, climate control unit, refrigerant handling, leak testing.
Body And Chassis:
Frame structure, body panels, doors, hood, tailgate, interior trim, glass replacement, bodywork repair.
Fuel System:
Fuel pump, fuel filter, fuel injectors, fuel tank, emissions control systems (EVAP).
Exhaust System:
Exhaust manifolds, catalytic converters, mufflers, pipe replacement.
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, brake pad/rotor replacement.
Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting, common problem diagnosis for various systems.
Repair:
Detailed step-by-step repair procedures for all major mechanical and electrical components. Includes component removal, installation, and adjustment.
Diagnostics:
OBD-II diagnostics, using scan tools, understanding sensor data, troubleshooting electronic modules.
Depth:
Comprehensive, covering routine maintenance to major overhaul and repair. Suitable for both DIY enthusiasts and professional technicians.
Length:
Approx. 189.5 inches (4813 mm)
Width:
Approx. 75.2 inches (1910 mm)
Height:
Approx. 71.2 inches (1808 mm)
Seating Capacity:
5 (optional 7-seater package available on some models)
Cargo Volume Behind Rear Seat:
Approx. 37.7 cubic feet (1068 L)
Curb Weight:
Approx. 4,600 - 4,900 lbs (2087 - 2223 kg) depending on engine and options
NHTSA Front Crash Test:
4-star driver, 4-star passenger (for early models)
IIHS Side Impact Test:
Good (for models equipped with side airbags)
Active Safety:
ABS, ESP (Electronic Stability Program), ASR (Acceleration Slip Regulation), 4-wheel traction control.
Passive Safety:
Front airbags, optional front side-impact airbags, optional side curtain airbags, three-point seatbelts with pretensioners.
Infotainment System:
Various Audio and COMAND (Cockpit Management and Navigation) systems, depending on model year and trim. Features may include CD player, radio, optional navigation, and premium sound systems.
Driver Assistance Features:
Standard: ABS, ESP. Optional/Later Models: Parktronic parking assist, rain-sensing wipers.
Connectivity Features:
Limited by era; early models may have integrated phone preparation. Later models with COMAND systems offered some limited connectivity options.
Oil Change Interval:
Typically every 10,000 miles (16,000 km) or 12 months, whichever comes first, using synthetic oil.
Transmission Fluid Interval:
Recommended at 60,000 miles (96,000 km) or every 5 years for the 722.6 transmission.
Spark Plug Interval:
V6 engines: approx. 100,000 miles. V8 engines: approx. 100,000 miles (using Iridium spark plugs).
Engine Oil Specification:
MB 229.3 or MB 229.5 approved synthetic engine oil (e.g., 0W-40, 5W-40, 5W-30 depending on climate).
Transmission Fluid Specification:
MB 236.10 or MB 236.14 Automatic Transmission Fluid (ATF) - Mercedes-Benz Specification 001 989 21 03 or equivalent.
Coolant Specification:
Mercedes-Benz approved coolant (e.g., ZEREX G-05 or similar HOAT coolant).
Brake Fluid Specification:
DOT 4 Plus (or DOT 4 as a minimum).
Common Problems:
Coolant leaks from the 'valley pan' or thermostat housing, transmission conductor plate failures, mass airflow sensor issues, ignition coil failures, rust on the tailgate and wheel arches, ABS/ESP sensor faults.
Heritage:
Mercedes-Benz has a long-standing reputation for engineering excellence, luxury, and durability.
First Generation:
The W163 ML-Class was Mercedes-Benz's first foray into the SUV market, launched in 1997. It was developed in collaboration with Chrysler.
Mid-Cycle Refresh:
Received a significant refresh for the 2002 model year, including updated styling, improved interior, new engine options (ML350, ML500), and enhanced technology.
Manufacturing Locations:
Primarily manufactured at the Tuscaloosa, Alabama, USA plant.
