Description
Factory Mercedes ML350 Workshop Manual (2002-2005)
This is the factory-level service manual for the 2002-2005 Mercedes-Benz ML350, covering the first-generation W163 M-Class. US-market technicians get complete repair procedures, wiring schematics, and diagnostic guidance in one searchable dealer-grade resource.
Powertrain & Drive Coverage
| Component | Variants Covered |
|---|---|
| Petrol | 3.7L M112 E37 V6 (SOHC 18-valve, ~232 hp) |
| Diesel | N/A |
| Transmissions | 5-speed automatic (722.6 series), 5-speed manual |
| Drive | 4MATIC AWD, RWD |
| Model Years | 2002, 2003, 2004, 2005 |
| Badge Twins | N/A |
Common ML350 Repairs Covered
| System | Procedures |
|---|---|
| Front Air Springs / Suspension | Air strut replacement, ride-height sensor calibration, compressor diagnostics |
| 722.6 Automatic Transmission | Valve body service, fluid and filter change, solenoid replacement, full overhaul specs |
| M112 Engine Oil Leaks | Camshaft adjuster seal replacement, valve cover gasket, oil separator/breather service |
| ABS / ESP Module | Wheel speed sensor testing, ABS pump removal, ESP system fault diagnosis and reset |
Format & Delivery
Dealer software. Instant download; lifetime re-downloads.
Frequently Asked Questions
Why do W163 ML350 air suspensions fail so commonly, and does the manual cover the fix?
The W163 ML350 air suspension system is known for compressor wear and air strut bladder failure, especially in vehicles over 100,000 miles. The manual includes full ride-height sensor calibration procedures, compressor testing steps, and individual strut replacement sequences so you can restore proper ride height without guesswork.
Is the W163 chassis shared with any other Mercedes models?
The W163 platform underpins the entire first-generation M-Class range sold from 1997 through 2005, including the ML320, ML430, ML500, and ML55 AMG. The ML350 joined the lineup for 2003 using the same W163 body and suspension architecture, so much of the structural and chassis content in this manual overlaps with those sibling variants.
Does the manual include 4MATIC transfer case and differential service?
Yes. Full service procedures for the 4MATIC transfer case, front and rear differentials, and front driveshaft are documented, including fluid specifications, seal replacement, and bearing preload settings.
What format is the manual?
This is dealer-grade Mercedes software, not a static PDF. It installs on Windows (XP through 11) and Mac, and features keyword search by engine code, gearbox code, model year, and system. Individual pages or full sections can be printed for bench use.
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