Description
Factory Mercedes-Benz M-Class W163 Workshop Manual (1998–2005)
This is the factory-level service manual for the first-generation Mercedes-Benz M-Class W163, covering every ML variant sold in the US market from 1998 through 2005 — from the entry-level ML230 to the fire-breathing ML55 AMG.
Powertrain & Drive Coverage
| Component | Variants Covered |
|---|---|
| Petrol | M111 2.3L I4, M112 3.2L & 3.7L V6, M113 4.3L & 5.0L V8, M113 5.4L AMG V8 |
| Diesel | OM612 2.7L CDI, OM628 4.0L CDI turbodiesel |
| Transmissions | 722.6 five-speed automatic, 722.9 seven-speed automatic; 4ETS & 4MATIC transfer case |
| Drive | AWD (4MATIC) |
| Model Years | 1998–2005 |
| Badge Twins | N/A |
Common M-Class Repairs Covered
| System | Procedures |
|---|---|
| Transfer Case | 4MATIC transfer case fluid service and actuator replacement — a well-documented W163 wear item |
| Engine Cooling | Plastic coolant reservoir and thermostat housing replacement; coolant flush procedures |
| Brake System | ABS/ESP module diagnostics, front and rear caliper overhaul, brake pad and rotor replacement |
| Electrical | SRS airbag fault diagnosis, wiring harness inspection, instrument cluster removal and repair |
Format & Delivery
PDF. Instant download; lifetime re-downloads.
Frequently Asked Questions
Is the notorious W163 4MATIC transfer case covered in detail?
Yes. The manual includes complete transfer case service procedures for both the 4ETS and 4MATIC systems, covering fluid specifications, actuator testing, and disassembly/reassembly torque values — essential reading given how commonly these units develop issues on higher-mileage W163s.
Which specific ML trim levels and engine codes are included?
All W163 variants are covered: ML230 (M111), ML270 CDI (OM612), ML320 (M112), ML350 (M112), ML400 CDI (OM628), ML430 (M113), ML500 (M113), and the ML55 AMG (M113 AMG). Every engine code and chassis configuration produced between 1998 and 2005 is documented.
Does the manual cover the 722.6 automatic transmission rebuild?
Yes. Full service and rebuild procedures are provided for the 722.6 five-speed automatic, including valve body removal, solenoid testing, and torque converter inspection. The 722.9 seven-speed unit fitted to late-production models is also documented.
What format is the manual?
This manual is a PDF file, delivered via instant download immediately after purchase. It is fully searchable, printable, and compatible with any PDF reader on Windows, Mac, tablet, or smartphone. Your download link is available for life.
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