🏷️ Basic Information Identification Make: Mercedes-Benz Model: ML320 Generation Generation Designation: W163 Codes Chassis Code: W163 👋 Introduction Market Position Segment: Luxury Mid-size SUV Competitive Analysis Key Competitors: BMW X5 (E53), Lexus RX (RX300/330), Porsche Cayenne (955), Land Rover Discovery Key Features Vehicle Strengths: Comfortable ride, premium interior, robust 4MATIC all-wheel-drive system, strong brand reputation for luxury and engineering. 📋 Manual Details Coverage Areas Years Covered: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Page Count Estimated Pages: 1000+ Manual Type Type: Workshop Repair and Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Drivetrain (4MATIC All-Wheel Drive) Chassis: Suspension, Steering, Brakes, Wheels and Tires Electrical: Engine Control Module (ECM), Body Control Module (BCM), Lighting, Instruments and Displays, Audio System, Climate Control, Power Accessories Body: Body Panels, Doors, Windows, Seats, Interior Trim, Exterior Trim Fuel System: Fuel tank, fuel pump, fuel filter, fuel lines, injectors. Exhaust System: Exhaust manifolds, catalytic converter, mufflers, exhaust pipes. Cooling System: Radiator, water pump, thermostat, cooling fans, coolant hoses. Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks and Replacements, Tune-ups Repair: Engine Overhaul, Transmission Repair, Brake System Overhaul, Suspension Component Replacement, Electrical Component Diagnosis and Repair Troubleshooting: Diagnostic Trouble Codes (DTCs), Symptom-based Troubleshooting Guides, Electrical Schematics Diagnostics: On-Board Diagnostics (OBD-II) system, diagnostic trouble code retrieval and interpretation, component testing procedures. Replacement: Component replacement procedures for all major mechanical and electrical systems. Adjustment: Wheel alignment specifications, steering system adjustments, parking brake adjustments. Technical Depth Depth: Comprehensive: From basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and electrical system tracing. Electrical Schematics: Detailed wiring diagrams for all electrical systems, including power distribution, grounds, and component connections. Torque Specifications: Comprehensive list of torque specifications for all fasteners, critical for engine, chassis, and drivetrain assembly. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Print Quality Image Resolution: High-resolution, suitable for printing individual pages or the entire document. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: M112 E32 - V6, SOHC, 18-valve (3 valves per cylinder) Displacement: 3.2 Liters (3199 cc) Bore X Stroke: 89.9 mm x 84.0 mm Compression Ratio: 10.0:1 Performance Horsepower: 215 hp @ 5,750 rpm Torque: 227 lb-ft (308 Nm) @ 3,250 rpm Fuel System Fuel Delivery: Sequential Multi-port Fuel Injection (SFI) Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Engine Codes Engine Family: M112 🔧 Transmission Standard Transmission Type: 5-Speed Automatic Transmission (722.6 '5G-TRONIC') Optional Optional Transmissions: N/A for ML320 during this period Features Drive System: 4MATIC All-Wheel Drive (Permanently Engaged) Transmission Fluid Type: MB 236.10 (or equivalent, e.g., Pentosin ATF1) 📐 Dimensions Exterior Length: Approx. 188.5 inches (4,788 mm) Width: Approx. 74.9 inches (1,903 mm) Height: Approx. 66.7 inches (1,694 mm) Wheelbase: Approx. 111.0 inches (2,820 mm) Weights Curb Weight: Approx. 4,500 - 4,700 lbs (2,041 - 2,132 kg) Towing Capacity: Up to 5,000 lbs (2,268 kg) Interior Seating Capacity: 5 or 7 (optional third-row seating) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4 Stars (1997-2001 models) NHTSA Front Impact Passenger: 4 Stars (1997-2001 models) Active Features Traction Control: Standard (ASR - Automatic Slip Regulation) Stability Control: Standard (ESP - Electronic Stability Program) Passive Features Airbags: Frontal airbags, optional side airbags Seatbelts: 3-point inertia-reel seatbelts with pretensioners 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, optional Bose sound system, optional navigation system (COMAND 2.0/2.5). Climate Control: Automatic Climate Control (often dual-zone) with pollen filter. Driver Assistance Cruise Control: Standard Parking Assist: Optional rear park assist sensors (Parktronic). Connectivity Prewiring: Optional telephone pre-wiring and CD changer pre-wiring. 🔧 Maintenance Service Intervals Oil Change Interval: Every 10,000 miles or 12 months (whichever comes first), using synthetic oil. Air Filter Replacement: Every 30,000 miles or 24 months. Cabin Air Filter Replacement: Every 15,000 miles or 12 months. Transmission Fluid Service: Every 60,000 miles or 48 months (recommended service, often debated). Fluid Specifications Engine Oil Type: Mobil 1 0W-40 Synthetic (or equivalent meeting MB-Approval 229.5) Engine Oil Capacity: Approx. 8.5 quarts (8.0 Liters) with filter change Coolant Type: MB 325.0 (or equivalent, typically a 50/50 mix of antifreeze and distilled water, e.g., Zerex G-05) Brake Fluid Type: DOT 4 Known Issues Common Failures: Mass Air Flow (MAF) sensor failure, ignition coil failure, crank position sensor failure, radiator support issues (plastic breaking), HVAC blower motor resistor failure, rust on rear hatch and rocker panels, O2 sensor failures. Maintenance Notes: Regularly check for oil leaks from the valve covers and oil filter housing. Ensure the drain holes in the cowl area are clear to prevent water ingress into the HVAC system. 📚 Vehicle History Brand Heritage Manufacturer Reputation: Mercedes-Benz: Renowned for luxury, engineering excellence, and robust build quality since its inception. Model Evolution First Generation: The...