🏷️ Basic Information Identification Make: Mercedes-Benz Model: ML-Class Model Variants: ML320, ML350, ML500 Chassis Code: W163 Generation Generation Code: First Generation Production Years Covered: 1997-2005 👋 Introduction Market Position Vehicle Segment: Luxury Mid-size SUV Brand Perception: Represents Mercedes-Benz's entry into the premium SUV market, offering luxury, comfort, and off-road capability. Competitive Analysis Key Competitors: BMW X5, Lexus RX, Audi Q7 (later models), Volvo XC90 Key Features Platform: Based on the same unibody construction as the E-Class sedan (W210), featuring independent suspension for improved on-road comfort. Drivetrain: Standard 4MATIC all-wheel drive system, offering enhanced traction and stability. Interior Appointments: Premium materials, comfortable seating, and a range of luxury features expected from Mercedes-Benz. 📋 Manual Details Coverage Areas Language: English Format: Digital (likely PDF) Manual Type: Workshop Service Repair Manual Completeness: Comprehensive (implied by 'complete service repair manual') 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, crankshaft, pistons, connecting rods, timing system, lubrication system, cooling system Engine Management: Fuel system, ignition system, emission control systems, sensors, actuators, ECU diagnostics, troubleshooting Transmission Manual: Manual transmission (if applicable, though W163 primarily used automatic), clutch system Transmission Automatic: Automatic transmission (e.g., 722.6 '5G-TRONIC'), valve body, torque converter, transmission control module (TCM), fluid service Drivetrain: Four-Wheel Drive (4MATIC) system, transfer case, drive shafts, axles, differentials Suspension: Front and rear suspension components, struts, shocks, control arms, springs, bushings, steering knuckles Steering: Power steering system, steering rack, steering column, linkages, troubleshooting Brakes: Front and rear brake systems (discs/drums), hydraulic system, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), parking brake Electrical System: Battery, charging system, starter, lighting (headlights, taillights, interior), fuses, relays, wiring diagrams Body And Chassis: Body panels, doors, hood, tailgate, interior trim, glass, chassis components, rust prevention HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant service, blower motor, controls Infotainment And Comfort: Audio system, navigation system (if equipped), climate control interfaces, power accessories (windows, mirrors, seats) Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, brake pad inspection Diagnostic Troubleshooting: Step-by-step diagnostic procedures for common and uncommon faults, fault code interpretation Component Removal Installation: Detailed instructions for removing and installing major and minor components (e.g., engine, transmission, alternator, starter, suspension parts, brake calipers) Rebuild Procedures: Overhaul instructions for engines, transmissions, and other major mechanical units Electrical System Repair: Wiring harness repair, component testing, diagnosing electrical faults Body Repair: Minor bodywork, panel replacement, alignment procedures Specifications And Tolerances: Torque specifications, clearances, wear limits for all major components Technical Depth Depth Level: Comprehensive; covers everything from basic maintenance to full engine and transmission rebuilds, including advanced diagnostics and wiring diagrams. 📊 Manual Specifications File Format Digital Format: Likely PDF, optimized for readability and searchability. Print Quality Print Readability: High-resolution images and diagrams suitable for printing or on-screen viewing. Binding Type Physical Binding: N/A (for digital format) Paper Type Physical Paper: N/A (for digital format) ⚙️ Engine Specifications Primary Engine Ml320 Engine: 3.2L M112 E32 V6 (SOHC) Ml320 Power Output: 215 hp @ 5750 rpm Ml320 Torque Output: 229 lb-ft @ 3750 rpm Ml350 Engine: 3.7L M112 E37 V6 (SOHC) Ml350 Power Output: 232 hp @ 5750 rpm Ml350 Torque Output: 258 lb-ft @ 3750 rpm Ml500 Engine: 5.0L M113 E50 V8 (SOHC) Ml500 Power Output: 292 hp @ 5500 rpm Ml500 Torque Output: 339 lb-ft @ 3000 rpm Fuel System Fuel Delivery: Multi-point fuel injection (MPI) Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Engine Construction Block Material: Aluminum Alloy Head Material: Aluminum Alloy 🔧 Transmission Standard Transmission Type: 5-speed automatic (722.6 '5G-TRONIC') Optional Optional Transmissions: N/A (5-speed automatic was standard across all models) Features Transmission Features: TouchShift (manual shifting mode), electronic control unit (ECU) integration for adaptive shifting. Fluid Specifications Transmission Fluid Type: MB 236.10 or 236.12 Automatic Transmission Fluid (ATF) Fluid Capacity Transmission Fluid Capacity: Approximately 8-10 liters (depending on converter drain/fill) 📐 Dimensions Exterior Length: Approx. 182.4 inches (4633 mm) Width: Approx. 71.5 inches (1816 mm) Height: Approx. 67.3 inches (1709 mm) Wheelbase: Approx. 111 inches (2820 mm) Cargo Cargo Volume Rear Seats Up: Approx. 37.1 cubic feet (1050 liters) Cargo Volume Rear Seats Down: Approx. 73.6 cubic feet (2084 liters) Weights Curb Weight Ml320: Approx. 4500 lbs (2041 kg) Curb Weight Ml500: Approx. 4700 lbs (2132 kg) Towing Capacity: Up to 5000 lbs (2268 kg) Wheels Tires Standard Wheel Size: 16-inch or 17-inch alloy wheels Standard Tire Size: 225/75 R16, 255/60 R17 (depending on model and year) Bolt Pattern: 5 x 112 mm 🛡️ Safety Features Ratings NHTSA Front Impact: 5-Star (driver and passenger) for 1999-2000 models NHTSA Side Impact: 4-Star (front and rear passenger) for 1999-2000 models Active Features Stability Control: Standard Electronic Stability Program (ESP) on most models. Traction Control: Standard ASR (Acceleration Slip Regulation) integrated with 4MATIC. Passive Features Airbags: Front airbags (driver and passenger), optional side airbags (front...