🏷️ Basic Information Identification Make: Mercedes-Benz Model: ML500 Model Line: M-Class Generation Chassis Code: W163 Generation Years: 1997-2005 Facelift Years: 2001-2005 Codes Engine Code Ml500: M113.960 👋 Introduction Market Position Vehicle Segment: Luxury Mid-Size SUV Target Audience: Affluent families, individuals seeking luxury and capability Competitive Analysis Primary Competitors: BMW X5, Lexus RX, Audi Q7 (early models), Land Rover Discovery Key Features Premium Interior: High-quality materials, comfortable seating, advanced features for its time Performance: Powerful V8 engine, refined ride, capable off-road (for an SUV of its class) Safety And Reliability: Mercedes-Benz engineering, robust construction 📋 Manual Details Coverage Areas Covered Model Years: 2001, 2002, 2003, 2004, 2005 Covered Trims: ML500 (All variants) Page Count Estimated Page Count: 1500+ Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: M113 5.0L V8 (SOHC) Transmission: 5G-TRONIC Automatic Transmission (722.6) Drivetrain: 4MATIC All-Wheel Drive System Suspension: Front and Rear Independent Suspension, AIRMATIC Suspension (if equipped) Brakes: Hydraulic Disc Brakes (Front and Rear), ABS, ESP Steering: Hydraulic Power Steering Electrical System: Engine Control Unit (ECU), Lighting, Instrumentation, Body Control Modules, SRS (Airbag) System Body And Frame: Exterior Panels, Doors, Windows, Interior Trim, Structural Components HVAC: Automatic Climate Control System Fuel System: Fuel Tank, Fuel Pump, Fuel Injectors, Fuel Filter Exhaust System: Manifolds, Catalytic Converters, Mufflers Procedures Included Maintenance: Oil Changes, Filter Replacements, Fluid Checks and Top-offs, Spark Plug Replacement, Belt Inspection/Replacement Troubleshooting: Diagnostic Trouble Codes (DTCs), Component Testing, Fault Isolation Engine Repair: Engine Overhaul, Cylinder Head Removal/Installation, Piston/Connecting Rod Replacement, Valve Train Servicing Transmission Repair: Transmission Overhaul, Torque Converter Replacement, Valve Body Servicing, Gearbox Reassembly Brake System Repair: Brake Pad/Rotor Replacement, Caliper Overhaul, Brake Line Replacement, Bleeding Procedure Suspension And Steering Repair: Shock Absorber/Strut Replacement, Bushing Replacement, Power Steering Pump/Rack Replacement, Alignment Procedures Electrical System Repair: Wiring Diagram Interpretation, Component Replacement (Sensors, Actuators), Module Programming (limited), Battery and Charging System Diagnostics Body Repair: Panel Replacement, Door Hinge/Latch Adjustment, Window Regulator Repair, Weatherstripping Replacement HVAC System Repair: Compressor Replacement, Evaporator/Condenser Servicing, Refrigerant Charging, Blower Motor Replacement Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and transmission rebuilds) Diagnostics: Detailed diagnostic procedures with DTC explanations and troubleshooting trees Torque Specifications: Extensive list of torque values for all critical fasteners Wiring Diagrams: Complete electrical system wiring diagrams 📊 Manual Specifications File Format Type: PDF Searchable: Yes (text-searchable) Print Quality Quality: High-resolution, suitable for printing Binding Type Binding Type: N/A (Digital) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: V8, SOHC, 3-valve per cylinder Displacement: 4966 cc (5.0 Liters) Bore X Stroke: 97.0 mm x 84.0 mm Compression Ratio: 9.0:1 Performance Horsepower: 302 hp @ 5600 rpm Torque: 339 lb-ft @ 2800-4500 rpm Fuel System Fuel Delivery: Sequential Electronic Fuel Injection (SEFI) Fuel Type: Premium Unleaded Gasoline Cooling System Coolant Type: Mercedes-Benz Approved Antifreeze/Coolant (e.g., G48) Engine Oil Recommended Oil Viscosity: SAE 0W-30 or 5W-40 (check owner's manual/manual for specific MB approvals) 🔧 Transmission Standard Transmission Type: 5-speed Automatic (5G-TRONIC) Transmission Code: 722.6 Optional Optional Transmission: N/A for ML500 in these model years Features Drive Modes: Comfort (C) and Sport (S) modes Fluid Specifications Transmission Fluid Type: MB 236.14 Automatic Transmission Fluid (ATF) 📐 Dimensions Exterior Length: Approx. 189.5 inches (4813 mm) Width: Approx. 73.6 inches (1869 mm) Height: Approx. 70.1 inches (1780 mm) Wheelbase: Approx. 111.0 inches (2819 mm) Weights Curb Weight: Approx. 4700 - 4850 lbs (2132 - 2200 kg) Gross Vehicle Weight Rating Gvwr: Approx. 6393 lbs (2900 kg) Cargo Cargo Volume Seats Up: Approx. 37.7 cu ft (1068 liters) Cargo Volume Seats Down: Approx. 73.0 cu ft (2065 liters) Towing Towing Capacity: Up to 5000 lbs (2268 kg) (with optional towing package) 🛡️ Safety Features Ratings NHTSA Front Crash Test Rating: 4 Stars (Driver), 5 Stars (Passenger) - Model Year Specific IIHS Side Impact Rating: Good (Refer to IIHS archives for specific year) Active Features Traction Control: ASR (Acceleration Slip Regulation) Electronic Stability: ESP (Electronic Stability Program) Braking System: 4-wheel Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD) Passive Features Airbags: Frontal Airbags, Side Airbags, Optional Front and Rear Head Curtain Airbags Seatbelts: 3-point Inertia Reel Seat Belts with Pretensioners and Load Limiters Child Seat Anchors: LATCH system (rear seats) 💡 Technology Features Infotainment Audio System: Optional Bose premium sound system, CD player, AM/FM radio Navigation: Optional COMAND (Cockpit Management and Navigation) system Climate Control: Standard automatic climate control (THERMATIC), optional dual-zone climate control (THERMATIC) Driver Assistance Cruise Control: Standard cruise control Parking Sensors: Optional PARKTRONIC parking assist system Headlights: Halogen projector headlights, optional Xenon headlights Connectivity Auxiliary Input: Optional auxiliary input for audio devices (may require adapter) 🔧 Maintenance Service Intervals Oil Change Interval: Every 10,000 miles (16,000 km) or 1 year (whichever comes first), using synthetic oil (refer to ASSYST system) Transmission Fluid Service:...