Mercedes ML Class ML280 CDI 4Matic Workshop Manual (2006-2010)

Description

Factory Mercedes ML Class ML280 CDI 4Matic Workshop Manual (2006-2010)

This factory-level service manual delivers complete repair and maintenance data for the W164-generation Mercedes ML280 CDI 4Matic – an ideal reference for US-based independent shops and serious DIY owners working on these capable diesel SUVs.

Powertrain & Drive Coverage

Component	Variants Covered
Petrol	N/A
Diesel	OM642 3.0L V6 turbodiesel (~190 hp / 440 Nm)
Transmissions	7G-Tronic 7-speed automatic
Drive	4Matic permanent AWD
Model Years	2006-2010
Badge Twins	W164 platform (ML320 CDI, ML350, ML500 share chassis)

Common ML280 CDI Repairs Covered

System	Procedures
OM642 Swirl Flap / Intake Manifold	Removal of failed plastic swirl flap actuators, intake manifold cleaning and replacement to prevent engine damage
7G-Tronic Transmission	Fluid and filter service, valve body inspection, conductor plate replacement, adaptive reset procedures
Air Suspension / AIRMATIC	Compressor diagnostics, strut replacement, level sensor calibration, and pressure testing
Fuel Injection & Turbocharger	Common rail injector testing, turbocharger boost pressure diagnosis, intercooler inspection, and EGR service

Format & Delivery

PDF. Instant download; lifetime re-downloads.

Frequently Asked Questions

What is the OM642 swirl flap issue and does the manual cover the fix?

The OM642 3.0L V6 diesel used in the ML280 CDI is well known for plastic swirl flap actuators that break apart and enter the engine, potentially causing serious damage. This manual covers full intake manifold removal and replacement procedures, including the steps needed to inspect and eliminate the swirl flap components.

Is this manual specific to the W164 ML280 CDI, or does it cover other W164 variants too?

The manual is focused on the ML280 CDI 4Matic variant of the W164 platform. While the W164 chassis underpins multiple ML Class models (including the ML320 CDI, ML350, and ML500), powertrain-specific content – such as OM642 diesel procedures and 7G-Tronic calibrations – is directly applicable to the ML280 CDI.

Are wiring diagrams and ESP/ABS electrical schematics included?

Yes. The manual contains comprehensive electrical documentation covering the engine management system, 4Matic AWD electronics, ABS and ESP control modules, climate control circuits, lighting systems, and body electronics. Connector pinouts, wire color codes, and component locations are all documented.

What format is the manual?

This manual is a PDF file delivered via instant download upon purchase. It is fully searchable, compatible with Windows and Mac computers, tablets, and smartphones, and individual pages or sections can be printed for bench use.