W163: DIY Thread and References
23983
25
GENERAL
STEERING, SUSPENSION, BRAKES
BODY
ELECTRONICS
MISCELLANEOUS
Special thanks to @Merzatt for his thread Useful W163 Docs
* denotes link/pdf/attachment was sourced from Useful w163 Docs Thread
* denotes link/pdf/attachment was sourced from Useful w163 Docs Thread
1 - 20 of 26 Posts
Manuals
TOP THREAD: W163: Intro, MB Official Materials
Reference
Fuse Box Diagrams:
Auxiliary/Passenger(need link)
Reference, Maintenance
Engine and Power
Alternator Change/Upgrade '98 ML430
Alternator Change '01 ML320
REF: Alternator and Voltage Regulator (MB Pdfs)*
Engine Crank Troubleshooting
Starter Motor Discussion
Spark Plug Changing (M-Class Outpost DIY)
Crankshaft Position Sensor Bolt Size
Crankshaft Position Sensor DIY
Crankshaft Position Sensor DIY (PDF)
Camshaft Sensor (Thread Post)*
REF: Crankshaft position sensor location and function*
Oil and Service
FSS (Service Interval) Reset Procedure (MB PDF)
Oil Filter Housing Seal and Oil Cooler Seals (Detane Writeup and MB PDFs)
Oil Filter and Cooler R&I Files
Oil Change DIY Using Vacuum Pump
Oil Pan and Sensor Removal
Engine / Motor Mount
Motor Mount Issues & Pics
Motor Mount Replacement
Engine Motor Mount Replacement Thread
DIY Engine Mount (Attachment Files)
Youtube: Engine Mount Replacement
Engine Cooling
Radiator Replacement Guide (DIY Writeup)
Radiator Replacement (DIY Thread#2)
Engine Coolant Flush (Steps)
Coolant Draining (pdf)
Poly V-belt / Tensioning Device Removal (MB PDFs)
Water Coolant Pump Replacement '02 (Full DIY PDF)
Water Pump Replacement (Thread)
Water Pump Replacement '02 (Thread)
Water Pump Replacement m112 m113 (Thread)
Auxiliary Water Coolant Pump Replacement
Auxiliary Coolant Water Pump Replacement - Video
Aux Water Pump Relay Install '02+ (DIY)
Aux Coolant Circulation Pump Replacement (DIY PDF and Thread Link)
REF: Auxilliary Coolant Pump Function and Location pdf link 1* , link 2* , and Post*
REF: Coolant Temperature Sensor Function and Location
Youtube: Coolant Flush
Youtube: Coolant / Expansion Tank Replacement
Air Fuel Systems and Emissions
EGR Valve Replacement (Thread)
EGR Tube Cleaning (DIY PDF)
EGR Tube and Valve R&I (DIY and MB PDFs)
EGR Vacuum Transducer (PDFs)*
REF: EGR Tube Function (MB PDF)
Intake Manifold Function (MB pdf)
Throttle Body Actuators (Thread Link, pdfs)*
O2 Sensor Connector Socket Replacement - "after TWC (CAT)" (DIY PDF)
Fuel Pump Remove and Install 02+ (DIY Instructions and PDFs)
Fuel Filter Replacement '02 ML500 (MB PDF)
Fuel Injectors ML320
Updated Fuel Lines and Filter (Thread Post)*
Fuel Rail Location, Function, Task (MB pdf)
Fuel Tank Venitlator and Canister (Thread Post)*
Charcoal Cannister Shut-off Valve Differences
REF: Fuel Pump and Sender (Wolfgang PDF)
REF: Fuel Pump and Filter Functions and Ref Docs*
PARTS PICS (REF): POST#21
Transmission Reset Procedure (Post)*
ETC Control Module Location and Task* and Codes, Functions and Adaptations*
Transmission 722.6 interchangeability
R&I Driveshaft Center Support Bearing part 1 and part 2
Center Support Bearing whine
Low Range Motor Repair
Parking Shift Lock (Troubleshooting Thread)
Transmission Fluid Change DIY part 1 and part 2
Transfer Case Fluid Change Discussion/Thread
Transmission and Torque Converter Flush
Checking Trans Fluid Level Procedure (PDF-posted by Wallyo)
REF: Recommended ATF List for 722.6 Transmission (MB Attachments)*
REF: ML430 Differential Gear Oil
REF: Front and Rear Axle Gear Oils (MB Attachments)*
REF: Transmission Troubleshooting (MB PDFs)*
REF: Transmission 722.6xx Diagnostic Chart - Post#6
REF: Transfer Case Diagnostic Manual (MB TECH pdf)
REF: 722.6 Transmission Technical Service Info (pdf)
REF: Transmission Info and Shift Points (Wolfgang PDF)
REF: Handy ML Transmission Notes
YouTube - Mercedes DIY Transfer Case Fluid Change
YouTube - DIY Differential Front Rear Fluid Change
Youtube - DIY Transmission Conductor Plate Change 722.6
REF PICS: Center support bearing / prop shaft bearing #58, #378 / Service Kit, Oil Parts, Tranny Tab #4, #170 / Tranny filler dipstick levels #259 / Transmission oil filter. #85 / transmission valve body and conductor plate. #37 / Complete transmission and torque converter. #42 / Transfer case and front propshaft. Rear propshaft #38 / Transfer case motor. #25 / Low range. #263 / Tranfer case seal #345
Power Steering Pump Removal PDF (by @Mattml430)
Power Steering Fluid Reservoir Replacement (and Attachments)
Power Steering Pump Reservoir and Seal Replacement (DIY PDF)
Power Steering Fluid Bleed (MB PDF) and Fluid Steering Gear Oil (Link)*
YouTube : E550 Steering Pump Removal and Install (from member Lsailor1)
YouTube : Power Steering Bleeding Procedure (easy)
YouTube: Power Steering Reservoir and O-ring Replacement
YouTube: Power Steering Hose Replace Pressure Line, Fluid Flush & Bleed '02-'05 ML350/500
DIY Rack and Pinion Seal Replacement
Steering Wheel, Airbag, Clockspring Removal
REF: 4ETS System for w163 (MB TECH pdf)
REF: ESP and Yaw Rate Sensor (MB TECH pdfs)*
REF: ESP tests and functionality
REF PICS: Power steering reservoir and pump. #57, #269, #226, #239, #321, #381, #389 / Power steering lines #232 / power steering return hose. #176 / Steering removed and steering related items. #351 / Steering Rack Bush kit and Steering Rack. #19, #94 / Rack and pinion steering rack spacers #402 / Steering column with angle sensor. #76, #261 / Steering wheel contact clock spring #224 / ESP Acceleration Turn Yaw Rate Sensor #63, #90 , #278 / ESP 4ETS brake system control module #169, #258 / Lateral Acceleration Sensor #89
Diagrams and Cutaways (new)
REF: cut away drawing, etc of front suspension design
REF: Suspension diagrams/info
Shocks/Springs
Front Shock Absorber DIY
Torsion Bar Bushing Replacement Link and Attachment File
Torsion Bushing Replacement DIY - Youtube links
MB TSB: Torsion Bar Maintenance
REF: Shocks and Springs Overview, Part Numbers (Wolfgang PDF)
Youtube: Indexing Torsion Bars (Front Lift)
Youtube: Changing Front Shock Absorbers
Youtube: Front Shock Absorbers
Linkages / Control Arms
Ball Joint and Tie Rod Replacement (Thread and PDFs)
Front Upper Control Arm Replacement (MB File)
Rear Bearing Replacement Using On-Car Press
Youtube: Changing Tie Rod Ends
Youtube: Changing Front Stabilizer Bushings
Youtube: Changing Front Upper Arms
REF PICS: front and rear suspension.#65, #251 / spring rates #252 / Front and rear shock and bushes/bumpstop #36 / Rear Shock Bearing and Lift Plate #216 , #249 / Torsion bar and components #66 / Torsion bar bracket. #92 / Lower front ball joint and special tightening tool #24 / Inner tie rod. Outer tie rod/track rod ends #8 / Front Left outer tie rod #211 / Front lower suspension wishbones #79 / Rear lower suspension wishbone #107 / Rear upper wishbone. #119 / Right-Rear-Lateral-Arm #147
Simple Maintenance
Brake Pad (Front and Rear) Replacement (DIY Writeup)
Brake and Rotor Replacement
Brake Pad and Rotor Replacement DIY#2
'99 ML430 Brake Pad and Rotor Replacement
Brake Caliper Rebuilding (and Bleeding)
Parking (Emergency) Brakes
Youtube - Front Brake / Rotor
Youtube - '05 Brake Pad Change
Youtube: Front Brake Disc / Rotor and Pad Replacement (w164 but good video)
Servicing
Brake Booster Repair
DIY Brake Fluid Flush / Bleed
Electronic Traction Control (BW Thread)
REF: MB Brake Fluid Sheets (MB PDFs)
REF: 98+ Brake Assist (BAS) (MB TECH PDF)
REF PICS: Master Cylinder. #26 / Booster Pipe fittings #113, #388 / Booster Parts #354, #356 / Servo w/ brake assist sensor. #257 / Rear brake hose #154 / ABS pump and module #158, #227 #228 #264 / pump bushing. #80 / ABS ESP module #210 / speed sensors Cable #61
REF: AAM Functions and Tasks (MB PDF)*
REF: EAM Functions and Task (MB PDF)*
REF PICS: EAM Module #122, #250 / Inside the AAM. #353 / AAM all activity module #122, #245
YouTube - Cabin Air Filter
Windscreeen defroster vent flap motor replacement
Rear Cabin Airflow Fix
Replacing Dash Vent Door Seals
02-05 Climate Control (pdfs)*
Blend Door Actuator / Motor Replacement and Attachment Files
Blend Door motor evaluation and replacement (Link)*
YouTube - Air Blend Motor Repalcement
REF: AC system Components (MB PDFs)*
REF: AC System, Sensors (MB PDFs)*
REF: AC Systems, Actuators (MB PDFs)*
REF: AC System, Troubleshooting (MB PDFs)*
REF: AC System, Wiring Diagram (MB PDFs)*
REF: AC Box Actuator Locations (BW Thread)*
REF: 02+ Climate Control Front and Rear with Pinouts (MB TECH PDF)*
REF: 98-01 Climate Diagnostic Manual (MB TECH PDF)
REF: Climate Control Function Tests, Codes (MB PDF)
REF PICS: Heater matrix. #47 / Heater blower and Blower recirculation actuator. #271 / Air blend motor. #46 / Rear Heater Blower Motor. #368 / AC heating sensor #254 /Cabin pollen filter. #196 / Blower regulator. #50, #246 / Heater Core #400 / AC lines #140 / AC compressor. #87, #265
DIY Windshield Washer Nozzle
Roof Antenna, Replacement / Fix DIY
Trailer Wiring DIY
Lower Exterior Tailgate Trim Panel Removal DIY
REF PICS: Tow Hitch Kit detailed #242, ball/ hitch. #74
Water Buildup in Legroom Area / Drain Tubes
Sunroof Drain Tube Fixes Thread 1 (updated), Thread 2, and Thread 3
Rear Door Window Regulator Replacement
Rear Quarter Panel Window Parts & Parts list
Door Lock DIY
Emergency Door Lock Opening
Removing Outer Door Handle (MB PDF)
Door Panel Repair / Removal Tips and Front Liner (pdf) and Rear Liner (pdf)
REF: Lower Control Panel (Thread Link, MB TECH pdf)
Youtube: Front Door Lock Actuator Replacement
Mirror Covers Removal / Replacement
Mirror LED blinker replacement
REF: Mirror Wiring Diagram ('02+)
REF PICS: Sunroof drain outlet located under front 2 fenders #432 / Front Door Glass #206 / Window Regulators and Motors. #49, #93 / 3rd Window Actuator motor and glass. #48 / Rear screen/Window #137
Steering Wheel, Airbag, Clockspring Removal
Stiff Accelerator Pedal
Rear View Mirror Replacement DIY
Sun Visor Replacement
Seatback Elastic Pocket Fix
Stuck Rear Seat
Stuck Rear Seat 2
PICS REF: Seat Frame #22 / Under Seat Components #236 /
REF: ALL Body Electrical Info (MB PDFs x3) <--- (recommended)*
REF: Location of Wiring Connectors (MB Pdfs)*
REF: Fuse and Relax Box ('00 ML320)
REF: Engine Diagnostic Manual*
REF: ESP and Diagnostics*
REF: Transfer Case DTC Codes (pdf)
REF: Electronic Components Location
Wiring Diagrams
REF: Interpreting MB Wiring Diagram (MB PDF)
REF: Online Index of All Wiring Diagrams (Thanks @DrX )* <-- requires .DWF viewer
REF: Heated Front Seat Wiring
Battery
Battery Reconnection Checklist (Thread Post)*
Better Removal and Install (pdf)
AGM and General Discussions (Thread 1) (Thread 2)
Parasitic Draw / Battery Test
REF: Battery Information (Wolfgang PDF)
Parasitic Draw Battery Drain (Tele-Aid Emergency Call circuit, Fuse 8)
Youtube - Parasitic Draw Battery Drain (Tele-Aid) ML350 ML500
Key / Keyfob Replacement
2021 Key Fob Replacements 1 & 2
Key Fob Replacement Notes (Ongoing Discussion) additional thread HERE
Replacement of ECUs and Adding Keys (Thread Link 1, Link 2, and Link 3)*
Valet (Mickey Mouse, "Secondary") Key Dissection
Keyfob Programming
Key Fob Programming Notes
AAM / Keyfob Syncing Issues (Thread 1)
AAM / Keyfob Synicing Issues (Thread 2)
Central Lock Remote Programming
Doors, Ignition, Window Electronics
Ignition Switch
Door Molex Connector Pin-Out
REF: 02+ Lower Control Panel (MB TECH PDF)
REF PICS: ignition switch and key transponder. #52, #290, #343, #297(key set) / Door Lock, and Handle #18 / Door Lock Actuator Exposed #416
Trip Computer, Instrument Cluster Electronics
Instrument Cluster Bulb Replacement
Trip Computer Backlight
Trip Computer, General (pdfs)*
Electronic Compass (pdfs)*
ML350 Retrofit DIY - Rain Sensing Wiper, Trip Computer, Autodim mirror
Instrument Cluster Troubleshooting and Diagrams (43sqd)
REF: Trip Computer and Pin Outs (Wolfgang PDF)
REF: Instrument Cluster Connector Pinout (Wolfgang PDF)
REF PICS: Instrument cluster and surround parts #16 / Alarm/Glass Breakage/Tow Away Sensor Module. #323 /
CD Magazine Error
Radio- NO Sound
MB Install Bulletin - Navigation Install (PDF)
THREAD: MCS Pinouts
THREAD: '02-'05 ML (and '00-01 ML55) DIY Writeup for FiberOptic New (HU) Headunit Install (by @j3cubcapt)
REF: Sound System Overhaul (incl. real subwoofer)
REF: ML HU Audio Wiring Diagrams Latter Years
REF: 02+ MCS Headunit Pinout (Thread Post)*
REF: Roof Antenna (pdfs)*
REF: Fiber Optic Cable Location (PDF) and (Thread Link)
REF PICS: Bose amp. #71 / Comand Double Din Unit. #165
Front Bumper Pieces
ML55 / Sport Right Foglight Cover
ML55 / Sport Headlight Washer Cover
Rear Bumper:
Rear Bumper Tow Cover
Various Trim:
Taillight retainer nut
Trunk Trim Clip
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