🏷️ Basic Information

Make:

Mercedes-Benz

Model:

ML320

Model Code:

W163

Generation:

First Generation

Chassis Code:

W163

👋 Introduction

Segment:

Luxury Mid-size SUV

Target Audience:

Consumers seeking a premium, capable, and comfortable SUV with robust engineering

Key Competitors:

BMW X5, Lexus RX300/RX330, Acura MDX, Cadillac Escalade, Land Rover Discovery

Distinguishing Features:

Mercedes-Benz build quality, available V8 engine (ML500), robust 4MATIC all-wheel-drive system, luxurious interior, strong towing capacity

Manual Value Proposition:

Provides comprehensive, dealer-level repair and maintenance information, crucial for DIY mechanics and independent workshops to service this complex luxury vehicle.

📋 Manual Details

Applicable Years:

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

Regions Covered:

Global (North America, Europe, Asia, etc.)

Estimated Page Count:

1000+

Type:

Workshop Service Repair Manual

Language:

English

Format:

Digital Download (PDF)

📖 Manual Coverage

Engine Mechanical:

Complete overhaul, diagnosis, component testing, timing, seals, gaskets

Engine Electrical:

Ignition system, starting system, charging system, ECU diagnostics, sensors, wiring diagrams

Fuel System:

Fuel injection, fuel pump, injectors, fuel filter, fuel lines, EVAP system

Transmission Automatic:

Removal, installation, overhaul, fluid service, torque converter, valve body, electronic controls

Drivetrain:

All-Wheel Drive (4MATIC) system, differentials, driveshafts, CV joints, wheel bearings

Suspension:

Front and rear suspension components, springs, shock absorbers, control arms, ball joints, bushings, alignment specifications

Brakes:

Brake system diagnosis, ABS, ESP, brake pads, rotors, calipers, brake lines, hydraulic system

Steering:

Power steering system, steering rack, tie rods, steering column, linkages

Cooling System:

Radiator, thermostat, water pump, cooling fans, coolant specifications, pressure testing

Exhaust System:

Catalytic converter, mufflers, pipes, hangers, oxygen sensors

Climate Control:

HVAC system, A/C compressor, refrigerant, evaporator, heater core, climate control unit

Body And Chassis:

Body panel removal/installation, doors, hood, tailgate, interior trim, structural components

Electrical Body:

Lighting system, power windows, central locking, mirrors, wipers, horn, alarm system, body control module (BCM)

Infotainment And Navigation:

Audio system, CD changer, navigation system, display units, antenna systems

Safety Systems:

Airbag system (SRS), seatbelt pre-tensioners, diagnostic procedures for safety components

Routine Maintenance:

Oil change, filter replacement, fluid checks and top-offs, tire rotation, brake inspection

Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, common fault analysis

Repair Procedures:

Step-by-step instructions for component replacement, adjustments, and overhauls

Diagnostic Procedures:

Using scan tools, electrical testing, mechanical component testing

Adjustment Procedures:

Wheel alignment, throttle linkage, parking brake

Wiring Diagrams:

Comprehensive electrical circuit diagrams for all vehicle systems

Depth:

Complete factory-level diagnostic and repair information

Detail Level:

Detailed specifications, torque values, clearances, and procedures for professional technicians

Rebuild Information:

Includes procedures for rebuilding major components like engines and transmissions

📊 Manual Specifications

Type:

PDF

Searchability:

Text-searchable for quick information retrieval

Printability:

Printable pages for workshop use

Quality:

High-resolution scans ensuring clarity of diagrams and text

Type:

N/A (Digital Download)

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

V6, SOHC, 18-valve (M112 E32)

Displacement:

3.2 Liters (3199 cc)

Bore X Stroke:

89.9 mm x 84.0 mm

Compression Ratio:

10.0:1

Horsepower:

215 hp @ 5750 rpm

Torque:

229 lb-ft (310 Nm) @ 3000-4500 rpm

Injection Type:

Sequential Electronic Fuel Injection (SEFI)

Fuel Type:

Premium Unleaded Gasoline (91 Octane Recommended)

Engine Family:

M112

Engine Orientation:

V-configuration, longitudinal

Valvetrain:

Single Overhead Camshaft (SOHC) per cylinder bank, 3 valves per cylinder

Emissions Control:

Catalytic converter, Secondary Air Injection (SAI) system (on some models/years)

🔧 Transmission

Type:

5-Speed Automatic (722.6 - NAG1)

Type:

N/A for ML320 in this generation

Drive Modes:

Comfort (C) and Sport (S) modes

Torque Converter Lockup:

Yes, provides direct drive efficiency

Fluid Type:

MB Spec 236.10 (ATF 3353, successor to ATF 3403)

Capacity Approx:

8-10 Liters (depending on service type)

📐 Dimensions

Length:

4638 mm (182.6 in)

Width:

1842 mm (72.5 in)

Height:

1757 mm (69.2 in)

Wheelbase:

2820 mm (111.0 in)

Ground Clearance:

Approximately 200 mm (7.9 in) (varies with suspension option)

Curb Weight:

Approx. 1950-2100 kg (4300-4630 lbs)

Gross Vehicle Weight Rating:

Approx. 2700 kg (5950 lbs)

Towing Capacity:

Up to 2600 kg (5730 lbs) with factory tow hitch

🛡️ Safety Features

NHTSA Front Impact:

4-Star (Driver and Passenger) for 1998 model

IIHS Side Impact:

Good (for models equipped with side airbags)

Traction Control:

ASR (Anti-Slip Regulation)

Stability Control:

ESP (Electronic Stability Program)

ABS:

Standard Anti-lock Braking System

Airbags:

Front airbags, optional front side-impact airbags, optional curtain airbags (later models)

Seatbelts:

3-point inertia-reel seatbelts with pre-tensioners and load limiters

💡 Technology Features

Audio System:

Factory AM/FM/CD player with optional CD changer, premium sound system options available (e.g., Bose).

Navigation:

Optional COMAND (Cockpit Management and Navigation) system with color display.

Cruise Control:

Standard electronic cruise control

Parking Assistance:

Optional parking sensors (Parktronic) on later models

Phone Integration:

Optional Mercedes-Benz TeleAid system (emergency calling) and integrated hands-free phone systems (various generations/options).

🔧 Maintenance

Oil Change Interval:

Every 10,000 miles or 12 months, whichever comes first (using synthetic oil)

Transmission Service Interval:

Every 60,000 miles (fluid and filter replacement recommended)

Air Filter Replacement:

Every 30,000 miles or as needed based on driving conditions

Spark Plug Replacement:

Every 100,000 miles (if original platinum/iridium plugs are used)

Engine Oil Type:

SAE 0W-40 or 5W-40 Full Synthetic, MB Approval 229.5 or 229.51

Engine Oil Capacity:

8.0 Liters (8.5 US Quarts)

Coolant Type:

MB Spec 325.0 (Glysantin G05 or equivalent, typically a pink/red long-life coolant)

Brake Fluid Type:

DOT 4 Plus (or DOT 4)

Power Steering Fluid Type:

MB Spec 236.3 (ATF Dexron II or equivalent)

Common Problems:

Mass airflow sensor (MAF) issues, EGR valve clogging (if equipped), oil cooler seals leaking, transmission conductor plate failure, rust on tailgate and wheel arches, HVAC blower motor resistor failure, ABS/ESP sensor issues, fuel pump failure.

Preventative Maintenance Focus:

Regularly check and replace PCV system components and vacuum hoses to prevent vacuum leaks and potential engine performance issues. Monitor transmission fluid and condition during services.

📚 Vehicle History

Manufacturer:

Mercedes-Benz AG

Established Year:

1886

Introduction Year:

1997

Development Basis:

Developed to compete in the growing SUV market, combining Mercedes-Benz luxury and engineering with off-road capability.

Facelift:

Minor refresh for the 2002 model year, including updated interior materials, revised exterior styling (grille, headlights, taillights), and engine enhancements.

Manufacturing Location:

Tuscaloosa, Alabama, USA

Production Period:

1997-2005

🏆 Awards & Recognition

Award Example:

Named MotorTrend's SUV of the Year for 1998.

Consumer Reports Reliability:

Variable, generally average to below average for this model year range, highlighting the importance of thorough maintenance and using this manual for accurate repairs.

Certification Type:

N/A for the manual itself, but the vehicle adheres to Mercedes-Benz's rigorous internal quality standards.