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W163 (1997-2005)
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  • W163 (1997-2005)

Car repair and maintenance Mercedes M-Class (W163)

This section contains a repair and maintenance manual for the German crossover (SUV) "Mercedes-Benz M-class (W163)", which was produced from 1996 to 2005. These cars were equipped with gasoline engines (in-line and V-shaped from 2.3 to 5.0 liters), as well as diesel engines (2.7 and 4.0 liters). See specs for details.

See this manual at: russian, bulgarian, belarusian, ukrainian, serbian, croatian, romanian, polish, slovak, hungarian
General information
Introduction to the guide
Mercedes-Benz M-Class Cars (W163) — Abstract
Vehicle Identification Numbers
Purchase of spare parts
Jacking and towing a car
Full list of articles in this category »
Controls and instruments
Single lock for access to the car
Unlocking and locking doors
Access to the luggage compartment
Access to the fuel tank filler neck
Full list of articles in this category »
Driving and operation
Running in the car for the first 1500 km
Operating techniques and auxiliary systems
Running in a new car
Features of operation of vehicles equipped with a three-function catalytic converter
Full list of articles in this category »
Maintenance
Recommended lubricants and fluids
Active Maintenance Warning System (ASSYST)
Schedule of current maintenance
General information about settings
Full list of articles in this category »
Power unit
Gasoline engines
Engine specifications
Checking the compression pressure in the cylinders
Checking the engine with a vacuum gauge
Replacement of the auxiliary drive belt and elements of its tensioning mechanism
Full list of articles in this category »
Diesel engines
Removal and installation the engine
Removal and installation timing belt covers
Replacing the timing chain
Removal and installation of timing drive components
Full list of articles in this category »
Cooling system
Cooling, Heating and Air Conditioning System Specifications
Antifreeze is a means of protection against freezing
Coolant Replacement — General Notes
Replacing cooling system hoses
Full list of articles in this category »
Heating and ventilation
General information and safety precautions
Removal and installation the control panel of the heating / ventilation / air conditioning systems
Removal and installation the heater/air conditioner fan and its resistive assembly
Removal and installation the heater heat exchanger
Full list of articles in this category »
Power system (gasoline)
Checking and adjusting idle speed / ignition timing / CO concentration
Relieving pressure in the fuel system of a gasoline engine
The operating principle of the control and injection system of a gasoline engine
General check of the petrol engine injection system
Full list of articles in this category »
Fuel system (diesel)
Diesel Engine Fuel System — General Information
Fuel injection system checks
Servicing air intake tract components
Servicing Throttle Actuator Components
Full list of articles in this category »
Exhaust system
Exhaust and emission control systems
Removal and installation of the exhaust system
Replacing the front sections of the exhaust system on gasoline models
Removal and installation catalytic converters on diesel models
Full list of articles in this category »
Ignition and control system
Engine Electrical System Specifications
Basic information and safety precautions
Checking the ignition and injection control system
Troubleshooting — General Information and Preliminary Checks
Full list of articles in this category »
Charging and starting system
Charging and starting systems — general information
Battery — General information, maintenance recommendations
Charging system — general information and safety precautions
Checking the charging system
Full list of articles in this category »
Transmission
Mechanical gearbox
Manual Transmission Specifications
Adjustment of the gear shift drive RCPP 717.461
Removal and installation the manual transmission shift lever 717.461
Design features of the rod-cable gear shift drive for the 716.644 manual transmission
Full list of articles in this category »
Automatic gearbox
Automatic transmission specifications
Troubleshooting — General Information
General principles of operation of the transmission system, control signals
Adjusting the automatic transmission shift drive
Full list of articles in this category »
Clutch
Transmission Line Specifications
Description of the clutch design
Assessing the degree of wear of the driven clutch disc
Removal, installation and testing of the clutch
Full list of articles in this category »
Drive shafts and cardan
Removal and installation the front propeller shaft
Removal and installation the rear propeller shaft
Removal and installation the intermediate bearing of the rear crankshaft
Removal and installation of steering knuckle, replacement of ball joint
Full list of articles in this category »
Transfer case
Removal and installation the transfer case control module
Removal and installation the transfer case
Replacing the transfer case input shaft seal
Replacing the rear propeller shaft output flange seal
Full list of articles in this category »
Chassis
Brake system
Brake and auxiliary systems specifications
General information and safety precautions
Checking the brake system for leaks
Checking the proper functioning of the brake booster
Full list of articles in this category »
Front suspension
Suspension and steering specifications
Removal and installation the front axle assembly
Removal, checking and installation front shock absorbers
Removal and installation the torsion bar
Full list of articles in this category »
Rear suspension
Removal and installation of the rear axle assembly
Removal, disassembly and installation of rear struts
Removal and installation the torsion bar
Removal and installation the lower wishbone
Full list of articles in this category »
Steering
Filling and «bleeding» the steering pump
Checking the steering pump pressure
Replacing the clamp securing the power steering fluid cooling hose
Evaluation of the condition of the steering rod joints and rack and pinion housing boots
Full list of articles in this category »
Suspension geometry
Checking the geometric parameters of the bridge installation
Checking and adjusting the ride height
Car Wheel Alignment Angles — General Information
Checking and adjusting camber and runout
Full list of articles in this category »
Body
Exterior (external elements)
Body specifications and dimensions
Removal and installation windshield wiper arms
Removal the front wiper drive
Removal and installation retractable telescopic headlight washer nozzles
Full list of articles in this category »
Interior (internal elements)
Removal and installation lower instrument panel covers
Removal and installation the instrument panel air duct deflectors
Removal and installation the central (console) section of the instrument panel
Removal and installation the main storage compartment
Full list of articles in this category »
Doors and locks
Removal and installation doors
Removal and installation side door opening limiters
Removal and installation tailgate hinges
Removal and installation the gas-filled sliding tailgate stop
Full list of articles in this category »
Electrical equipment
Equipment and devices
Fuses and Relays Specifications
General information and precautions
Search for causes of electrical equipment failures
Fuses — General Information
Full list of articles in this category »
Drive motors
Removal and installation of electric motor groups for the front seat adjustment drive
Removal and installation of electric motors for the door window regulator drives
Removal and installation electric motors for adjusting the position of door rear-view mirrors
Removal and installation the electric motor for the upper sunroof drive
Full list of articles in this category »
Lighting and signaling
Removal and installation horn horns
Removal and installation of headlights, replacement of lamps
Removal, installation and replacement of fog lamps
Removal and installation rear lights, replacing bulbs
Full list of articles in this category »
Audio system
Removal and installation the radio
Removal and installation door speakers
Removal and installation the AM/FM amplifier
Removal and installation the antenna splitter
Full list of articles in this category »
Electrical circuits
Abbreviations and designations used in electrical circuits
Manual air conditioning system with cooling fan control module (ML 430)
Air conditioning system with manual control and without cooling fan control module (ML 430)
Anti-lock brake system (ABS) (ML 430)
Full list of articles in this category »

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W163 (1997-2005) 
  • General information
  • Introduction to the guide
  • Controls and instruments
  • Driving and operation
  • Maintenance
  • Power unit
  • Gasoline engines
  • Diesel engines
  • Cooling system
  • Heating and ventilation
  • Power system (gasoline)
  • Fuel system (diesel)
  • Exhaust system
  • Ignition and control system
  • Charging and starting system
  • Transmission
  • Mechanical gearbox
  • Automatic gearbox
  • Clutch
  • Drive shafts and cardan
  • Transfer case
  • Chassis
  • Brake system
  • Front suspension
  • Rear suspension
  • Steering
  • Suspension geometry
  • Body
  • Exterior (external elements)
  • Interior (internal elements)
  • Doors and locks
  • Electrical equipment
  • Equipment and devices
  • Drive motors
  • Lighting and signaling
  • Audio system
  • Electrical circuits
 
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