Mercedes M Class ML320 CDI 4Matic Workshop Manual (2006-2009)

Description

Factory Mercedes M Class ML320 CDI 4Matic Workshop Manual (2006-2009)

This official factory-level service manual gives US technicians and DIY owners complete repair authority over the W164-platform ML320 CDI 4Matic – covering everything from OM642 diesel diagnostics to 7G-TRONIC transmission overhaul.

Powertrain & Drive Coverage

Component	Variants Covered
Diesel	OM642 3.0L V6 CDI Turbodiesel
Transmissions	7G-TRONIC 7-speed automatic
Drive	4Matic permanent AWD
Model Years	2006-2009
Chassis	W164
Badge Twins	N/A

Common ML320 CDI Repairs Covered

System	Procedures
OM642 Diesel Injector Seals	Carbon build-up and injector sleeve seal replacement – a known W164 CDI issue
7G-TRONIC Transmission	Fluid service, valve body inspection, conductor plate replacement, and electronic calibration
Air Suspension (AIRMATIC)	Strut replacement, compressor diagnostics, and ride-height sensor calibration
Brake & ESP System	ABS module diagnostics, brake pad and rotor replacement, ESP sensor testing

Format & Delivery

PDF. Instant download; lifetime re-downloads.

Frequently Asked Questions

What is the known injector issue on the ML320 CDI and does this manual cover it?

The OM642 engine in the W164 ML320 CDI is prone to injector sleeve seal failure, which allows exhaust gases to leak and causes carbon fouling around the injector bores. This manual includes complete step-by-step procedures for injector removal, sleeve seal replacement, torque specifications, and reinstallation – exactly what’s needed to address this common repair correctly.

Is the W164 ML320 CDI related to any other Mercedes platform or badge twin?

The W164 is a dedicated Mercedes-Benz M Class chassis with no direct badge twin sold in the US market. The platform underpins the full ML lineup of that generation, and the OM642 engine it shares appears in other Mercedes products such as the E320 CDI (W211) and R320 CDI, though those vehicles use different chassis documentation.

Does this manual cover the 4Matic transfer case and AWD system?

Yes. The 4Matic permanent all-wheel-drive system, including the transfer case, front and rear differentials, and driveshaft assemblies, is fully documented. Service procedures cover fluid changes, seal replacements, and electronic control diagnostics for the 4Matic system specific to the W164 platform.

What format is the manual?

This manual is delivered as a PDF file. It is fully searchable, zoomable, and compatible with any PDF reader on Windows, Mac, tablet, or smartphone. Download it instantly after purchase and re-download anytime at no additional cost.