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Five cylinder diesel: CDI technology brings 4WD fuel consumption down to just 9.4 litres.

Mercedes-Benz has released its newest, price-sharp, M-class with power on tap. The new diesel ML 270 CDI with five-cylinder engine, extends the portfolio of successful M-Class models in Australia. Three variants are now offered, ML430, ML320 and ML270 CDI.

The M-Class was originally launched in the USA late 1997 before being premiered in Australia in September 1998. During this brief period, the versatile all-activity vehicle has already conquered pole positions in international registration statistics. Australians have snapped up more than 2160 M-class vehicles since sales began and between late 1997 and January 2000 Mercedes-Benz manufactured around 150,000 M-Class models.

Accolades from international trade journals, including the awards "Sport Utility Vehicle of the Year", "Best Buy" or "Car of the Year" are also very much part of the M-Class success story. In addition, it has recently been hailed by the Insurance Institute for Highway Safety in the USA which, having carried out a number of different crash tests, found it to be the "safest car" in the sport utility vehicle segment. The M-class also won RACQ and NRMA Best 4WD awards in Australia in 1998 and 1999.

ML 270 CDI: Five-cylinder diesel with high-tech features

The new ML 270 CDI is the first M-Class diesel variant Mercedes-Benz offers. Advanced common rail direct injection, four-valves-per-cylinder technology, VNT turbocharger and intercooler are just some of the special technical attributes of the newly developed five-cylinder engine.

The engine, which debuted with E270 CDI model late last year, delivers 120 kW and provides an enormous maximum torque of 400 Newton meters with the 5-speed electronic automatic transmission fitted standard in Australia.

The CDI engine not only has excellent flexibility at low and medium revs - the fuel gauge points to another of its major strengths: overall fuel consumption of the ML 270 CDI Australian specification is a frugal 9.3 liters per 100 kilometers (NEDC figures) . Key specs at a glance:

The five-cylinder unit owes its high pulling power from low revs mainly to the use of a variable nozzle turbine (VNT) turbocharger that varies the air flow cross section to reflect the current engine operating point thereby producing the optimum charging pressure. Thanks to the

dynamic adjustment of the guide vanes inside the turbocharger, the entire emission energy is used to maximum efficiency.

The new CDI engine is based on the cast-iron crankcase of its predecessor. To cope with the increased mechanical load posed by

direct injection, the crankcase now has additional reinforcements and ribs and thicker walls.

The displacement reflects the modular construction principle, since all the CDI engines have the same cylinder spacing of 97 millimetres and the same bore and stroke dimensions of 88 x 88.34 millimetres.

The outstanding results achieved by Mercedes-Benz diesel engines on output, torque, fuel consumption and ride comfort are partly down to the use of innovative common rail technology.

With a high injection pressure, mixture formation in the cylinders is substantially improved, giving low fuel consumption and exhaust emissions.

Another feature of the new CDI engines are the pilot injections which pre-heat the combustion chamber. Thanks to the pilot injections, noise emission of the new Mercedes CDI engines is substantially below the values of comparable diesel direct injection engines and is even below the level of state-of-the-art pre-chamber engines.

The alternator too has been slightly modified. The CDI engine in the ML270 is the first diesel engine to be fitted with a water-cooled alternator. The new unit - with water jacket for noise insulation - operates at over 10,000 revolutions per minute and releases heat to the cooling water. This significantly improves heater performance.

The equipment of the new ML 270 CDI will also meet the highest demands. Brake Assist, Electronic Stability Program (ESP) and alloy wheels are just as much part of the standard package as air conditioning, cruise control and side bags for the driver and front seat passenger.

The M-class enters the model year 2000 with a number of new features which significantly enhance its safety, comfort, functionality and visual appeal.

Safety: Three inertia-reel belts are now provided for rear seat occupants. The automatic retractors for the outer seats feature belt tensioners which in the event of an accident take away the slack instantly and effectively prevent passengers moving forward. A passive head-protection system is also provided. The system mainly consists of padded roof and pillar linings. Side bags are now also optionally available for the rear doors of the M-class. On the new ML55 AMG these are part of the standard equipment.

Comfort: Redesigned front seats with ruffled pockets on the seat backs offer M-class passengers an even higher level of comfort. Standard courtesy lights fitted in the doors and to the underside of the instrument panel make entry and exit more convenient as well as safer. In Australia, the standard automatic transmission is equipped with the newly developed one-touch gearshift. Gears can be selected manually by simply tapping the selector lever to the left or right. Another new development concerns the indicators: it has a flick-flash function making the appropriate indicator flash three times. This setting is particularly useful when overtaking other vehicles on the highway.

Functionality: Rear seat bench and backrest of the M-class can now be splitfolded in a 60:40 ratio to improve cabin versatility. The new bench division also offers rear seat passengers greater comfort when one side of the seat bench or backrest is folded down. Better still: a new feature makes it even easier to adjust the rear bench. On model year 2000 vehicles, opening the bonnet is made even more convenient thanks to the standard-fitting of gas-filled struts.

Looks: From model year 2000, the leather trim (standard on ML430 and luxury pack versions) now extends to door trims and the surface of door handles.

Standard Equipment M-Class

"Classic" Package

• Active Service System ASSYST (displays distance to next service based on the cars' operating data)
• Air conditioning with electrostatic dust-and pollen filter. 100 % CFC-free
• 16 inch Alloy wheels (5-whole design)
• AM/FM Radio/Cassette, aerial integrated into rear window
• Armrests front (with storage compartment) and rear
• Cargo Cover
• Cloth Upholstery
• Courtesy ligtht in all doors, footwell lights in front
• Cupholder front and rear
• Driver-adaptive 5-speed automatic transmission with Tippshifting feature in gera indication in tachometer
• Electronic cruise control and variable speed limiter (Speedtronic)
• Engine "touch-start" function
• Headrests adjustable up-down and fore/aft
• Heated rear window with integrated wiper switching on automatically when rear gear is selected and front wipers are on
• Heated side mirrors, electrically adjustable and foldable
• Illuminated vanity mirrors in sunvisors
• Interior trim in "Carbon Optic"
• Map pockets on front seatbacks
• Mobile phone pre-installation (antenna and wiring for hands-free system)
• Outside temperature gauge
• Power-assisted steering with safety steering column
• Power windows (front & rear), remote opening & closing with car key
• Reading lamps in rear
• Remote central locking system with interior switch and crash sensor (automatic opening). Rolling-ode signal protects from transmitter cloning
• Steering Column height adjustable
• Tinted safety glass all around with integrated windscreen band filter

• Anchor points in luggage compartment
• Anti-lock braking system (ABS) with off-raod mode
• Brake assist (BAS, automatic brake boosting in critical braking situations, can shorten braking distances by as much as 45%)
• Child-proof locks on rear doors
• Double roller-blind for luggage cover and passenger protection (wagons only)
• Engine Immobilizer with electronic drive authorisation system (ELCODE)
• Electronic Stability Program (ESP, prevents wheel slippage when accelerating and swerve of vehicle on slippery surfaces by automatic braking of individual wheels)
• Front airbags and sidebags for driver and front passenger
• Halogen front fog lamps, rear fog lamp
• Integrated first aid kit
• Seat belts with emergency pre-tensioner (front and outer rear seats) and belt force limiter
• Seat occupancy sensor (prevents front passenger airbags and belt pre-tensioner from deploying if seat is unoccupied)
• Anti-lock braking system (ABS)

Versatility

• Folding rear seat bench 60:40 split, adjustable fore/aft, with 3 removable headrests and 3 three-point seat belts
• 12 V power outles in front passenger footwell and in boot

• Permanent Four wheel Drive
• Four wheel Electronic Traction System (4-ETS) ensures torque is applied automatically to the wheel(s) with the most grip
• Electronically selectable low range gear ratio

• "Luxury" package (see below)
• 17 inch alloy wheels with wider tyres, 7-hole star design
• Anti-theft alarm system with tow-away protection and glass breakage sensor
• Burr walnut gear shift lever
• Heated Front seats

   

  "Luxury" Package (optional)

• Anti-Dazzle rear view mirror
• Burr Walnut interior trim
• Full Leather Upholstery
• Leather-bound steering wheel and shift lever
• Power Front Seats
• Trip Computer

Mercedes-Benz M-Class

Luxury pack (inc. electrically operated leather seats, woodtrim, leather bound steering wheel and shift lever, trip computer) available for ML270 and ML320 at $6,000 (standard on ML430).

M-Class - Project Update

Daimler-Benz AG (now DaimlerChrysler) announced in April 1993 that it would build its first passenger vehicle manufacturing facility in the United States.

This decision emphasized the company's globilization strategy and desire to move closer to its customers and markets. After an intensive, six-month site selection process, DBAG chose Tuscaloosa County, Alabama, as the location for its $300 million plant.

Mercedes-Benz U.S. International, Inc. (MBUSI), based in Tuscaloosa, was formed to fulfill the goal of producing the new M-class, All-Activity Vehicle.

Construction of the plant was completed in November 1996. The entire team is located under one roof to foster open communication and a team spirit.

Production of customer vehicles began in January of 1997 to support a U.S. market launch in the fall of 1997. Currently, as many as 376 vehicles a day are coming off the line, to achieve an annual volume of about 80,000 units in 1999.

MBUSI recently made a $US80 million capital investment in the plant to increase production and productivity to help satisfy the overwhelming worldwide demand for the M-class. The additional investment will also enable MBUSI to add product variations to the M-class. With more automation installed in the body and paint shops, and additional logistics bays in the assembly shop, MBUSI will achieve a 20 per cent production increase annually. The company exceeded its 1998 goals by producing 68,735 M-classes, last year.

In addition to increasing production in Tuscaloosa, DaimlerChrysler is assembling supplemental M-classes in Graz, Austria, to help satisfy the increasing demands of the European market. Up to 30,000 additional M-class vehicles, including all of Australia's ML270 CDI supply will be assembled at the Steyr-Daimler-Puch manufacturing facility.

Besides body, paint and assembly shops, also located on the Tuscaloosa site are a comprehensive training facility and a visitor centre.

The Visitor Centre, which houses entertaining exhibits detailing the history of Mercedes-Benz - including its products, technology and commitment to safety - is open to the public. Public plant tours run five times each day.

Currently, there are over 1900 team members working on site in Tuscaloosa. An additional 150 persons working on vehicle development are based in Germany. Up to 70 German trainers moved to Alabama during the past four years to assist with the training process of production team members.

The combination of German and American team members with experience from U.S. and Japanese automakers, as well as from Mercedes-Benz has made for a "melting pot" in terms of corporate culture.

Training is a vital component of the DaimlerChrysler corporate strategy. Team members have undergone extensive training at plants in Germany, some living and working there for more than six months.

Approximately, 65 major suppliers work as partners in the development and production of the M-class. More than two-thirds of the vehicle's components come from North American suppliers, with engines and transmissions coming from DaimlerChrysler plants in Germany.

Nine major suppliers are located in Alabama, alone, representing purchases of more than $US300 million annually from Mercedes-Benz.

In its product design and in what it offers consumers, the M-class, All-Activity Vehicle, is an evolution of the sport utility vehicle. It is a true off-roader, with all the ruggedness and durability of a sport utility.

However, it combines these off-road capabilities with the safety, quality, on-road performance and comfort of a Mercedes passenger car. In essence, it represents the best of a sport utility and the best of a Mercedes-Benz.

The M-class also sets the benchmark in terms of safety, quality and four-wheel-drive technology in the sport utility segment. It goes beyond what sport utility vehicles currently do and offer consumers. But, most of all, the M-class clearly sets a new benchmark in terms of value to the customer, with a starting price in Australia of $64,900 for its all new model year 2000 product line.

The M-class went on sale in Australia in September 1998 and has sold more than 2,160 units since then. The Tuscaloosa plant serves the worldwide market in over 135 countries. Last year, the long-awaited 4.3 litre V8 ML430 debuted.

The company just began full production of the all new ML55 AMG, a 5.5 litre, 260 kW vehicle recently certified as "the fastest SUV in the world". Right Hand Drive versions are expected to commence production later this year.

The M-class has won more than 40 awards in the U.S.A. including the 1998 North American Truck of the Year, Motor Trend Truck of the Year and Consumers Digest "Best Buy".

In Australia, the ML320 currently holds the coveted NRMA/RACV "Best Recreational 4WD" Award.

The new Mercedes-Benz Plant in Tuscaloosa, U.S.A

"Sweet home Alabama" has new meaning for Mercedes-Benz. The Mercedes-Benz M-Class is manufactured at the production facility in

Tuscaloosa County, Alabama. The board of management gave the go-ahead for the M-Class project in early 1993 and has invested more than $300 million in the plant. Including development costs, the project represents an investment of about $1 billion.

The first passenger vehicle production facility for Mercedes-Benz in the U.S. includes body, paint and assembly shops, along with a training institute and a visitors centre. The one-million-square-foot facility sits on about one-third of its 1000-acre site.

At full capacity, the plant produces some 85,000 vehicles annually, with half for North America and the remainder for Europe and Australia. Another plant at Graz in Austria also assembles M-Class products.

Mercedes-Benz announced its decision to locate the M-Class plant in Tuscaloosa following a comprehensive site selection process throughout the U.S., which included more than 150 sites and existing facilities in 30 states.

Construction began in October 1994 and the plant was completed 18 months later.

In early 1995, the first production team members from Alabama were hired and sent to Germany, where they spent the next six months training on-the-line at the company's Sindelfingen plant, preparing to build the M-Class.

Located 19 kilometres east of Tuscaloosa, Alabama, and 51 kilometres west of Birmingham, Alabama, the contemporary, white and glass one-million-square-foot facility includes a Training Institute and a Visitors Centre. The major sections of the plant include a body shop; an environmentally safe paint shop that is pressurised to keep out the fine red clay soil of Alabama; and an assembly shop, where the chassis is married to the body.

The plant configuration breaks the typical automotive paradigm. All shops - body, paint and assembly - as well as the administrative areas are located under one roof, with the administrative offices running though the heart of the manufacturing area.

In addition, as vehicles in production move from the paint shop to the assembly shop along a conveyor, team members and visitors can see them through windows and glass walls.

Adjacent to the plant, the Mercedes-Benz Visitors Centre and Training Institute has already become somewhat of an architectural landmark in Tuscaloosa, the building is topped by a large, revolving three-pointed star.

The development process of the Mercedes-Benz M-Class began in early 1993 with an unprecedented amount of market research. Research indicated that almost 70% of worldwide sports utility sales are in the United States, which provided the rationale for the M-Class plant to be located there.

Research also showed that owners of current, truck-derived sport utilities although pleased with the ruggedness and cargo capacity of their vehicles, also desired a more comfortable ride, better fuel economy, greater passenger safety and improved reliability.

Drawing upon this information - and combining it with the decades of expertise in four-wheel-drive technology that Mercedes-Benz had - it was decided that the M-Class would be designed and developed from a clean sheet of paper approach, rather than rebadge or redesign an existing car or truck platform.

Some 15 function groups were established and included members from almost every area of the organisation. These groups were empowered and accountable for meeting cost, quality, development times and weight targets for the M-Class.

The overall development time of the M-Class was 34 months, particularly short for developing a completely new vehicle from the ground up.

Training is a vital component of the MBUSI (Mercedes-Benz U.S.

International, the company formed with responsibility for M-Class development, production and worldwide strategic marketing) corporate strategy. It begins even before a team member joins the organisation, during their interview and screening process.

Production team members underwent extensive training in Germany, some living and working there for more than six months. More than 150 MBUSI team members have trained at Mercedes-Benz plants in Germany.

When a team member is hired, their training process begins in the MBUSI Training Institute, located near the plant and adjacent to the MBUSI's Visitor's Centre.

Following the Mercedes-Benz tradition of being an environmentally-conscious company, MBUSI has integrated sweeping environmental policies throughout its vehicle development, production process and plant engineering.

Almost all of MBUSI's product coatings are water-based with only one being solvent-based. All of its E-Coat is lead free, and primer and colour coats are all water born. If the coating is not water based, MBUSI recycles it.

MBUSI recycles sludge, cardboard, wood, plastic, steel and paper. It shreds the crushed car bodies, launders kevlar gloves instead of throwing them away, and recycles pain sludge into cinder blocks or roof tiles.

The public has the opportunity to learn all about the history of the world's oldest auto maker at an innovative new facility on the

Mercedes-Benz site in Tuscaloosa County. The Centre offers an entertainingpresentation of the history of Mercedes-Benz, the vehicles and includes a tour of the new production facility for the M-Class.

The 2,230 square metre Centre includes exhibits detailing the history of Mercedes-Benz, including its products, technology and commitment to safety. Displays with historical and current photography, video, artifacts, interactive modules and actual vehicles are used throughout the facility to tell the Mercedes-Benz story, including the decision to locate its first North American passenger vehicle plant in Alabama.

Many of the artifacts on display come from the Mercedes-Benz Museum in Stuttgart, Germany.

Included among the vintage items is one of the world's first motor vehicles, a Daimler motor carriage built in 1886 by Gottlieb Daimler and Wilhelm Maybach.

After viewing the exhibits, visitors can tour the production facility and witness the M-Class being built. Also included is a Delivery Centre for customers who choose to take factory-delivery of their new M-Class.