🏷️ Basic Information Identification Make: Mercedes-Benz Model: M-Class Product Name: Mercedes ML320 ML350 ML430 ML500 M55 1997-2005 Service Repair Manual Codes Internal Chassis Codes: W163 Generation Generation Identifier: First Generation (W163) 👋 Introduction Market Position Segment: Luxury Mid-size SUV Target Audience: Affluent individuals and families seeking a blend of luxury, capability, and off-road prowess in an SUV. Competitive Analysis Key Competitors: BMW X5, Lexus RX, Audi Q7 (later years), Volvo XC90. Key Features Premium Appointments: High-quality interior materials, advanced comfort features, powerful engine options, sophisticated styling. Capability: Standard 4MATIC all-wheel-drive system (on most models), respectable towing capacity, optional off-road packages. 📋 Manual Details Coverage Areas Covered Regions: Global (factory specifications applicable to all markets) Page Count Estimated Page Count: Thousands (typically over 2000 pages for comprehensive factory manuals) Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: Digital (likely PDF or similar, based on product description) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, engine management (ECU), cooling system, lubrication system, transmission (automatic), transfer case, drivetrain (4MATIC AWD). Chassis: Suspension (front and rear, independent), steering system, braking system (ABS, ESP), wheels, tires. Electrical: Battery, charging system, starter, lighting system, instrument cluster, infotainment system, body control modules (BCM), comfort systems (HVAC, power windows, seats), diagnostic systems (OBD-II), SRS airbag system. Body: Exterior body panels, doors, hood, tailgate, interior trim, glass, seals, bumpers, aerodynamic components. Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and changes, brake pad/rotor replacement, spark plug replacement, belt inspection/replacement. Diagnostics: Troubleshooting guides, fault code interpretation (DTCs), diagnostic procedures for all major systems, wiring diagrams, component testing. Repair Rebuild: Engine overhaul and rebuilding, transmission service and repair, suspension component replacement, brake system repair, electrical component repair, body panel repair. Installation Adjustment: Component installation and removal, alignment procedures, system adjustments, calibration procedures. Technical Depth Depth: Comprehensive factory-level detail, suitable for professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format Digital Format: PDF (common for factory manuals, allowing searchability and printing) Print Quality Quality: High-resolution, clear diagrams and text (typical of official factory publications) Binding Type Binding: N/A (for digital format) Paper Type Paper Quality: N/A (for digital format) ⚙️ Engine Specifications Primary Engine Ml320 Engine: 3.2L M16.3 V6 (Gasoline) Ml350 Engine: 3.7L M112 E37 V6 (Gasoline) Ml430 Engine: 4.3L M113 E43 V8 (Gasoline) Ml500 Engine: 5.0L M113 E50 V8 (Gasoline) M55 Engine: 5.4L M113 E55 AMG V8 Supercharged (Gasoline) Performance Ml320 Horsepower: 215 hp @ 5750 rpm Ml320 Torque: 229 lb-ft @ 3000 rpm Ml350 Horsepower: 232 hp @ 5750 rpm Ml350 Torque: 236 lb-ft @ 3000 rpm Ml430 Horsepower: 268 hp @ 5500 rpm Ml430 Torque: 288 lb-ft @ 3000 rpm Ml500 Horsepower: 290 hp @ 5500 rpm Ml500 Torque: 302 lb-ft @ 3000 rpm M55 Horsepower: 349 hp @ 5500 rpm M55 Torque: 376 lb-ft @ 3500 rpm Fuel System Fuel Injection: Electronic Fuel Injection (EFI) / Multi-point Fuel Injection (MPI) Recommended Fuel: Premium Unleaded Gasoline (91 Octane or higher) 🔧 Transmission Standard Type: 5-speed Automatic (722.6 '5G-Tronic') Optional Type: N/A (5-speed automatic was standard across the range) Features Drivetrain System: 4MATIC All-Wheel Drive (Standard) Transfer Case: Two-speed transfer case with center differential lock (on select models/off-road packages). 📐 Dimensions Exterior Length: Approx. 189.2 inches (4806 mm) Width: Approx. 74.4 inches (1890 mm) Height: Approx. 70.0 inches (1778 mm) Wheelbase: Approx. 111.0 inches (2820 mm) Weights Curb Weight: Approx. 4400 - 4700 lbs (2000 - 2130 kg), varies by model and equipment. 🛡️ Safety Features Ratings NHTSA Front Impact: 4/5 Stars (Driver/Passenger, pre-2000s testing protocols) IIHS Side Impact: Acceptable (varies by year, often improved with later facelifts) Active Features Esp: Electronic Stability Program (standard on most models) ABS: Anti-lock Braking System (standard) Passive Features Airbags: Frontal airbags, front side-impact airbags (optional on early models, standard later). Seatbelts: Pretensioning seatbelts with force limiters. 💡 Technology Features Infotainment Navigation: Optional COMAND (Cockpit Management and Navigation) system, often featuring a CD-ROM based navigation. Audio: Premium audio systems (e.g., Bose) available on higher trims, CD changer integration. Driver Assistance Cruise Control: Standard cruise control, optional Distronic adaptive cruise control on some later models. Parking Assist: Optional parking sensors (front and rear). Connectivity OBD Ii: Standard OBD-II diagnostic port for fault code reading. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10,000 miles (16,000 km) or 12 months, whichever comes first, using synthetic oil. Major Service Intervals: Refer to manual for specific mileage/time intervals for spark plugs, transmission fluid, coolant, etc. (e.g., 30,000-60,000 miles for certain items). Fluid Specifications Engine Oil: SAE 0W-30 or 0W-40 Synthetic (MB 229.5 approved) Transmission Fluid: MB 236.10 (e.g., Pentosin ATF 1 or equivalent) Coolant: MB 325.0 (Ethylene Glycol based, blue color) Known Issues Interior Wear: Cracking dashboard, worn leather, failing seat adjustments, pixelated instrument cluster displays. Engine Components: Misfires due to...