🏷️ Basic Information Identification Make: Mercedes-Benz Model: ML-Class Chassis Code: W163 Generation: First Generation (W163) Production Years Covered By Manual: 1997-2005 Codes Internal Reference Code: 6442 👋 Introduction Market Position Segment: Luxury Mid-size SUV (Sport Utility Vehicle) Target Audience: Technicians, DIY enthusiasts, and owners seeking in-depth knowledge for maintenance and repair. Competitive Analysis Key Competitors: BMW X5 (E53), Lexus RX (RX300/RX330), Volvo XC90 (First Generation) Key Features Design Philosophy: Combines Mercedes-Benz luxury and engineering with SUV practicality and off-road capability. 📋 Manual Details Coverage Areas Primary Coverage: North America, Europe, and Global Markets for W163 ML-Class Page Count Estimated Page Count: Thousands (Printable High Quality) Manual Type Type: Factory Service and Repair Manual Language Language: English Format Digital Format: PDF Delivery Delivery Method: Instant Download 📖 Manual Coverage Systems Covered Powertrain: Engine Service/Repair, Transmission Service/Repair, Fuel Injection, Fuel System, Cooling System, Emission System, Engine Control System, Differential/Drive, Axle Chassis: Brake System, Suspension, Steering, Chassis/Body Electrical: Electrical System, Wiring Diagrams Comfort And Safety: Heater/Air Conditioning, Restraint System, Interior Body And Frame: Body construction, collision repair, exterior trim, interior trim, doors, windows, seals. Exhaust System: Exhaust manifold, catalytic converter, mufflers, piping. Wheels And Tires: Tire types, sizes, pressures, wheel specifications, lug bolt torque. Procedures Included Maintenance: General Maintenance, Periodic Lubrication, Tyre Rotation Diagnostics And Repair: Troubleshooting, Component Repair, System Diagnosis, Overhaul Procedures Special Tools: Lists and diagrams for specialized tools required for specific repair and diagnostic procedures. Troubleshooting Methodology: Systematic approach to diagnosing common and complex vehicle issues. Technical Depth Depth: Comprehensive factory-level repair and diagnostic procedures, including detailed specifications, torque values, and component testing. Diagnostic Procedures: Includes detailed diagnostic trees, fault code interpretations, and procedures for using diagnostic tools (e.g., Star/DAS). Rebuild Procedures: Detailed procedures for major component rebuilds, including engine, transmission, and differentials. 📊 Manual Specifications File Format Requirements: Adobe PDF Reader Searchability: Likely searchable PDF content (depending on creation quality), allowing for quick information retrieval. Print Quality Quality: Great Quality (Printable) Binding Type Type: Digital Download (PDF) Paper Type Type: Not Applicable (Digital) ⚙️ Engine Specifications Primary Engine Engine Options Covered: M112 (4.3L V8), M111 (2.3L Supercharged Inline-4), OM611 (2.7L Turbo Diesel - some markets) Performance Typical Horsepower Range: 170 hp (ML320) to 288 hp (ML500) Fuel System Injection Type: Electronic Fuel Injection (EFI), Common Rail Direct Injection (for Diesel models) 🔧 Transmission Standard Transmission Type: 5-Speed Automatic (722.6 '7G-TRONIC' predecessors) Optional Transmission Type Offered: Not applicable for standard models; variations existed based on engine. Features Drive System: All-Wheel Drive (4MATIC) 📐 Dimensions Exterior Typical Length Approx: 4638 mm (182.6 in) Typical Width Approx: 1840 mm (72.4 in) Typical Height Approx: 1776 mm (69.9 in) Weights Curb Weight Approx: 1950 kg (4300 lbs) Towing Capacity Approx: 3500 kg (7700 lbs) 🛡️ Safety Features Ratings NHTSA Front Impact Rating: 4-star (Driver and Passenger - simulated) Active Features Stability Control: Electronic Stability Program (ESP) Traction Control: All-Season Traction Control (4-ETS) Passive Features Airbags: Frontal airbags, Optional side airbags 💡 Technology Features Infotainment Optional Features: Bose premium sound system, CD changer, COMAND navigation system (later models). Driver Assistance Available Features: Parking Assist (PARKTRONIC), Cruise Control, Rain-sensing wipers. Connectivity Early Connectivity: Analog cellular phone integration (optional). 🔧 Maintenance Service Intervals Oil Change Interval: Approximately 10,000 miles (16,000 km) or 12 months, whichever comes first (dependent on driving conditions). Transmission Fluid Change: Recommended every 60,000 miles (96,000 km) or as per severe service schedule. Fluid Specifications Engine Oil Specification: MB 229.5 or MB 229.51 (e.g., Mobil 1 0W-40, Castrol Syntec 0W-30) depending on engine and year. Coolant Type: Mercedes-Benz Approved Antifreeze/Coolant (e.g., ZEREX G-05) Brake Fluid Type: DOT 4 (or MB specification) Transmission Fluid Specification: MB 236.10 or MB 236.12 (e.g., ATF 4-speed, ATF 5-speed) Known Issues Common Electrical Faults: Crankshaft position sensor failures, MAF sensor issues, SAM unit (Signal Acquisition Module) problems. Common Powertrain Issues: Timing chain wear (M112 engine), transmission valve body issues, differential seal leaks. Common Suspension Issues: Worn control arm bushings, premature failure of strut mounts. 📚 Vehicle History Brand Heritage Brand Philosophy: Mercedes-Benz is renowned for engineering excellence, luxury, and safety innovations. Model Evolution Positioning In Lineup: The first SUV offered by Mercedes-Benz, designed to compete in the burgeoning luxury SUV market. Production Manufacturing Locations: Tuscaloosa, Alabama, USA; Rastatt, Germany (later models) 🏆 Awards & Recognition Recognitions Notable Awards: MotorTrend SUV of the Year (1998)