Description
Factory Mercedes ML400 CDI Workshop Manual (2001-2005)
This official Mercedes-Benz dealer-level software manual covers the W163-generation ML400 CDI from model year 2001 through 2005 – giving US-based technicians and owners complete service data for one of Mercedes’ most capable diesel-powered SUVs.
Powertrain & Drive Coverage
| Component | Variants Covered |
|---|---|
| Petrol | N/A |
| Diesel | 4.0L OM628 V8 CDI Turbodiesel (~250 hp / 560 Nm) |
| Transmissions | 5-speed manual; 5-speed automatic (722.6 series) |
| Drive | 4MATIC AWD; LHD and RHD configurations |
| Model Years | 2001, 2002, 2003, 2004, 2005 |
| Badge Twins | N/A |
Common ML400 CDI Repairs Covered
| System | Procedures |
|---|---|
| OM628 Fuel System | Common-rail injector removal, leak-off testing, high-pressure pump service |
| 722.6 Automatic Transmission | Valve body overhaul, fluid and filter change, conductor plate replacement |
| 4MATIC Transfer Case | Front differential seal replacement, transfer case fluid service, viscous coupling inspection |
| W163 Air Suspension / Brakes | Front and rear brake pad/rotor replacement, ABS/ESP sensor diagnostics, suspension ball joint service |
Format & Delivery
Mercedes dealer software. Instant download; lifetime re-downloads.
Frequently Asked Questions
What is the known weak point of the OM628 engine in the ML400 CDI?
The OM628 4.0L V8 CDI is known for common-rail injector seal failures that allow diesel to contaminate engine oil. The manual provides full injector removal sequences, leak-off test specifications, and seal replacement torque values to address this issue correctly.
Does this manual cover the 4MATIC all-wheel-drive system?
Yes. The 4MATIC transfer case and front/rear axle differentials are fully documented, including fluid specifications, seal replacement procedures, and electronic AWD control diagnostics specific to the W163 platform.
Are wiring diagrams included for the ABS and ESP systems?
Complete circuit diagrams are included for the ABS and ESP systems, covering sensor locations, connector pin assignments, and ground reference points. The instrument cluster, climate control, central locking, and engine management wiring are also fully illustrated.
What format is the manual?
This is official Mercedes-Benz dealer software – not a PDF. It runs on Windows (XP through 11) and Mac, features full-text search by model, engine code, and gearbox code, and includes zoom-capable diagrams. Access is granted immediately upon purchase with no shipping required.
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