🏷️ Basic Information Identification Make: Mercedes-Benz Model: ML320 Model Code: W163 Generation: First Generation Production Years: 1997-2005 Codes Chassis Code: W163 👋 Introduction Market Position Vehicle Class: Luxury Mid-size SUV / Sport Utility Vehicle Segment: Premium SUV segment, competing with brands like BMW X5, Lexus RX, and Land Rover Discovery. Competitive Analysis Key Competitors: BMW X5 (E53), Lexus RX (XU10), Land Rover Discovery II, Jeep Grand Cherokee (WJ). Key Features Offroad Capability: Known for its blend of luxury and respectable off-road capability, especially with the 4MATIC all-wheel-drive system and available off-road packages (though often not heavily utilized by typical owners). Luxury Appointments: Typical Mercedes-Benz interior quality, comfort features, and advanced (for its time) technology. Powertrain Options: Primarily known for its smooth and powerful V6 engine, offering a refined driving experience. Manual Purpose Target Audience: Service technicians, dealership repair shops, and knowledgeable DIY car owners undertaking maintenance and repairs. 📋 Manual Details Coverage Areas Primary Coverage: Mercedes-Benz ML320 (W163) models Year Coverage: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Page Count Estimated Pages: Hundreds of pages (exact count not specified but implied to be comprehensive) Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: Download PDF 📖 Manual Coverage Systems Covered Engine: Comprehensive diagnosis, repair, overhaul, and specifications for all ML320 engines offered during the W163 generation (primarily M112 V6). Transmission: Detailed service and repair procedures for the automatic transmission (e.g., 722.6 NAG1), including hydraulic systems, electronic controls, and torque converter. Drivetrain: Front and rear axle assemblies, differential service, driveshafts, CV joints, and transfer case (4MATIC all-wheel drive system). Brakes: Front and rear brake system service, ABS, ESP (Electronic Stability Program), brake fluid flush, caliper and rotor replacement. Suspension: Front and rear suspension components, shock absorbers, springs, control arms, ball joints, bushings, and steering linkage. Steering: Power steering system diagnosis and repair, steering column, steering rack, and alignment procedures. Electrical System: Complete wiring diagrams, fuse and relay locations, charging system (alternator, battery), starting system, lighting, and accessory circuits. Engine Management: ECU/ECM operation, sensors (e.g., MAF, O2, crankshaft position), actuators, fuel injection, ignition system, and emission control systems (e.g., EGR, catalytic converter). Climate Control: HVAC system diagnosis and repair, A/C compressor, refrigerant system, heater core, blower motor, and climate control modules. Bodywork: Body panel removal and installation, door mechanisms, glass replacement, interior trim, and exterior moldings. Safety Systems: Airbag system diagnosis and components, seat belt mechanisms. Procedures Included Maintenance: Routine maintenance tasks such as oil changes, filter replacements, spark plug replacement, brake fluid changes, coolant flushes, and belt inspections. Diagnostics: Systematic troubleshooting guides, diagnostic trouble codes (DTCs) and their meanings, component testing procedures, and fault finding strategies. Repair: Step-by-step instructions for component removal, repair, and reinstallation for all major vehicle systems. Overhaul: Complete engine and transmission overhaul procedures, including disassembly, cleaning, inspection, and reassembly with torque specifications. Replacements: Detailed procedures for replacing common wear items like brake pads, rotors, belts, hoses, and suspension components. Adjustments: Procedures for adjusting critical systems like parking brake, door latches, and electronic control modules where applicable. Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems, facilitating accurate diagnosis of electrical faults. Technical Depth Depth: Expert-level diagnostic and repair information suitable for professional technicians and experienced DIY enthusiasts. Detail Level: Includes detailed torque specifications, special tool requirements, clearances, and critical tolerances for all repair procedures. Diagnostic Tools: References diagnostic procedures that would typically utilize Mercedes-Benz proprietary diagnostic tools (e.g., STAR Diagnosis), though general troubleshooting is also covered. 📊 Manual Specifications File Format Format: PDF Searchability: Likely searchable text content within the PDF for efficient information retrieval. Print Quality Quality: Assumed high-quality digital reproduction of original factory documentation. Binding Type Type: Digital Download (PDF) - Not applicable for physical binding. Paper Type Type: Not applicable for digital format. ⚙️ Engine Specifications Primary Engine Engine Family: M112 Engine Type: SOHC V6 (90-degree bank angle) Displacement: 3.2 Liters (3199 cc) Bore X Stroke: 89.9 mm x 84.0 mm Compression Ratio: 10.0:1 Performance Horsepower Peak: 215 hp @ 5750 rpm (approx.) Torque Peak: 229 lb-ft @ 3250 rpm (approx.) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with sequential port injection. Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Engine Management ECM Type: ME 2.0 / ME 2.8 (depending on model year and specific variations) Cooling System Coolant Type: MB Approved Antifreeze/Coolant (e.g., G48 or equivalent) Coolant Capacity: Approximately 9.0 - 10.0 Liters 🔧 Transmission Standard Type: 5-speed Automatic Transmission Transmission Code: 722.6 (NAG1) Features Electronic Control: Electronically controlled with multiple shift modes (Comfort, Sport). Fluid Specification Transmission Fluid: MB Approved ATF (e.g., ATF 3403-M115 or similar approved fluid) Fluid Capacity Capacity: Approximately 7.5 - 8.5 Liters for a fluid change (dry fill is higher) 📐 Dimensions Exterior Length: Approx. 4637 mm (182.6 in) Width: Approx. 1829 mm (72.0 in) Height: Approx. 1790 mm (70.5...