Mercedes-Benz ML320 ML350 ML500 2003 Repair Service Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: ML-Class Year: 2003 Chassis Code: W163 Engine Variants Covered: ML320, ML350, ML500 Codes Engine Code Ml320: M112.944 (3.2L V6) Engine Code Ml350: M112.970...

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类型: Car

斯库: 390083

标签: 2003 Car Cars Mercedes Mercedes-benz Misc ML320 ML350 ML500

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

ML-Class

Year:

Chassis Code:

Engine Variants Covered:

ML320, ML350, ML500

Codes

Engine Code Ml320:

M112.944 (3.2L V6)

Engine Code Ml350:

M112.970 (3.7L V6)

Engine Code Ml500:

M113.960 (5.0L V8)

👋 Introduction

Market Position

Segment:

Luxury Mid-size SUV

Target Audience:

Premium SUV buyers seeking comfort, utility, and luxury.

Competitive Analysis

Key Competitors 2003:

BMW X5, Lexus RX 330, Acura MDX, Volvo XC90.

Key Features

Platform:

Built on the W163 platform, shared components with other Mercedes-Benz models.

Drivetrain:

Standard 4MATIC all-wheel drive system for enhanced traction and stability.

Luxury Appointments:

High-quality interior materials, advanced comfort features, and refined ride quality.

📋 Manual Details

Coverage Areas

Diagnostic Procedures:

Comprehensive diagnostic procedures, fault code interpretation, and troubleshooting guides for all major systems.

Repair Procedures:

Detailed step-by-step repair instructions for mechanical, electrical, and body components.

Maintenance Schedules:

In-depth maintenance schedules including fluid changes, filter replacements, inspections, and lubrication points.

Electrical System:

Complete coverage of the vehicle's electrical system, including wiring diagrams, component locations, and diagnostic procedures.

Engine Mechanical:

Engine assembly and disassembly, internal component specifications, timing, and overhaul procedures for all variants.

Transmission Service:

Detailed procedures for automatic transmission service, including fluid changes, filter replacement, and internal component repair.

Suspension Steering:

Diagnosis and repair of suspension and steering components, including alignment specifications.

Brake System:

Complete service and repair procedures for the braking system, including ABS and traction control.

Body And Chassis:

Body panel removal and installation, interior trim, chassis adjustments, and collision repair information.

Climate Control HVAC:

Service and repair procedures for the heating, ventilation, and air conditioning (HVAC) system.

Safety Systems:

Information on SRS (Supplemental Restraint System) components and service, including airbag system precautions.

Fuel System:

Fuel injection system diagnosis and repair, fuel pump, injectors, and fuel tank service.

Exhaust System:

Service and repair procedures for the exhaust system, including catalytic converters and muffler replacement.

Cooling System:

Radiator, water pump, thermostat, and coolant system service and repair.

Wheels And Tires:

Tire pressure monitoring system (TPMS) information, wheel installation, and tire specifications.

Page Count

Estimated Pages:

Likely over 1500 pages (typical for comprehensive factory-level service manuals).

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

All Major Systems:

Covers all major mechanical and electrical systems of the W163 ML-Class.

Procedures Included

Routine Maintenance:

Scheduled maintenance tasks, fluid checks and changes, filter replacements.

Engine Repair:

Internal engine diagnostics, component replacement, cylinder head service, timing chain/belt service (if applicable).

Transmission Overhaul:

Full overhaul procedures for the 5-speed automatic transmission (722.6), including torque converter, valve body, and clutch pack service.

Brake System Overhaul:

Brake caliper, rotor, and fluid service, ABS modulator and sensor diagnosis.

Electrical Troubleshooting:

Wiring diagrams, component testing, diagnostic trouble codes (DTCs), and electrical component replacement.

Suspension And Steering Diagnosis:

Ball joint, control arm, shock absorber, strut, and power steering system repair.

Body Repair:

Door, hood, trunk, bumper, and interior trim component replacement and adjustment.

HVAC System Service:

Refrigerant handling, compressor, evaporator, and heater core replacement.

Fuel System Diagnosis:

Fuel injector testing, fuel pressure regulation, and fuel pump replacement.

Technical Depth

Depth:

Professional-level diagnostic and repair information suitable for experienced technicians and advanced DIY enthusiasts.

Diagnostic Tools:

References diagnostic procedures typically requiring Mercedes-Benz specific diagnostic tools (e.g., Star Diagnosis).

Rebuild Procedures:

Detailed procedures for rebuilding key components like engines, transmissions, and differentials.

📊 Manual Specifications

File Format

Format Type:

Searchability:

Likely text-searchable PDF for efficient information retrieval.

Print Quality

Quality:

High-resolution scans optimized for clarity and readability of diagrams and text.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Ml320 Engine:

3.2L SOHC V6 (M112.944)

Ml350 Engine:

3.7L SOHC V6 (M112.970)

Ml500 Engine:

5.0L SOHC V8 (M113.960)

Performance

Ml320 Horsepower:

215 hp @ 5750 rpm

Ml320 Torque:

229 lb-ft @ 3250 rpm

Ml350 Horsepower:

232 hp @ 5750 rpm

Ml350 Torque:

236 lb-ft @ 3250 rpm

Ml500 Horsepower:

288 hp @ 5500 rpm

Ml500 Torque:

325 lb-ft @ 2800 rpm

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Recommended Fuel:

Premium Unleaded Gasoline (91 octane or higher)

Emission Control:

California Emission Standards (for US models), includes catalytic converters and oxygen sensors.

🔧 Transmission

Standard

Transmission Type:

5-speed automatic (722.6)

Optional

Optional Transmission:

N/A (Standard for all variants in 2003)

Features

Drivetrain Integration:

Integrated with 4MATIC all-wheel drive system.

Transmission Fluid Spec:

MB 236.14 (or equivalent ATF)

Transmission Fluid Capacity:

Approximately 8.0 liters (8.5 US quarts) for complete fluid change.

📐 Dimensions

Exterior

Length:

184.5 inches (4686 mm)

Width:

71.7 inches (1821 mm)

Height:

70.1 inches (1780 mm)

Wheelbase:

111.4 inches (2830 mm)

Weights

Curb Weight Ml320:

4542 lbs (2060 kg)

Curb Weight Ml500:

4762 lbs (2160 kg)

Towing Capacity:

Up to 5000 lbs (2268 kg) with optional towing package.

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

4-star (Frontal Offset Crash Rating)

Active Features

Traction Control:

4-ETS (Electronic Traction System) standard.

Stability Control:

ESP (Electronic Stability Program) standard.

Anti-lock Braking System (ABS) standard.

Passive Features

Airbags:

Front and side airbags, optional rear side airbags.

Seatbelts:

Height-adjustable front seat belts with pretensioners and load limiters, three-point rear seat belts.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Infotainment

Audio System:

Optional COMAND (Cockpit Management and Navigation) system with integrated GPS navigation, CD player, and premium sound systems (e.g., Bose).

Driver Assistance

Parking Assist:

Optional Parktronic parking assist system.

Cruise Control:

Standard cruise control system.

Connectivity

Phone Integration:

Optional integrated mobile phone preparation with Bluetooth connectivity (depending on market and option package).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 10,000 miles (16,000 km) or 12 months, whichever comes first, with synthetic oil.

Transmission Fluid Interval:

Recommended every 60,000 miles (96,000 km) or 3-4 years, although some sources suggest earlier intervals.

Coolant Change Interval:

Every 30,000 miles (48,000 km) or 2-3 years.

Fluid Specifications

Engine Oil Spec:

SAE 0W-30 or 0W-40 Synthetic Engine Oil meeting MB 229.5 specification.

Coolant Spec:

Mercedes-Benz approved coolant (e.g., G05 or equivalent) mixed with distilled water (50/50 ratio).

Brake Fluid Spec:

DOT 4 specification.

Known Issues

Common Problem Aos:

Air oil separator (AOS) leaks leading to oil consumption and potential intake manifold contamination.

Common Problem Intake Manifold:

Cracked plastic intake manifolds (particularly on V6 engines) leading to vacuum leaks and performance issues.

Common Problem Transmission Conductor Plate:

Failure of the transmission conductor plate in the 722.6 transmission, causing shifting problems and limp mode.

Common Problem Balance Shaft Sprag Clutch:

Failure of the sprag clutch within the balance shaft assembly on certain M112 engines, leading to starting issues.

Common Problem Rust:

Potential for rust on wheel arches, rocker panels, and tailgate, especially in rust-prone climates.

Common Problem Window Regulators:

Failure of power window regulators.

📚 Vehicle History

Brand Heritage

Mercedes Benz Legacy:

Mercedes-Benz has a long-standing reputation for engineering excellence, luxury, and safety dating back to the late 19th century.

Model Evolution

W163 Generation:

The W163 generation ML-Class debuted in 1997 and received a significant facelift for the 2002 model year, which carried into 2003.

Production

Manufacturing Location:

Initially produced in Tuscaloosa, Alabama, USA.

Production Years W163:

1997-2005

🏆 Awards & Recognition

Recognitions

Model Recognition:

The ML-Class has generally been well-received for its luxury, comfort, and off-road capability for a luxury SUV.

Ratings

Desempeño Adac:

Mercedes-Benz vehicles often rank highly in European automotive club surveys like ADAC for reliability and breakdown statistics.

Certifications

Engineering Standards:

Adheres to stringent Mercedes-Benz engineering and quality standards.