Description
Factory Mercedes ML450 CDI 4Matic Workshop Manual (2009-2011)
This official factory-level service manual gives US technicians and hands-on owners complete repair authority over the W164-chassis Mercedes ML450 CDI 4Matic – the brand’s flagship diesel SUV of the era. Every procedure mirrors what Mercedes-Benz dealer technicians reference on the shop floor.
Powertrain & Drive Coverage
| Component | Variants Covered |
|---|---|
| Petrol | N/A |
| Diesel | OM629 4.0L V8 CDI Twin-Turbo (~306 hp / 516 lb-ft) |
| Transmissions | 7G-Tronic 7-speed automatic |
| Drive | 4Matic permanent AWD (transfer case & front/rear differentials) |
| Model Years | 2009-2011 |
| Badge Twins | N/A |
Common ML450 CDI Repairs Covered
| System | Procedures |
|---|---|
| OM629 Diesel Injection | Common-rail injector removal, coding, and return-leak testing; injection pump service |
| Turbocharger System | Twin-turbo actuator inspection, boost pressure diagnosis, intercooler pipe replacement |
| 4Matic Transfer Case | Transfer case fluid service, front differential seal replacement, driveshaft R&R |
| Air Suspension (AIRMATIC) | Compressor replacement, air strut R&R, ride-height sensor calibration procedures |
Format & Delivery
PDF. Instant download; lifetime re-downloads.
Frequently Asked Questions
What is the engine code for the ML450 CDI, and what known issues does this manual help address?
The ML450 CDI uses the OM629 4.0-liter V8 twin-turbodiesel. Known trouble areas include injector return-line leaks that cause rough cold starts and loss of power, as well as turbocharger actuator failures leading to reduced boost. This manual provides step-by-step injector removal and coding procedures, turbo actuator testing, and all associated torque values.
Does this manual cover the full W164 platform, including chassis and AWD components?
Yes. The W164 chassis is fully documented, including the 4Matic permanent AWD system – transfer case, front and rear differentials, prop shafts, and the electronic traction management interface. Suspension geometry, front and rear axle service, and AIRMATIC air suspension procedures are all included.
Are wiring diagrams and ESP/ABS electrical schematics included?
Complete electrical documentation is part of this manual. Circuit diagrams cover the CDI engine management system, 4Matic AWD electronics, ABS/ESP modules, COMAND infotainment, climate control, and body electronics – with connector pinouts, wire colors, and ground locations throughout.
What format is the manual?
This is a PDF manual. After purchase you receive an instant download link, and the file can be accessed on any desktop, tablet, or mobile device using a standard PDF reader. Your download is available for re-access any time through your account.
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