Mercedes-Benz W163

Mercedes-Benz W163 (M-Class ML 1997–2005): common faults, maintenance guides and repair tips.

Mercedes-Benz W163 automatic transmission slips

The most common cause is too little or foamed fluid. Overheating, or a fault in the torque converter lockup valve or the speed sensor, can also cause ...

ML 270 CDIML 400

Mercedes-Benz W163 transmission oil leaks

The most common leak points are the oil pan gasket and the transmission plug, or connector, where the O-ring of the sleeve lets oil through. Other typ...

Mercedes-Benz W163 automatic transmission does not upshift

A common cause is oil that has got into the transmission plug, which disturbs the control. Cleaning and drying it can restore operation, but the cause...

ML 320ML 270 CDI

Mercedes-Benz W163 transfer case low range does not work

Low range cannot be engaged unless the main transmission is in neutral (N). In addition, the engine must be running and the car stationary, the batter...

ML 270 CDI

Mercedes-Benz W163 ABS, ETS and BAS/ESP lights on: wiring harness or pump

The cause is often the rear ABS wiring harness, which has chafed through against the body, or worn brushes in the ABS pump motor. A wiring harness fau...

ML 320ML 270 CDI

Mercedes-Benz W163 BAS/ESP light stays on

There are several causes: the brake light switch, relay K6, a brake fluid level that is too low, an incorrect reading from the steering angle sensor o...

ML 270 CDIML 400

Mercedes-Benz W163 A/C compressor does not run

Often the fault is in the compressor's magnetic clutch: the coil, the clutch air gap or the clutch plate. Alternatively, the fault can be in the contr...

ML 270 CDIML 270ML 400 CDI

Mercedes-Benz W163 alternator and fluctuating charging voltage

Voltage can climb as high as 16-17 volts while driving, which resets the instrument cluster and makes the lights flicker. The cause is usually the alt...

ML 270 CDI

Mercedes-Benz W163 CDI injector leak-off

Typical symptoms are hard starting, especially when warm or in cold weather, and fuel pressure staying low. Sometimes the car stalls and the EPC light...

ML 270 CDIML 400 CDI

Mercedes-Benz W163 stalls while driving and restarts only after cooling down

A typical cause is a sensor that tracks engine position: the crankshaft position sensor or the camshaft sensor. As the engine warms up, the faulty sen...

Mercedes-Benz W163 CDI boost pressure leaks and turbo noises

Yes. A crack in the boost hose between the turbo and the intercooler can cause heavy smoke and a lack of power. Typical leak points are cracks in the ...

ML 270 CDIML 400 CDI

Mercedes-Benz W163 CDI: air in the fuel line, engine does not start properly

The cause is often air in the fuel line. The engine needs long cranking, starts and then stalls right away. Air gets in through a leak on the low-pres...

ML 270 CDIML 400 CDI

Mercedes-Benz W163 axle and transfer case oils

The axles use GL5-grade oil that meets approval MB 235.7 when the axle has no locks. The transfer case takes automatic transmission fluid (ATF) with a...

ML 270ML 320

Mercedes-Benz W163 cooling system leak and bleeding

Pressurise the cold cooling system to a good bar with a rubber plug that tightens in place and a pressure gauge. Listen for where it hisses. This also...

ML 320ML 270 CDI