🏷️ Basic Information Identification Make: Mercedes-Benz Model: ML500 Exclusive Year: 2002-2003 Powertrain Type: Gasoline Codes Chassis Code: W163 👋 Introduction Market Position Segment: Mid-size Luxury SUV (Sport Utility Vehicle) Positioning: Positioned as a premium, capable, and luxurious SUV offering a blend of on-road refinement and off-road capability, reflecting Mercedes-Benz's brand heritage. Competitive Analysis Key Competitors: BMW X5 (E53), Lexus RX (XU30), Porsche Cayenne (955), Volvo XC90, Audi Allroad Quattro Key Features Distinctive Features: Powerful V8 engine, standard 4MATIC all-wheel drive, luxurious interior appointments, advanced safety features for its time, excellent build quality. 📋 Manual Details Coverage Areas Market Focus: North America (implied by 'GAS' designation and typical sales markets for ML-Class) Vehicle Variant Coverage: ML500 Exclusive trim level Page Count Estimated Page Count: 1500-2000 (typical for comprehensive factory-level service manuals of this era) Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical (M113 V8), fuel system, ignition system, emissions control, cooling system, lubrication system Transmission: 5G-TRONIC automatic transmission (722.6 series) Drivetrain: All-wheel drive (4MATIC), differentials, drive shafts, axles, transfer case Suspension: Front independent suspension, rear multi-link suspension, shock absorbers, springs, control arms, bushings Brakes: Hydraulic system, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), brake calipers, rotors, pads, lines, parking brake Steering: Power steering system, steering column, steering gear/rack and pinion Electrical: 12V electrical system, battery, alternator, starter, fuse box, wiring diagrams, lighting systems, instrumentation, power accessories Body: Body panels, doors, hood, tailgate, interior trim, glass, seals, bumpers HVAC: Heating, ventilation, air conditioning, climate control system, components (compressor, evaporator, heater core) Comfort Features: Power seats, sunroof, door locks, windows, mirrors Diagnostics: On-board diagnostics (OBD-II), fault code retrieval and interpretation, diagnostic trouble codes (DTCs) Procedures Included Routine Maintenance: Oil and filter changes, fluid level checks and top-offs, tire rotation, air filter replacement, spark plug replacement Component Replacement: Brake pads and rotors, belts, hoses, battery, alternator, starter motor, suspension components, exhaust system components Major Repairs: Engine rebuilds, transmission overhauls, driveline component repair Troubleshooting: Step-by-step diagnostic procedures for common and uncommon issues Special Tools: Identification and use of Mercedes-Benz specific tools required for certain procedures Technical Depth Level Of Detail: Comprehensive factory-level repair procedures, detailed specifications, diagnostic flowcharts, and wiring schematics 📊 Manual Specifications File Format PDF Quality: High-resolution scans or digitally created, with searchable text where possible Printable: Designed to be printable, with clear formatting for individual pages Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code: M113 Engine Type: V8, SOHC (Single Overhead Camshaft), 3 valves per cylinder (2 intake, 1 exhaust) with Variable Valve Timing (VVT) Displacement: 4966 cc (5.0 Liters) Bore X Stroke: 97.0 mm x 84.0 mm Compression Ratio: 9.5:1 Performance Horsepower: 292 hp @ 5500 rpm (approx.) Torque: 306 lb-ft @ 3500 rpm (approx.) Fuel System Fuel Delivery: Sequential Multi-port Fuel Injection (SFI) Recommended Fuel: Premium Unleaded Gasoline (91 octane or higher) Other Engine Management System: ME 2.8 (Motronic Electronic Engine Control) 🔧 Transmission Standard Type: 5-speed Automatic Transmission Transmission Code: 722.6 (NAG1 - Neue Automatik Getriebe Generation 1) Optional Availability: Not Applicable for ML500 Exclusive in these model years; standard 5-speed automatic. Features Drivetrain Integration: Electronically controlled, integrated with 4MATIC all-wheel-drive system. Shift Modes: Comfort (C) and Sport (S) modes 📐 Dimensions Exterior Length: 4637 mm (182.6 inches) Width: 1897 mm (74.7 inches) Height: 1829 mm (72.0 inches) Wheelbase: 2820 mm (111.0 inches) Weights Curb Weight: 2070 kg (4564 lbs) (approx.) Gross Vehicle Weight Rating: 2600 kg (5732 lbs) (approx.) Cargo Cargo Volume: 31.7 cu ft (seats up) / 74.5 cu ft (seats folded) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 5-Star (for 2002 model year) NHTSA Front Impact Passenger: 5-Star (for 2002 model year) IIHS Frontal Offset: Good (for 2002 model year) Active Features Electronic Stability Program: Standard (ESP - Electronic Stability Program) Antilock Brakes: Standard (ABS - Anti-lock Braking System) Traction Control: Standard (ASR - Acceleration Slip Regulation, integrated with ESP) Passive Features Airbags: Driver and front passenger airbags, front side-impact airbags, optional rear side-impact airbags Seatbelts: 3-point seatbelts with pretensioners and force limiters 💡 Technology Features Infotainment Audio System: Optional COMAND (Cockpit Management and Navigation) system, high-quality audio with CD player, optional CD changer. Navigation: Optional factory-integrated navigation system with CD-ROM based maps. Driver Assistance Cruise Control: Standard cruise control with speed limiter. Parking Assistance: Optional Parktronic parking sensors (front and rear). Connectivity Phone Integration: Optional integrated hands-free telephone system (often requires a specific car phone cradle or Bluetooth adapter for later retrofits). 🔧 Maintenance Service Intervals Oil Change: Every 10,000 miles or 12 months, whichever comes first (using synthetic oil) Major Service A: Typically around 15,000-30,000 miles, including fluid checks, brake inspection, filter replacements Major Service B: Typically around 30,000-60,000 miles, including spark plug replacement, transmission fluid...