🏷️ Basic Information Identification Make: Mercedes-Benz Model: ML-Class (W163) Model Variant: ML320, ML350, ML500 Production Years: 1997-2005 Generation Generation Code: W163 👋 Introduction Market Position 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. Competitive Analysis Competitors: Competed against luxury SUVs like the BMW X5, Lexus RX, and Land Rover Discovery during its production run. Key Features Features: Offered a comfortable ride, premium interior, powerful engine options, and the advanced 4MATIC all-wheel-drive system. 📋 Manual Details Coverage Areas Vehicle Models Covered: Mercedes-Benz ML320, ML350, ML500 Vehicle Years Covered: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Manual Type Type: Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered 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. Procedures Included 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. Technical Depth Depth: Comprehensive, covering routine maintenance to major overhaul and repair. Suitable for both DIY enthusiasts and professional technicians. 📊 Manual Specifications File Format Format: Digital PDF Document Print Quality Quality: High-resolution scans of original factory documentation, ensuring clear text and diagrams. Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Ml320 Engine: 3.2L SOHC V6 (M112 E32) Ml350 Engine: 3.7L SOHC V6 (M112 E37) - introduced later in the generation Ml500 Engine: 5.0L SOHC V8 (M113 E50) Performance Ml320 Horsepower: Approx. 215-221 hp Ml320 Torque: Approx. 229-232 lb-ft Ml500 Horsepower: Approx. 292-298 hp Ml500 Torque: Approx. 339-335 lb-ft Fuel System Injection Type: Sequential Electronic Fuel Injection (SEFI) Fuel Type: Premium Unleaded Gasoline (91+ Octane Recommended) 🔧 Transmission Standard Transmission Type: 5-Speed Automatic (722.6 NAG1) Optional Optional Transmissions: N/A (Only the 722.6 automatic was offered) Features Transmission Features: Touchshift (manual shifting capability), Electronic transmission control, Torque converter lock-up. 📐 Dimensions Exterior Length: Approx. 189.5 inches (4813 mm) Width: Approx. 75.2 inches (1910 mm) Height: Approx. 71.2 inches (1808 mm) Interior Seating Capacity: 5 (optional 7-seater package available on some models) Cargo Cargo Volume Behind Rear Seat: Approx. 37.7 cubic feet (1068 L) Weights Curb Weight: Approx. 4,600 - 4,900 lbs (2087 - 2223 kg) depending on engine and options 🛡️ Safety Features Ratings 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 Features Active Safety: ABS, ESP (Electronic Stability Program), ASR (Acceleration Slip Regulation), 4-wheel traction control. Passive Features Passive Safety: Front airbags, optional front side-impact airbags, optional side curtain airbags, three-point seatbelts with pretensioners. 💡 Technology Features Infotainment 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 Driver Assistance Features: Standard: ABS, ESP. Optional/Later Models: Parktronic parking assist, rain-sensing wipers. Connectivity Connectivity Features: Limited by era; early models may have integrated phone preparation. Later models with COMAND systems offered some limited connectivity options. 🔧 Maintenance Service Intervals 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). Fluid Specifications 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...