Description
Factory Mercedes ML320 CDI 4Matic Workshop Manual (2006-2009)
This is the official factory-level service manual for the W164 Mercedes-Benz ML320 CDI 4Matic, covering every major repair and maintenance procedure US technicians and serious DIYers need for the 2006 through 2009 model years.
Powertrain & Drive Coverage
| Component | Variants Covered |
|---|---|
| Petrol | N/A |
| Diesel | 3.0L OM642 V6 turbodiesel (~224 hp / 376 lb-ft) |
| Transmissions | 7G-Tronic 7-speed automatic |
| Drive | 4Matic permanent AWD |
| Model Years | 2006-2009 |
| Badge Twins | N/A |
Common ML320 CDI Repairs Covered
| System | Procedures |
|---|---|
| OM642 Diesel Engine | Swirl flap actuator removal and replacement (known failure point causing rough idle and limp mode) |
| Fuel System | Common-rail high-pressure fuel pump diagnostics, injector seal replacement |
| Suspension | Front and rear airmatic strut replacement, height sensor calibration |
| Electrical / Safety | ESP, ABS module diagnostics, wiring diagram-guided fault tracing for COMAND and climate control |
Format & Delivery
PDF. Instant download; lifetime re-downloads.
Frequently Asked Questions
What is the W164 chassis code and which years does it apply to?
The W164 is the internal Mercedes-Benz platform designation for the second-generation ML-Class, produced from 2005 through 2011. This manual covers the 2006-2009 ML320 CDI 4Matic built on that platform, including all production updates introduced during that span.
Does the manual address the OM642 swirl flap failure issue?
Yes. The 3.0L OM642 V6 diesel is known for swirl flap actuator failure, which can lead to rough idle, reduced power, and limp-home mode. The manual includes full intake manifold removal sequences, actuator replacement steps, and torque specifications needed to complete this repair correctly.
Are wiring diagrams and electrical diagnostics included?
Complete circuit diagrams are included for the engine management system, ABS/ESP, climate control, lighting, central locking, power windows, and the COMAND infotainment system. Each diagram identifies connector locations, wire colors, pin assignments, and ground references to streamline fault diagnosis.
What format is the manual?
The manual is delivered as a fully searchable PDF file. It works on Windows and Mac computers, tablets, and smartphones, and individual pages or entire sections can be printed for bench use.
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