Description
Factory Mercedes-Benz ML420 CDI 4Matic Workshop Manual (2006-2009)
This is the official factory-level service manual for the Mercedes-Benz W164 ML420 CDI 4Matic – the essential reference for US owners and independent shops tackling everything from routine maintenance to major drivetrain repairs on this diesel-powered luxury SUV.
Powertrain & Drive Coverage
| Component | Variants Covered |
|---|---|
| Petrol | N/A |
| Diesel | OM629 4.0L V8 CDI (~306 hp / 700 Nm) |
| Transmissions | 7G-Tronic 7-speed automatic |
| Drive | 4Matic full-time AWD |
| Model Years | 2006-2009 |
| Badge Twins | N/A |
Common ML420 CDI Repairs Covered
| System | Procedures |
|---|---|
| OM629 Diesel Injection | Common-rail injector removal, coding, and return-flow testing; turbocharger inspection and replacement |
| Air Suspension (AIRMATIC) | Compressor unit overhaul, strut replacement, level sensor calibration, and leak-down diagnosis |
| 7G-Tronic Transmission | Fluid and filter service intervals, mechatronic unit diagnostics, shift quality fault-finding |
| ESP / ABS Braking | Wheel speed sensor replacement, brake caliper service, hydraulic unit bleeding procedures |
Format & Delivery
PDF. Instant download; lifetime re-downloads.
Frequently Asked Questions
Why does the AIRMATIC suspension fail on the W164 ML420 CDI and how is it fixed?
The AIRMATIC air suspension on the W164 ML-Class is a known weak point – compressor motors wear and air struts develop leaks, causing the vehicle to sag on one corner or trigger a suspension fault light. This manual covers full compressor disassembly, strut replacement torque specifications, and level sensor recalibration so you can restore correct ride height without dealer-only tools.
Is the W164 ML420 CDI related to any other Mercedes platform or model?
Yes. The W164 platform underpins the full 2006-2011 M-Class range, including the ML320 CDI, ML350, ML500, and the high-performance ML63 AMG. The GL-Class (X164) shares significant architecture. This manual is specific to the ML420 CDI 4Matic variant but the W164 chassis and 4Matic drivetrain content applies broadly across that generation.
Does the manual cover the 4Matic transfer case and front/rear differential service?
Yes. Complete 4Matic all-wheel-drive system coverage is included – transfer case fluid service, front and rear differential removal and overhaul procedures, driveshaft torque specs, and electronic AWD control module diagnostics are all documented with step-by-step instructions and exploded diagrams.
What format is the manual?
This manual is a PDF file. After purchase you receive an instant download link. The document is fully searchable, printable, and compatible with any device running a standard PDF reader – laptop, tablet, or smartphone.
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