03.TÀI LIỆU ĐÀO TẠO VÀ SỬA CHỮA MERCEDES BENZ M-CLASS

Cars complete vehicle M-Class (164
model series) AKUBIS Initial training
Cars • complete vehicle

M-Class (164 model series)
AKUBIS
Initial training
r As at 05/05
This document is for training purposes only and is not subject to ongoing revision.
Printed in Germany Note:

© 2005 Copyright DaimlerChrysler AG The term »employee« always refers to both
female and male members of staff.
Publisher: Global Training
This document, including all its parts, is protected under the laws of copyright. Any further processing or use
requires the previous written consent of DaimlerChrysler AG. This applies in particular to reproduction, distribution,
alteration, translation, microfilming and storage and/or processing in electronic systems, including databases and
online services.
1511 1638 02 - 1st edition 05/05 128 As at 05/05

Content 24.05.2005
Title Page
Dimensional drawings......................................................................................................................................................................................................................... 1
Model plates ....................................................................................................................................................................................................................................... 3
Equipment packages........................................................................................................................................................................................................................... 4
Seats .................................................................................................................................................................................................................................................. 8
Fuse plan .......................................................................................................................................................................................................................................... 11
Battery arrangement......................................................................................................................................................................................................................... 14
Overall network: location of control units ......................................................................................................................................................................................... 16
Instrument cluster ............................................................................................................................................................................................................................ 21
Drive authorization system (DAS) ..................................................................................................................................................................................................... 23
Central locking (ZV) .......................................................................................................................................................................................................................... 24
Anti-theft alarm system (ATA) ........................................................................................................................................................................................................... 26
Vehicle climate control ..................................................................................................................................................................................................................... 27
Improved verification of repairs (VRV) .............................................................................................................................................................................................. 32
Engines ............................................................................................................................................................................................................................................. 36
Walkaround....................................................................................................................................................................................................................................... 54
Wheels and tires ............................................................................................................................................................................................................................... 60
Brake system .................................................................................................................................................................................................................................... 61
Tire pressure monitoring system (TPM) ............................................................................................................................................................................................ 63
05/05 Cars complete vehicle M-Class (164 model series) AKUBIS Initial training
Content I 1
Steering ............................................................................................................................................................................................................................................ 66
Suspension ....................................................................................................................................................................................................................................... 67
All-wheel drive system ...................................................................................................................................................................................................................... 76
Telematics ........................................................................................................................................................................................................................................ 84
Vehicle shell...................................................................................................................................................................................................................................... 92
Supplemental restraint systems ....................................................................................................................................................................................................... 97
NECK-PRO (special equipment) ...................................................................................................................................................................................................... 106
Power liftgate.................................................................................................................................................................................................................................. 108
Removing and installing the instrument cluster .............................................................................................................................................................................. 112
Emergency operation...................................................................................................................................................................................................................... 113
Automatic transmissions with DIRECT SELECT............................................................................................................................................................................... 116
AKUBIS online................................................................................................................................................................................................................................. 122
Content I 2
Dimensional drawings 24.05.2005
P00.10-2724-00
Dimensional drawings 1
Dimension comparison: W164/W163 W164 W163 W164/W163
Vehicle length mm 4780 4630 + 150
Vehicle width mm 1911 1840 + 71
Vehicle height (design height), w/o roof railing mm 1768 1776 –8
Wheel base mm 2915 2820 + 95
Front track width mm 1635 1555 + 80
Rear track width mm 1639 1555 + 84
Front overhang mm 865 866 +1
Vehicle weight ML 350 ML 500 ML 280 CDI ML 320 CDI

Curb weight kg 2135 2175 2185 2185
Permissible gross vehicle weight kg 2830 2830 2830 2830
Maximum roof load kg 100 100 100 100
Maximum payload kg 695 655 645 645
Towing capacities ML 350 ML 500 ML 280 CDI ML 320 CDI

Permissible towing capacity, braked kg 3500 3500 3500 3500
Permissible towing capacity, unbraked kg 750 750 750 750
Maximum tongue weight kg 140 140 140 140
Dimensional drawings 2
Model plates 24.05.2005
The vehicle identification number is located:

∗ on the crossmember under the right rear seat
bench. In case of repairs, the vehicle
identification number must be stamped in
using the special stamping guide tool.
∗ on the model plate on the lower left of the
B-pillar. If it becomes damaged due to an
accident, it can be re-ordered.
P60.00-2638-06
The model plates on the engine hood and the rear

right longitudinal member can not be re-ordered if
they are damaged in an accident.
GT00_01_0042_C71 GT00_01_0043_C71
Model plates 3
Equipment packages 24.05.2005
Offroad styling package

∗ Complete underride guard in stainless steel,
front and rear
∗ Radiator grille with three radiator slats in
silver/chrome
GT88_20_0024_C71 GT88_20_0023_C71
Chrome package (standard for ML 500)

∗ Radiator grille painted black, features three
chrome-trim radiator slats
∗ Four trim strips on the doors with a light matt
aluminum overlay
silver/chrome
∗ Door handles in vehicle color and with a
chrome insert
∗ Chrome-plated stainless steel tailpipe,
rectangular
∗ Scratch protection on rear bumper in chrome,
ribbed design
∗ Rear bumper with chrome insert GT88_00_0020_C71 GT88_00_0021_C71
Equipment packages 4
Sport package (exterior)
∗ Door handle in vehicle color and with a chrome
insert
∗ Side rub strips in vehicle color and with a
chrome insert
silver/chrome
∗ Rear bumper insert, black/clear with a chrome
strip
∗ Taillamps with a dark sport design
∗ Chrome-plated stainless steel tailpipe, GT88_00_0022_C71 GT88_00_0023_C71
rectangular
∗ Scratch protection on rear bumper in chrome,
ribbed design
∗ 5-spoke 19" light alloy sport wheels
∗ All windows with heat-insulating blue glass
Sport package (interior)

∗ Lower half of the center console features a
high-gloss black aluminum overlay
∗ Upper half of the center console in high-gloss
black
∗ Sport pedals
∗ Electrically adjustable front sport seats.
Upholstery features Alcantara/ARTICO
leather* and contrast stitching
∗ Sport instrument cluster
∗ Interior light package
GT68_00_0061_C71 GT68_00_0062_C71
Interior equipment package
∗ 4 trim strips on upper door panels in burred
walnut veneer wood trim
∗ Lower half of the center console has a burred
walnut veneer wood trim
∗ Center console paneling in burred walnut trim
with chrome elements
∗ Leather upholstery
∗ Interior light package
∗ Electrically adjustable front seats
∗ Stowage compartment with cover
GT68_00_0063_C71
Trim parts package
"Fineline" bird's-eye maple paneling

∗ 4 trim strips on upper door panel
∗ lower half of the center console
∗ center console trim
GT68_00_0064_C71 GT68_00_0065_C71
Interior light package
(only in combination with the Interior equipment and Sport packages)
∗ Illuminated and door handle recess in the front and rear
∗ Right liftgate marking lamp
∗ Ambient lamp in the liftgate
∗ Illuminated stowage compartment at the front of the center console
∗ Illuminated cupholder at the front of the center console
∗ Rear footwell illumination
AIRmatic package
∗ Front and rear air suspension with level control (+50 mm to –30 mm)
∗ Adaptive damping system (ADS)
Offroad Pro technical package

∗ Off-road reduction (Low Range) with shift on the move (can be selected while driving) and a gear ratio of 2.93:1
∗ Multiple disk limited-slip center differential with up to 100% locking capability
∗ Multiple disk limited-slip rear axle differential with up to 100% locking capability
∗ Mode selection (using the switch on the center console):
1. Automatic mode for center and rear axle differential locks
2. Manually lock center differential
3. Manually lock rear axle differential
∗ Underride guard
∗ Compass
∗ Front axle differential can be locked when brakes are activated by ETS
∗ Air suspension with a wider setting range (+30 mm compared to the AIRmatic package)
∗ Transmission control: automatic standard transmission mode "S" and manual transmission mode "M" (can be selected using the button)
Seats 24.05.2005
Electric front seats

∗ Electric front seats are standard equipment
and come with manual steering column
adjustment.
Note: Power is supplied to the seat adjustment
once the driver door is opened.
∗ Electric seats are also available as special
equipment with electric steering column
adjustment and memory
Note: Power is supplied to the seat adjustment
once the door is opened.
∗ Move the seat backrest switch up or down to
adjust both head restraints.
GT91_10_0051_C71 GT91_10_0052_C71
Electric seats with memory

∗ Each front seat has its own control unit (left N32/1, right N32/2)
∗ Each front seat has 3 seat position memories (set manually and saved by the user)
∗ The most recent seat position is also stored when the key is removed
∗ Easy entry and exit, as in other Mercedes-Benz model series
∗ The driver seat control module also stores the values of actuator motors for the steering column and
outside mirrors (controls the actuator motor on the steering column adjustment)
∗ The seat actuator motors must be normalized to use the seat position memory function.
GT91_10_0050_C71
Seats 8
Seat normalization
∗ To return to normal positions, move the seat into the following final position until the mechanical stop has been reached. Then engage the switch a further
250 ms for:
− fore-and-aft adjustment: front stop
− inclination adjustment: down stop
− height adjustment: down stop
− backrest adjustment: front stop
− head restraint adjustment: down stop
∗ If the seat is used after normalization, the seat control unit shuts off the drive motor before the mechanical stop is reached.
Note:
If a Hall sensor is malfunctioning, the seat control unit cancels the attempted adjustment function after 2 seconds. The motor can only run in the respective
direction once the switch has been released for a period longer than 2 seconds. The motor is immediately fully functional in the opposite direction.
Heated front seats

∗ Standard equipment in the ML500 (otherwise special equipment).
∗ Front seat switches are read in via the upper control panel (N72/1).
∗ Switch position message for the front signal acquisition and actuation module (N10) is sent via
CAN B.
∗ Heated seat elements are supplied via the front signal acquisition and actuation module (N10)
depending on the switch position and/or time.
Heat level / LED Heat output Duty cycle in (%) Operating time
1 Low 0 - 40 20 min. (∞ when the seat ventilation is
on and operating*)
2 Medium 41 - 70 10 min.
3 High 71 - 100 5 min.
* Heating levels switch down as the operating time progresses: e.g. Level 3 switches to Level 2 and then Level 1 before shutting off.
Seats 9
Front seat ventilation & heated rear seats
∗ Heating package available for model year 2007 as an equipment option
∗ Controlled by the heated seats control unit (N25/5)
∗ The upper (N72/1) and rear control panels (N72/2) read in the switch position and provides a
message for N25/5 to CAN B
∗ N25/5 supplies the rear seat heater elements with current and sends the control signals of the
electronic blower for front seat ventilation.
Installation location: beneath the left rear seat

GT91_10_0049_C71
Seats 10
Fuse plan 24.05.2005
The prefuse box F33 (battery compartment) distributes current to the fuse boxes in the instrument cluster (F3) as well as the right rear load compartment (F4).
The prefuse box in the engine compartment (F32) supplies current to the fuse box in the engine compartment (F58).
∗ Fuse box (F3)

Right instrument cluster, removable plastic
cover, fuses f10 to f18,
at market launch all fuses to circuit 30
∗ Luggage compartment fuse and relay box (F4)
∗ Prefuse box (F32)
up to 5 prefuses (bolted version)
∗ Prefuse box (F33)
contains bolted and plugged prefuses
Note: Bolted prefuses must not be replaced
individually
∗ Engine compartment fuse and relay box (F58)
Fuse and relay assignment diagram located

beneath the folding wheel chock.
P54.15-2726-09
Fuse plan 11
Prefuse plan
A32n1 Blower motor

A80 Intelligent servo module (ISM)
F3 Instrument panel fuse box
F4 Rear fuse and relay box
F32 Front prefuse box
F33 Battery compartment prefuse box
F58 Engine compartment fuse and relay box
G1 Main battery
G2 Alternator
M1 Starter
N2/7 ARCADE airbag control unit
N2/11 Weight sensing system (WSS)
N4/3 Suction fan
N10 Front SAM
N10/8 Rear SAM
N15/9 Control unit for rear differential lock
N33/4 PTC heater booster
N47/5 Electronic Stability Program (ESP)
GT00_19_0096_C06
Fuse plan 12
Jump starting, charging the battery
∗ The jump-starting/battery charging point is located in the engine compartment (red plastic cover).
∗ When charging the main battery at the workshop, the charger can be connected directly to the jump-
starting point.
∗ To test the main battery, the Midtronics Tester MCR 717 must be connected directly to it (this
prevents inaccurate measurements caused by line resistance).
∗ The (charging) status of the additional battery G1/7 is monitored by the front SAM (N10). Discharged
additional batteries are recognized by the front SAM (N10) and shown on the instrument cluster's
multifunction display via CAN B.
Fuse plan 13
Battery arrangement 24.05.2005
The M-Class features a two-battery arrangement.
∗ Installed underneath the front passenger seat:

− Main battery (G1) 12 V 95 Ah AGM battery
− Additional battery (G1/7) 12V 1.2 Ah
∗ The main battery is responsible for supplying the entire vehicle with
voltage (including starter power supply).
∗ Only one plastic cover needs to be removed to disconnect the batteries.
∗ Also remove the ground plug for the additional battery at the main
negative terminal.
GT54_10_0047_C81
Battery arrangement 14
Additional battery (G1/7)
∗ If the main battery does not supply enough
voltage, the additional battery provides an
emergency supply for the intelligent servo
module ISM (A80).
∗ This ensures that the parking position is
engaged and that the drive authorization is
immobilized. Drive authorization (shift
mechanism) can only be enabled using the
main battery.
∗ The charging and the status of the additional
battery G1/7 is regulated by the front SAM
(N10).
∗ The instrument cluster displays an error GT54_10_0045_C71 GT54_10_0046_C71
message for faulty or disconnected additional
battery.
∗ When disconnecting the main battery, also
remove the ground plug for the additional
battery at the main negative terminal.
∗ The N10 voltage supply to the G1/7 ensures
that: CAN C
Circuit 30
− the battery status is checked Circuit 31
− the additional battery's charging status is G1/7
displayed
− the battery is charged N10 N73 A80
∗ The electronic ignition switch supplies voltage
to the ISM (A80m2) when:
− the main battery G1 fails to supply voltage
G1/7 Additional battery
and the electronic ignition key is removed or
A80 Intelligent servo module (ISM)
− the ignition is turned off and the driver door N10 Front SAM
is opened (only with Keyless Go) N73 Electronic ignition switch (EIS)
Battery arrangement 15
Overall network: location of control units 24.05.2005
Overall network: location of control units 16
CAN bus Class B CAN bus Class C
1 Instrument cluster (IC) 1 Instrument cluster (IC)
2 Electronic ignition switch (EIS) 2 Electronic ignition switch (EIS)
3 Electronic compass 4 Central gateway (CGW)
4 Central gateway (CGW) 21 Steering column switch module (MRSM)
5 Keyless Go (KG) 22 ARCADE airbag
6 Front SAM 23 Motor electronics (gasoline)
7 Rear SAM 24 Motor electronics (diesel)
8 Automatic air conditioning operating unit (C-AAC)) 25 Intelligent servo module (ISM)
9 Weight Sensing System (WSS) 26 Air spring with adaptive damping system (ADS)
10 Driver seat adjustment with memory (SCU-D) 27 Electronic transmission control (NAG2)
11 Passenger seat adjustment with memory (SCU-FR) 28 Electronic stability program (ESP)
12 Parktronic System (PTS) 29 Headlamp range adjustment (HRA)
13 Driver-side front door control unit (DCU-D) 30 Left front reversible emergency tensioning retractor
14 Passenger-side front door control unit (DCU-FR) 31 Right front reversible emergency tensioning retractor
15 Overhead control panel (OCP)
16 Upper control panel (UCP)
17 Liftgate remote locking (HFS) CAN bus Class D
18 Tire pressure monitoring system (TPM) 4 Central gateway (CGW)
19 COMAND 39 Emergency call system (LCT), USA only
20 Rear control panel (RCP)
MOST ring
19 COMAND
LIN bus 34 CD changer (CD-C)
8 Automatic air conditioning operating unit (C-AAC) 35 Satellite Digital Audio Radio System (SDARS), USA only
13 Driver-side front door control unit (DCU-D) 36 Universal portable CTEL interface (UPCI)
15 Overhead control panel (OCP) 37 Sound amplifier
16 Upper control panel (UCP)
18 Tire pressure monitoring system (TPM)
21 Steering column module (SCM) DYNAMICS CAN
28 Electronic stability program (ESP)
38 Yaw rate sensor, ax and ay sensors
Signal acquisition and actuation module (SAM)
The front and rear SAM control units take on multiple electric functions. They are not directly connected to the fuse and relay modules, but are installed
separately, just like other control units.
Main functions of the front SAM (N10)
∗ Front windshield wipers

∗ Front exterior lights (lights master)
∗ Front/rear windshield wiper pump (dual pump)
∗ Headlamp cleaning system
∗ Footwell lighting
∗ Spray nozzle heating
∗ Heated front seats (with timer control)
∗ Power windows on right and left rear doors
∗ Central locking system for the left rear door
∗ Monitoring and charging the additional battery G1/7
∗ Reading in switches and sensors
∗ Diagnosis and coding
GT54_21_0056_C81
Main functions of the rear SAM (N10/8)
∗ Heated rear window

∗ Anti-theft alarm system
∗ Turn signal indicator (master)
∗ Central locking system for the left rear door and the fuel filler flap
(CLS master)
∗ Liftgate central locking and power closing
∗ Trailer recognition
∗ Trailer illumination (ECE/USA)
∗ Rear window wiper
∗ Right rear entrance illumination
∗ Rear-end door and load compartment illumination
∗ Right and left vent windows (X164)
∗ Electric load compartment floor (X164)
∗ Diagnosis and coding
P46.15-2188-01
Overview
Compared to its predecessor, the W163, the W164 makes use of a variety of communication networks, most of them already familiar from other Mercedes-Benz
passenger car models.
The entire communication network in the W164 consists of:

∗ CAN C (CAN engine)
∗ CAN B (CAN interior compartment)
∗ CAN D (CAN diagnosis)
∗ CAN S (Sensor CAN or Dynamic CAN) (Yaw sensor/Lateral acceleration sensor)
∗ MOST bus
∗ Local Interconnect Network (LIN bus)
∗ Private bus (e.g. headlamp range adjustment)
Central gateway (N93)
Installation location: beneath the left front seat
Tasks:
∗ CAN B master
∗ Vehicle variant codings
∗ Gateway between CAN C and CAN B
∗ CAN status diagnosis (system diagnosis)
∗ Interface between CAN C and CAN D
∗ Interface between CAN B and CAN D
P00.19-3294-04
Instrument cluster 24.05.2005
Features
∗ Speedometer
∗ Tachometer
∗ Analog clock
∗ Indicator lamps
∗ Dimmable instrument cluster illumination
∗ Reset button
∗ Multifunction display
∗ Fuel level indicator
As in many other passenger model series, several

functions and displays can be regulated and
accessed by pressing the buttons on the
multifunction steering wheel and display.
GT54_30_0101_C75
Maintenance system
The instrument cluster displays the Assyst Plus data stored in the central gateway, i.e. the instrument cluster displays the customer service codes "A-G".
Instrument cluster 21
Menu navigation
Pressing the buttons on the multifunction steering
wheel allows maintenance data to be selected,
read out to the display, and confirmed or reset if
so desired.
Instrument cluster 22
Drive authorization system (DAS) 24.05.2005
Function
No mechanical gearshift linkages have been installed on the W164. Instead, the “Intelligent Servo Module” (A80) was installed and takes over gear selection
(“Shift by Wire”).
The new ISM (A80) component of the drive authorization replaces the manual steering wheel lock of the predecessor, the 163.
The ISM (A80) enables the standard shifting operations of P-R-D and N as well as engaging the parking position (towing protection) if the electronic ignition key
is removed or the front door is opened using Keyless Go.
The electronically generated code is first recognized by the electronic ignition switch (DAS master) and is then relayed to the:
∗ engine control unit
∗ electronic transmission control module
∗ intelligent servo module
Tasks
∗ Access authorization (central locking
system)
∗ Check the drive authorization codes
(DAS 3)
∗ NO key-dependent memory
∗ Linked to CAN-B and CAN-C
∗ Supplementary battery connection to
the intelligent servo module (ISM)
(key function ‘P’)
∗ Start button for Keyless Go GT80_61_0013_C01 P80.57-2077-04
Drive authorization system (DAS) 23
Central locking (ZV) 24.05.2005
Arrangement of components
P80.20—275509
Central locking (ZV) 24
Features
∗ Electronic transmitter key with radio and infrared function (DAS3, RoW 433 MHz)
∗ RF antenna integrated into the antenna module
∗ Electric actuator motors in every door, the liftgate, and the fuel filler flap
∗ Can be set for global or selected unlocking
∗ Automatic locking set to vehicle speed:
∗ Locks at 15 km/h
∗ Liftgate cannot be opened at speeds faster than 3 km/h
∗ Relocking after ∼ 40 seconds (when door/doors is/are not opened after being unlocked)
∗ Emergency unlocking via SRS after airbags and/or emergency tensioning retractors have been deployed
∗ Liftgate opens and closes using an electronic key (if the vehicle is equipped with an automatic liftgate)
∗ Turn signal indicator indicates locked or unlocked status: ± = 3 flashes ² = 1 flash
Operation
Only the driver door has an infrared receiver
(A26/1) and a mechanical lock cylinder for
emergency unlocking.
Each front door has a lock-unlock button in front
of the inside door release. The switch is read by
the respective door control unit. The subsequent
message is forwarded to CAN-B.
If the vehicle is equipped with Keyless Go and an

automatic liftgate, an additional locking button is
located on the underside of the liftgate (S62/26).
The switch is read out by the automatic liftgate
control unit (N121). P80.20-2765-01
Central locking (ZV) 25
Anti-theft alarm system (ATA) 24.05.2005
The anti-theft alarm system (ATA) (code 551) monitors the status of the alarm inputs and evaluates them.
The following are monitored:
∗ Doors, the engine hood, and the liftgate
∗ Interior and
∗ Vehicle position
A change in the vehicle's parking state activates a country-specific visual and acoustic alarm.
Special equipment for interior protection (code 882)

via the ultrasonic sensor in the overhead control panel (OCP [DBE]). The following are monitored:
∗ Left rear window glass breakage sensor (B39), side window
∗ Right rear window glass breakage sensor, (B39/1), side window
∗ Rear window glass breakage sensor (B39/4), rear window
∗ Ultrasonic sensors CDBE
Alarm triggering
Alarm types and lengths differ greatly from country to country. Using STAR Diagnosis, the alarms can be
coded from options provided for the rear SAM and the central gateway.
ATA activation
The anti-theft alarm system (ATA) is activated and deactivated by locking or unlocking the vehicle using
the transmitter key (A8/1) (radio/infrared hand transmitter or Keyless Go).
Once the ATA has been activated, the LED in the UCP control unit (N72/1) will flash intermittently.
Activation takes 10 seconds. Activation of the interior protection takes an additional 30 seconds.
GT80_50_0014_C03
Anti-theft alarm system (ATA) 26
Vehicle climate control 24.05.2005
Thermatic air conditioning

(standard)
Dual-zone air conditioning

without a rear booster blower
GT83_30_0003_C01 GT83_30_0004_C01
Front control and operating unit Rear operating unit
Comfort Thermotronic air

conditioning
(code 581)
Tri-zone air conditioning with

a rear booster blower
GT83_30_0005_C01 GT83_30_0006_C01
Front control and operating unit Rear operating unit
Vehicle climate control 27
Dust and combination filter
The dust or combination filters are located behind
the glove box.
∗ The glove box must be removed in order to

exchange the filters.
∗ Push aside and remove the filter cover.
∗ To exchange the filter, remove the first
element, then shift the second one over and
likewise remove it.
∗ To avoid whistling sounds and reduce the
speed of outlet air, make sure the filter cover
is properly seated once the filters have been
exchanged.
P83.00-2161-05
Interior air outlet temperature sensor
∗ NTC sensor type
∗ Connected directly to the climate control
control and operating unit
∗ Located as close as possible to the outlet to
ensure precise temperature measurement of
outlet air.
B10/31 Left side temperature sensor

B10/32 Right side temperature sensor
B10/33 Center left temperature sensor
B10/34 Center right temperature sensor
B10/35 Left footwell temperature sensor
B10/36 Right footwell temperature sensor
P83.30-4147-09
∗ The interior temperature sensor (N22/b1) is located on the climate control control and operating
unit (1), below the left temperature dial buttons.
∗ The control module regulates the temperature according to the Energy Requirement Level-System
(ERL).
∗ As a rule, temperature is regulated according to a programmed performance map.
∗ The interior temperature sensor provides various inputs, e.g. the interior temperature when the
vehicle is started, during driving, and during the first 30 minutes after shut down. It even recognizes
heat radiation through the sunroof.
∗ This provides the automatic air conditioning (AAC) control unit with a starting point to regulate the
temperature. Sensors on the vent outlet check if the outlet temperature meets the requirements of
the control unit.
GT83_30_0002_C01
The sun sensor (B32) or the dual sun sensor
(B32/3, Thermotronic only) is located on the
centerfill loudspeaker trim.
P83.57-2087-04
The pollutant sensor (air quality) (B31) is located

on the fresh air intake duct below the right side of
the engine hood (Thermotronic only).
GT83_30_0007_C01
Dew point sensor (B11/12)
∗ Measures the moisture of incoming air and
calculates the dew point.
∗ Installed between the blower motor and the
heater housing.
∗ Connected to the climate control control and
operating unit via LIN bus.
∗ The dew point is used to regulate the air
conditioning compressor. It is shared with the
door control units via CAN B to regulate
mirror heating.
P83.30-4152-04
Rear air conditioner housing

If the vehicle is equipped with Thermatic, the housing has only one actuator motor for the rear air
distribution flap.
Vehicles equipped with Thermotronic also have the following integrated components:
1 Actuator motor for rear air distribution flap
B10/7 Rear air temperature sensor
N29/2 Rear booster blower regulator
M2/1 Rear booster blower
GT83_50_0011_C71
Improved verification of repairs (VRV) 24.05.2005
VRV: overview and background

A new project was launched in light of the rising costs of repairs under Integrated into the DAS software, VRV provides workshop technicians
warranty and repeated visits for the same complaint. The project aims to with additional information on malfunctions.
uncover causes and provide concrete solutions.
According to VRV, all faults must be remedied. This guarantees complete
Target: and successful repairs.
Increase customer satisfaction In addition to the displayed current and stored fault codes, fault codes
Reduce warranty costs and malfunctions that were not tested can be displayed after the DAS
This project is known as “Fixed First Visit”. software reads out and evaluates the fault memory of every control unit.
One of the solutions which emerged from the project concerned improving It is still possible to select fault codes which then provide guided tests,
STAR Diagnosis (DAS). These improvements are implemented parallel to actuations, or specific conditions to the code to be checked.
the W164 introduction. If these test conditions are met and all faults have been remedied, the
fault code either converts to a stored event or disappears from the
In many cases, these changes will appear for the first time during displayed DAS list.
diagnosis of the newly developed or modified control units installed in the
W164.
Improved verification of repairs (VRV) 32
Quick test with function view
This extended DAS feature makes troubleshooting more efficient by:
∗ displaying malfunctions after evaluating all of the control unit fault codes.
(Cross references to customer complaints can be inserted here.)
∗ accessing conducted tests directly.
∗ providing any existing links to service information (SI) or updated
troubleshooting documents (AF)
∗ displaying control units affected by malfunctions.
Deleting faults
These extended DAS features allow faults to be deleted only after:
∗ performing DAS troubleshooting
∗ carrying out required steps
∗ and their DAS confirmation
If a fault has produced more than one fault code, remedying the specific fault
allows all of its resulting fault codes to be deleted. When working on a vehicle, GT00_00_0433_C11
∗ The creation of new faults should be prevented.
∗ The processing of the fault should always be completed.
VRV-enabled control units Control unit flashing
In conjuction with the DAS release in March 2005, the following control Software in an increasing number of control units can be updated by
units will be VRV-enabled for the W164 launch: flashing. This substantially reduces repair costs. The following control
∗ OCP Overhead control panel units can be flashed:
∗ EIS Electronic ignition switch ∗ Instrument cluster (A1)
∗ IC Instrument cluster ∗ Front SAM (N10)
∗ AAC, C-AAC Automatic air conditioning ∗ Rear SAM (N10/8)
∗ DCU LF Left front door control unit ∗ Climate control control and operating unit (N22)
∗ DCU RF Right front door control unit ∗ ESP control unit (N47/5)
∗ CM Compass module ∗ COMAND (A40/3)
∗ RCP Rear control panel ∗ Electronic engine control unit (N3/10)
∗ KG Keyless Go control unit ∗ Central gateway (N93)
∗ TPM Tire pressure monitor ∗ New Automatic Transmission 2 control unit (N15/11)
∗ Sound system ∗ Dual-mode TELEAID (N123/4) (USA only)
∗ ESA-RF Right front electric seat adjustment ∗ Sound amplifier control unit (N40/3)
∗ ESA-LF Left front electric seat adjustment
Note:
Flashing with STAR Diagnosis no longer requires a flash CD.
Notes on replacing the instrument cluster

Replacing the instrument cluster requires comprehensive coding.
Codings must be carried out according to the SCN coding principle.
SCN online coding was developed to increase process reliability during this
comprehensive coding. The W164 ist the first model to use SCN online
coding.
Engines 24.05.2005
GT00_01_0151_C72 P00.50-2068-81
Engines 36
Engine overview
The M-Class program launches with a new OM642 V6 diesel engine in two performance variants and a new M272 V6 gasoline engine as well as the well-proven
M113 V8 gasoline engine. Engine power ranges from 140 kW to 225 kW.
V6 diesel engine V6 gasoline engine V8 gasoline engine
The redeveloped OM642 V6 diesel engine belongs The ML 350 uses a 6-cylinder 272 E35 engine The ML 500 features the 8-cylinder 113 E50 -
to a new generation of common rail engines with which takes the place of the 112 E37 engine in known from the W163 - which has a maximum
piezo injection. The new M-Class features two the predecessor model series. The new 200 kW output of 225 kW.
performance variants, the ML 280 CDI with engine is 27 kW more powerful, yet it consumes It consumes 13.1 L per 100 km, one liter less than
140 kW and the ML 320 CDI with 165 kW. They less fuel (11.5 l per 100 km). the predecessor model W163.
meet strict EU 4 standards.
P01.10-2564-50 P01.00-2479-50 P01.10-0387-50
Engines 37
Engine and vehicle data
ML 280 CDI ML 320 CDI ML 350 ML 500

Engine configuration and V6 V6 V6 V8
number of cylinder
Engine type OM642 OM642 M272 M113
Valves per cylinder 4 4 4 3
Displacement cm³ 2987 2987 3498 4966
Bore x stroke mm 83 x 92 83 x 92 92,9 x 86 97 x 84
Air supply Turbocharger with adjustable turbine geometry Naturally aspirated engine
Rated output kW at rpm 140 at 4000 165 at 3800 200 at 6000 225 at 5600
Rated torque Nm at rpm 440 at 1400-2800 510 at 1600-2800 350 at 2400-5000 460 at 2700-4750
Acceleration 0-100 km/h s 10.4 9.4 8.4 6.9
Maximum vehicle speed km / h 200 210 215 235
Tank capacity L 95
Included reserve capacity L 13
Coefficient of drag cd-value 0.34
All models in the 164 model series come standard with a 7-speed automatic transmission. Manual transmissions are not available for this model series.
Engines 38
OM642 highlights
Essential highlights of the OM642 Main innovations of the CDI 4 system
∗ Crankcase made from aluminum with cast-in cast iron cylinder liners ∗ Engine control of the latest generation with extended functions for the
∗ Balance shaft to compensate for first-degree free mass moment selection of the injection time
∗ Four valves per cylinder with 2 camshafts per cylinder bank ∗ Revised high pressure pump (gear drive) with a maximum injection
∗ CDI 4 Common rail direct injection with up to 5 injections per cycle pressure of 1600 bar
∗ Maximum peak pressure in the combustion chamber up to 175 bar ∗ Fuel injectors with indirect actuation by piezo actuators (a more
∗ Instant start glow system (ISS) precise selection of the injection point of the up to five injections with
∗ VTG turbocharger with electrical adjuster and charge air cooling the lowest drift values and stable small quantities)
∗ Electrically set EGR valve for the exhaust gas recirculation ∗ Fuel injectors with 7-digit IMA coding (injector quantity compensation)
∗ Electrically set intake air throttling to support exhaust gas recirculation ∗ Hydraulically optimized nozzles with eight injection holes
and particulate filter regeneration ∗ Double preinjection (load case controlled; for reduction of the
∗ Electrically set intake port shutoff (EKAS) combustion noises)
∗ Crankcase ventilation with centrifugal oil separator ∗ Double postinjection (with DPF (SE)) load case controlled (for the
required regeneration of the diesel particulate filter)
∗ Emissions standard EURO 4 both with and without DPF
Engines 39
M272 highlights
The most important highlights of the new V6 engine:
∗ Balance shaft
∗ Direct ignition system
∗ Hot film MAF sensor based on the latest technology (HFM-SFI 6 Bosch)
∗ Near-engine mounted catalytic converters
∗ Crankcase made from aluminum
∗ Crankshaft forged and with four bearings
∗ Light-weight crank assembly with weight-reduced pistons and connecting rods
∗ Linear lambda control
∗ Air filter in two-cartridge design with integral resonators
∗ Control unit permanently mounted on engine
∗ Continuously variable camshaft adjustment for intake and exhaust camshafts
∗ Oil/water heat exchanger
∗ Variable intake manifold with variable-length intake manifold flaps and swirl flaps in the intake ports
∗ Four-valve technology with roller-type cam followers and hydraulic valve clearance compensation
P01.00-2486-12 ∗ Thermal management with map-controlled thermostat
∗ Cylinder liners from low-friction aluminum/silicon technology
Engines 40
Engine electrical systems
F58 Engine compartment fuse and relay box

(right)
f101 Gasoline/diesel
f103 Gasoline/diesel
f104 Gasoline
f105 Gasoline
f107 Gasoline
f118 (Circuit 15)
f120 (Circuit 30) Gasoline/diesel
D Engine circuit 87
E Air pump relay
I Starter relay
F4 Rear fuse and relay box
57 Fuel pump fuse

O Fuel pump relay
P54.15-2728-03 P54.15-2729-03
Engines 41
Engine control unit arrangement
Engine 272
The M272 uses a new fuel injection and ignition

system with the designation ME 9.7
The ME control unit from Bosch is attached to the
intake manifold on the engine.
Rubber mounts help suppress vibration. Cooling

fins on top of the control unit provide the
necessary cooling.
The electronic engine management is a further

development of the ME 2.8 from the M112 and
M113, which was adapted to the new conditions
and functions of the M272.
Engines 42
Engine 113
The engine control unit was placed beneath the

front passenger footrest for reasons of space.
Service note
To access the engine control unit, the floor mat
must first be removed.
P07.61-2353-04
In order to continue to use the standard wiring harness from the 113, an intermediate connector was
placed in the fuse and relay box in the right side of the engine compartment.
GT54_10_0048_C72
Engines 43
OM642 diesel engine
For thermal reasons, the engine control unit was

placed in the wheelhouse (with splash protection).
For theft protection the connectors (4 and 5) of
the control unit are secured with a safety strap (1)
which is riveted to the control unit.
The connectors are attached to the control unit

with a safety strap for theft protection. This strap
is riveted to the control unit.
To remove the control unit, this rivet has to be
drilled out.
P07.08-2099-09
Engines 44
Engine cooling
The most important components that comprise the cooling module are:
∗ a cross-flow radiator with an integrated transmission oil cooler in the right
radiator tank and a power steering fluid cooler in the left radiator tank.
∗ an A/C condenser with an integrated drier and accumulator
∗ a charge air cooler for diesel engines
∗ a continuously variable electric suction fan controlled by PWM signals
from the engine control unit
Component dimensions and versions depend on cooling needs. The chart

below lists the most important sizes.
P20.20-2280-05
Suction fan Radiator AC condenser

Max. output (W) Fan ∅ (mm) Depth (mm) Surface (dm²) Depth (mm)
ML 350 600 486 24 31.7 16
ML 500 600 486 24 / 40* 31.7 16
ML 280 CDI 850 530 40 31.7 16
ML 320 CDI 850 530 40 31.7 16 * for trailer hitches
The stationary heater special equipment adds the stationary heater unit with hot water hoses, a pump, and valves to the cooling system.
Engines 45
Fuel system
OM642 diesel engine
Design
∗ Saddle tank with a 95 L filling capacity
∗ Two tank modules
∗ Modules are connected in the tank by hoses
∗ Each module is equipped with a separate MAPPS
fuel level sensor
∗ The left module holds the connections for the fuel
feed line and return flow
∗ The right module holds the electric fuel feed pump
∗ Quick-release fittings (Quickconnect) on the tank let
the filler neck, fuel feed and return flow lines, and
the vent be connected and removed quickly.
Service note
∗ Replace the tank module through the interior
compartment (bonded shell cover underneath the
rear seat bench)
∗ Always replace the vise ring and the seal after
working on the tank module. (Self-locking vise ring)
∗ A special tool is required to open/close the vise ring
∗ To remove the tank, the exhaust system and
driveshaft must first be removed.
GT 47_10_0029_C76
Engines 46
M113, 272 engines
Design
∗ Saddle tank with a 95 L filling capacity
∗ Two tank modules connected by inner hoses
∗ Each module is equipped with a separate
MAPPS fuel level sensor
∗ The left module contains the connections for
the fuel feed line and the lifetime fuel filter
∗ The right module holds the electric fuel feed
pump
∗ Quick-release fittings (Quickconnect) on the
tank let the filler neck, fuel feed line, and the
vent to be connected and removed quickly
∗ The fill level limiter for turning off the filling
station nozzle is actuated by a float-controlled
cut-off mechanism in the tank
∗ The tank is ventilated by three float-controlled
valves in the tank
∗ Rollover valves in the ventilation valves close
when the vehicle rolls over
Service note:
∗ Refer to the diesel tank system
Engines 47
Exhaust system
M113, 272 engines
Design
∗ Two-pipe exhaust system with a firewall
catalytic converter, without an underfloor
catalytic converter
∗ Two center mufflers followed by a mixing area
and two end mufflers
∗ Fastened to the automatic transmission with
aluminum screws.
∗ M272
Four-sensor control, two broadband oxygen
sensors upstream of the catalytic converter,
and two planar sensors downstream of the
catalytic converter
∗ M113
4-sensor control, two planar sensors
upstream of the catalytic converter, and two
downstream
Service note:
∗ Always replace the clamps on the separation
points after repairs.
∗ Only use aluminum screws when attaching the
engine to the NAG2.
∗ These screws are attached with specified
torque and tightening angle.
Engines 48
OM642 engine with a diesel particulate filter:
This system is standard equipment in Germany,
Austria, Switzerland, and the Netherlands. It is
offered for other countries as special equipment
(code 474).
An extensive package of measures is offered for

the variant with the diesel particulate filter (DPF).
This single-pipe exhaust system has two oxidation
catalytic converters, one close to the engine as a
start-up catalytic converter as well as one large-
volume main catalytic converter downstream.
The exhaust downstream passes then through the
4.5 L volume particulate filter. It is made of
silicone carbide and is capable of filtering out
over 99% of exhaust particulate mass.
Exhaust system without a diesel particulate

filter:
Instead of a particulate filter, these vehicles have
a 5.5 L front muffler (same housing as the
particulate filter).
Service note P49.10-2571-06

Refer to the gasoline exhaust system. On the diesel exhaust system, the mounting flange for the turbocharger is slotted, so the screws only need to be loosened.
Engines 49
ASSYST PLUS maintenance system
The 164 model series is equipped with the ASSYST PLUS maintenance system. The ASSYST PLUS
software is in the central gateway control unit along with the ASSYST, system diagnosis, and gateway
modules.
ASSYST PLUS reviews all items that might require service within their intervals and flexibly includes them
into a service.
This review is specific to the vehicle and takes into account model designation, engine type,
date/mileage, service-relevant special equipment/retrofits, and driver behavior.
Service display:
The next required service appointment can be accessed by pressing the buttons on the multifunction
steering wheel.
The service display is composed of the term "Service" followed by the single-letter service code (A
through H). The service code indicates how much time the service package requires.
∗ Service code A Service time up to 1 hour

∗ Service code B Service time up to 2 hours
∗ Service code H Service time up to 8 hours
Engines 50
Maintenance scopes of service packages
Engine version Kilometers Time Remarks

Service 3
Engine oil with filter change
Gasoline M113 / 272 Oil 229.1 15,000 starting distance 1 to 2 years
Oil 229.3 15,000 starting distance 1 to 2 years
Diesel OM642 without DPF Oil 229.3 15,000 starting distance 1 to 2 years
OM642 with DPF Oil 229.3.1 15,000 starting distance 1 to 2 years
Service 8
Replace air filter
Gasoline M113 / 272 80,000 4 years
Diesel OM642 120,000 4 years
Service 11
Replace fuel filter
Gasoline in-tank type M113 / 272 250,000 15 years
Diesel external filter OM642 120,000 4 years
Service 12
Replace spark plugs M113 / 272 100,000 4 years
Service 19
Check diesel particulate filter OM642 80,000
Engines 51
Removing and installing the engine
Starting with the 164 model, engines will be removed from the bottom in all passenger car model series. During the transition stage, the 164 model engine can
also be removed from the top. However, the engine will be much more difficult to access. Removal from the bottom requires a major assembly platform lift with
a universal adapter plate to support the engine. This plate provides ideal working conditions for carrying out repairs. It can also be used as an assembly table for
smaller repairs.
Ordering Manufacturer: Blitz Rotary

Description: Major assembly platform lift Master Gear 1.0 with universal major assembly support
Order no.: 620-107857
P58.40-2013-11 GT01_10_0028_C01
Engines 52
Engines 53
Walkaround 24.05.2005
Front interior compartment
Task 1 P Switch function: A selector lever on the steering wheel replaces the familiar gearshift lever on the
center console. The shift directions are shown. On vehicles equipped with Keyless Go, please also
close the driver door.
Please specify what is required to shift out of "P".
Task 2 P Shift the individual gears "R", "N", and "D". What do you notice here?
Walkaround 54
Task 3 P Shift to "D" and remove the ignition key. Open the driver door on vehicles equipped with Keyless Go.
What do you notice here?
Note: The new intelligent servo module (ISM), located on the side of the transmission, is responsible
for shifting. A manual parking release does not exist.
Task 4 P Where is the interior switch for the central locking located in the new M-Class?
Task 5 P Vehicles equipped with a hydraulic liftgate also feature an additional liftgate switch located on the
lower half of the left door lining. Try to actuate the liftgate.
Walkaround 55
Task 6 P Take a look at the fully electric and partially electric seat adjustment. Try to adjust the head restraint.
Fully electric seats
Partially electric seats
Walkaround 56
Rear interior compartment
Task 7 P Pull on the seat cushion release handle and tip the seat cushion forward. Then pull on the backrest
release handle and tip the backrest forward.
Do the head restraints need to be removed in order to fold down the backrests?
Note: In order to remove the seat cushions on the rear bench seat, the vehicle must be equipped with
the EASY-PACK load compartment management system (special equipment).
Walkaround 57
Vehicle exterior and trunk
A Information P The vehicle is equipped with the standard ambient illumination function. If the interior lights are
switched off on the overhead control panel, ambient illumination is also deactivated once the doors
are opened (also known as the hunter stealth switch).
Task 8 P Open the liftgate and remove the small plastic cover in the middle of the inner paneling.
Task 9 P Open the right inner paneling cover.

Look for the red line and pull lightly on it once you have found it. What does this do?
Walkaround 58
Engine compartment, underneath the vehicle
Task 10 P There is a switch in the left hood lock for the anti-theft alarm system.
What does switch additionally control?
Task 11 P Where is the jump-start connection located in the engine compartment?
B Information Transfer case

Two different transfer cases can be installed: a one-speed transfer case (without electrical
connections) and one with reduction and locks (actuator motor, shift valve, and position sensor
attached).
Rear axle center assembly

Two different rear axle center assemblies can be installed: a standard differential and a center
assembly with locks 75401010 (actuator motor attached).
Walkaround 59
Wheels and tires 24.05.2005
235/65 R17 V (M+S) or 255/55 R18 V (M+S) or 255/55 R18 V (M+S) or

235/65 R17 H (M+S) 255/55 R18 H (M+S) 255/55 R18 H (M+S)
on 7½ J x 17 ET56 on 8 J x 18 ET60 on 8 J x 18 ET60
Standard on ML 350, ML 280 CDI, ML 320 CDI Standard on ML 500 Special equipment
Special equipment for ML 350, ML 280 CDI,
ML 320 CDI
255/50 R19 W Front: 255/50 R19 W on 8,5 J x 19 ET60 255/50 R19 W

on 8 J x 19 ET60 Rear: 285/45 R19 W on 9,5 J x 19 ET56 on 8½ J x 19 ET58
Special equipment with small Sport package Special equipment with large Sport package Special equipment with AMG package
in titanium silver or chrome-plated in titanium silver or chrome-plated
Spare wheel
Depending on the country, engine option, or installed wheels, the vehicle can be equipped with either TIREFIT or a "Minispare" compact spare tire.
Wheels and tires 60
Brake system 24.05.2005
General
The 164 model series uses a hydraulic dual-circuit brake system with an x-split. The ESP function comes as standard equipment. This allows
Mercedes-Benz to continue to provide high quality in braking distance, response characteristics, fade resistancy, and service life for brake
linings and directional stability.
Vehicle specific parameters are taken into account, such as 4-wheel drive with on-road and off-road use, axle load distribution, weight, and
driving performance.
Operation
The use of the ESP-off switch and the emissions-test-mode were adopted from the familiar passenger car model series.
The chapter "All-Wheel Drive Systems" covers the downhill speed regulation and ESP in offroad mode functions.
Start-off assist
Start-off assist activates automatically at inclinations of 5° and higher. In "D", the brake pressure is maintained for 1 second after the brake
pedal has been released. This lets the driver switch comfortably from the brake to the accelerator pedal. The start-off assist is also available in
reverse gear on 5° inclinations.
Brake system 61
Mechanical system
Front brakes floating caliper ML 350 ML 500

Brake piston diameter mm 44 44
Brake disk diameter mm 330 330
Brake disk thickness (ventilated) mm 32 32
Rear brakes floating caliper

Brake piston diameter mm 40 42
Brake disk diameter mm 330 330
Brake disk thickness mm 14 (solid) 22 (ventilated)
Wear sensor located on the front and right rear
Brake system 62
Tire pressure monitoring system (TPM) 24.05.2005
The tire pressure loss warning comes standard on all vehicles and is known from other passenger car model series.
The tire pressure monitor control unit (N88) is used in two versions:
∗ Low line (special equipment in USA, not availabe in other national versions)
∗ Mid line (special equipment in RoW, code 475)
Both versions use the same control unit. The hardware and software are identical.
The "mid line" version of the TPM control unit has the following features:
∗ Warning message showing position
∗ Pressure display showing position
∗ Temperature compensation of pressures
∗ "Moderate" warning displayed at a minor pressure loss; "urgent" message displayed during significant or rapid pressure loss
∗ Automatic filling recognition
∗ 20 minutes of stationary monitoring after circuit 15 switched off
∗ Warning issued below a preset threshold (p < 1.6 bar)
Functions
The TPM system constantly monitors the tire pressure of all wheels when circuit 15 is switched on and during travel. It also performs stationary monitoring for
20 minutes after circuit 15 is switched off. By assisting the driver in checking for the correct tire pressure, it contributes to active safety. The TPM system
responds to various vehicle conditions such as outside temperature, vehicle speed, etc. The driver can get information on the system's condition through the
multifunction display in the instrument cluster (A1).
Tire pressure, tire temperature, ID, and other additional information from the 4 wheel electronic units are sent by radio to the central tire pressure monitor
antenna (A2/97). This information is then transmitted to the tire pressure monitor control unit (N88). A mounted, full-size spare wheel (with wheel electronics)
is recognized minutes after travel begins and is taught in automatically.
Tire pressure monitoring system (TPM) 63
Operation
Manual reactivation
The driver can manually determine the filling pressure to be monitored by "reactivating" the tire pressure
monitor via the operating menu in the instrument cluster (A1.
Manual reactivation is only intended as a stopgap solution in critical cases when the automatic filling
recognition fails. Under normal circumstances (changing wheels or the driver changes tire pressure), the
filling recognition automatically determines the new target values.
Automatic reactivation
Filling criteria P54.30-7068-01
General filling recognition: increasing or decreasing pressure by more then 0.2 bar above the reference
value was detected on at least two wheels. Filtered pressure values compensated for temperature are
used as a comparison.
Or: Filling recognition for a wheel with an alert issued: increasing pressure by more than 0.2 bar was
detected on the tire in question. The pressure on the alerted tire at the time of the warning serves as a
comparison value.
Saving new reference values

After the successful plausibility check, new reference values are saved for all 4 wheels. Pressure values
filtered during the observation period (3 minutes) after filling recognition are used as a reference. The
reference values are saved and are used as a comparsion value in filling recognition.
Service note:
It is also possible to teach in the wheel sensors using DAS. P54.30-7117-71
Wheel electronics
Model 164 wheel sensors can not be used in or from other vehicle model series.
GT40_15_0023_C71
Steering 24.05.2005
Steering gear
As in the predecessor model series, the W164 features rack and
pinion steering. However, it is located centered in front of the
front axle.The steering gear has a variable gear ratio which is
more indirect in the middle position area than in outer areas.
This is made possible by a toothed rack whose gear rack has
been manufactured with varying modules and pressure angles.
Models equipped with the extended Offroad package and air
suspension as special equipment are the first M-Class vehicles to
feature speed-sensitive power steering.
Steering column
The steering column was redesigned. The major improvements
compared to the predecessor model series are:
∗ extended adjustment options for the steering column
(manual height and length adjustment) and electric height
and length adjustment including a memory feature. The latter
is available as special equipment.
∗ a further minimized risk of the steering column being
displaced into the passenger compartment in a severe head-
on collision. Starting from the original position, the steering
column can be adjusted by ± 25 mm vertically, as well as 25
mm forwards or 35 mm aft. A steering lock was not used
since a transmission lock is already used to prevent theft.
Steering 66
Suspension 24.05.2005
3 suspension systems are available for M-Class:
∗ Steel suspension (standard)

The standard system consists of traditional cylindrical coil springs with
single-tube gas pressure shock absorbers and a large-volume bearing.
∗ Air suspension (code 489)

The AIRMATIC air suspension system features greater driving comfort,
particularly during onroad operation. The package includes an adaptive
damping system (ADS). There are also three vehicle levels to choose from.
∗ Air suspension with the Offroad Pro technical package (code 430)
The extended Offroad package (Offroad Pro technical package) presents
another performance improvement. Five vehicle levels are now available.
This increases vehicle ground clearance by 110 mm.
Suspension 67
Steel suspension
Front axle suspension strut Separate steel spring and

shock absorber on the rear axle
Front axle level can be set with a
plastic shim. Rear axle level can be set with
spacers on the steel spring.
Spring must be removed first.
Suspension 68
Air suspension
The customer can select three damping system The vehicle level can be changed (air spring code The vehicle level can be changed in four steps
maps using the button (N72/1s3). The switching 489) by using the button (N72/1s2) (code 430) using the button (N72/ )
sequence is predefined. Normal level LED off Normal level LED off
AUTO LED‘s off Offroad level LED on Offroad levels 1-3 LED's on
SPORT Upper LED on for the corresponding level
COMFORT/COMF Lower LED on
The customer can activate the Highspeed level using a defined vehicle speed or by selecting the "Sport" damping performance map.
Suspension 69
Without Offroad Pro technical package
Level [mm]
Function
The complete function of AIRmatic can be divided 80
into subfunctions:
Level adjustment 50
Level control enables a manual, as well as a
speed-dependent automatic raising or lowering of
t
the vehicle level.
Level adjustment differs between vehicles with
and without the Offroad Pro technical package 0
and the selected damping setting.
- 30
t t
- 45
Auto / Sport 40 70 90 120 140 v [km / h]

Comfort 160 180
Suspension 70
Vehicles without the Offroad Pro technical package
Auto mode
The vehicle is at Highway level (-30). After pressing the switch N72/1s2, the vehicles raises to Raised level (+50). If the vehicle maintains a speed
of 70 km/h or faster longer than 20 seconds or if the speed exceeds 90 km/h, the vehicle lowers to Highway level (-30). Level selection is
canceled.
If the vehicle maintains a speed of 120 km/h or faster longer than 20 seconds or if the speed exceeds 140 km/h, the vehicle lowers to Highspeed
level (-45). If a speed below 70 km/h is maintained for longer than 20 seconds or if the speed falls below 40 km/h, the vehicle raises again to
Highway level (-30).
Comfort mode
The vehicle is at Highway level (-30). After pressing the switch N72/1s2, the vehicles raises to Raised level (+50). If the vehicle maintains a speed
of 70 km/h longer than 20 seconds or if the speed exceeds 90 km/h, the vehicle lowers to Highway level ). Level selection is canceled.
If the vehicle maintains a speed faster than 160 km/h longer than 20 seconds or if the speed exceeds 180 km/h, the vehicle lowers to
Highspeed level (-45). If the speed falls below 40 km/h, the vehicle raises again to Highway level (-30).
Sport mode
The vehicle is automatically lowered to Highspeed level in sport mode. The vehicle lowers to Highspeed level (-45) even when it is not moving.
Offroad level 1 lowers directly into Highspeed level. The vehicle no longer raises during deceleration.
Trailer operation (new function)

Trailer operation is recognized by the rear SAM (N10/8) with the following effects:
∗ If the vehicle is in a raised position after the ignition is turned on, the driver is notified in the instrument cluster (A1) that the vehicle must be
lowered.
∗ If the driver does not lower the vehicle and accelerates above 8 km/h, the vehicle is automatically lowered to Highway level.
∗ The Highspeed level (automatically lowered level) can no longer be started or executed.
Suspension 71
With Offroad Pro technical package
Level [mm]
80
50
0
t
- 30
t t
- 45
Auto / Sport 30 40 50 70 80 90 115 120 140 v [km / h]

Comfort 160 180
Suspension 72
With Offroad Pro technical package
Auto mode
The vehicle is at Highway level (-30). After pressing the switch N72s32, the vehicles raises to Offroad level 1 (+/- 0). If the vehicle maintains a speed of
100 km/h or faster longer than 20 seconds or if the speed exceeds 115 km/h, the vehicle lowers to Highway level (-30). Level selection is canceled.
If the vehicle maintains a speed of 120 km/h or faster longer than 20 seconds or if the speed exceeds 140 km/h, the vehicle lowers to Highspeed level (-45). If
a speed below 70 km/h is maintained for longer than 20 seconds or if the speed falls below 40 km/h, the vehicle raises again to Highway level (-30).
The vehicle is at Highway level (-30). After pressing the switch N72s32 twice, the vehicle raises to Offroad level 2 (+50). If the vehicle maintains a speed faster
than 70 km/h longer than 20 seconds or if the speed exceeds 90 km/h, the vehicle lowers to Offroad level 1 (+/-0). Level selection is canceled. Additional level
selection and lowering logic is the same as the Offroad 1-Highway-Highspeed level sequence (see above).
The vehicle is at Highway level (-30). After pressing the switch N72s32 three times, the vehicle raises to Offroad level 3 (+ 80). If the vehicle's speed exceeds
30 km/h, the vehicle lowers to Offroad level 2 (+50). Level selection is canceled. Additional level selection and lowering logic is the same as the Offroad 2 -
Offroad 1 -Highway - Highspeed level sequence (see above).
In Comfort mode, changes are made to the speed ranges for lowering Highway to Highspeed level (160 km/h for 20 seconds and 180 km/h, respectively)
Trailer operation and Sport mode same as Standard
The following functions are well-known in other passenger car model series: level control, adaptive damping system, wake-up, and locking the air suspension.
Suspension 73
Components
The AIRmatic system consists of the following components:

∗ Four air springs carry and damp the vehicle
∗ Compressed air reservoir
∗ Air pump
∗ One valve block/valve unit
∗ Level sensor and body acceleration sensor
∗ Level control with selectable levels
∗ Adaptive damping system (ADS) with a 3-stage shock aborber setting
∗ The ADS system controls the setting of the vehicle damping dependent on:
− the driver's selection/desired setting
− the vehicle body acceleration
Struts
The basic design of the suspension struts is familiar from the 220 model series. Thicker rubber bellows
have been installed to reduce possible damage in case of air leakage. The shock absorber and the bellows
on the rear axle were physically separated.
Compressed air reservoir

Task
Storage of compressed air for level adjustment. To guarantee fast adjustment times of vehicle level
independent of compressor operation. To enable level adjustment without actuation of the AIRmatic
compressor unit (A9/1) when stopped or at low speeds.
Normal air bellows pressure: 6-11 bar P32.22-2337-03

Volume of 12.6 liters (system pressure 16 bar) broken down into 8.1 liters in a larger reservoir and
4.5 liters in a smaller one
Suspension 74
Compressor
The AIRmatic compressor unit (A9/1) is located on a bracket behind the right
side of the bumper. The AIRmatic compressor unit generates the air pressure
required to raise the vehicle.
Function
The compressor motor is not controlled directly by the AIRmatic control unit
with ADS (N51). Instead, load power is supplied by the AIRmatic relay (K67).
A drain valve has also been integrated into the AIRmatic compressor unit to
assist in lowering the vehicle level.
If an excessively high pressure is generated in the AIRmatic compressor unit

by mistake, it is reduced automatically by an integrated mechanical pressure
relief valve.
P32.22-2339-06
Suspension 75
All-wheel drive system 24.05.2005
Standard
Permanent all-wheel drive with three open differentials. The division of torque between the front and rear axle is fixed in the transfer case. The ESP control unit
(N30/4) governs various functions such as acceleration slip regulation (ASR). The driver can turn downhill driving assistance on or off using the DSR (downhill
speed regulation) button found in the upper control panel (UCP) control unit (N72/1). The driver can also activate an offroad function in the NAG II transmission
(modified shift characteristics) using the Offroad button, also located in the upper control panel (UCP) control unit (N72/1). Pressing this button also activates
the accelerator pedal characteristic in the motor electronics (ME) control unit (N3/10) and the ABS function (offroad ABS) in the ESP control unit (N30/4).
Offroad Pro technical package (special equipment)

Permanent all-wheel drive with two lockable differentials (transfer case and
rear axle) and one open differential (front axle). Two gear ratios (onroad and
offroad) can be set in the transfer case. The transfer case control unit
(N15/7) and the rear axle differential lock control unit (N15/9) control the
two differentials.
The DSR button is located in the lower control panel control unit (N72).
Using the low range (LR) button in the lower control panel control unit (N72),
the driver can change the gear ratio in the transfer case (onroad or offroad).
The driver can operate the differential locks on the rear axle and in the
transfer case with the differential lock selector wheel. This is located in the
lower control panel control unit (N72).
GT00_10_0149_C81
All-wheel drive system 76
Operation - Standard
Downhill speed regulation button (N72/1s24)

Downhill speed regulation assists in driving downhill. Using this functions turns off a preset, variable speed limiter (cruise control).
Using the vehicle configurations in the instrument cluster (A1), speeds can be preset in 2 km/h increments, from 4 km/h up to 18 km/h. Pressing the cruise
control button changes the preset speed during downhill driving. If the driver accelerates during this function, downhill speed regulation becomes passive. Up to
a speed of 35 km/h, it reactivates and regulates the previously set speed if the driver no longer accelerates. If the vehicle accelerates above 35 km/h, downhill
speed regulation switches off. An abort message also appears in the instrument cluster (A1) multifunction display.
Speed is maintained by the engine, transmission, and brake system.
P28.60-2077-04
Offroad program button (N72/1s25)
The Offroad button affects the 4ESP, ASR, and ABS. It also changes the shift points in the automatic
transmission.
In 4ESP/4ETS, an ESP specially adapted for offroading is activated automatically. It intervenes with
delayed response during understeering or oversteering, thus improving traction.
During ABS brake application, ABS allows a longer skid phase to allow a braking wedge to build up in
front of the wheels. This function is active up to 30 km/h.
The engine torque is slightly reduced so that the driver can better modulate the accelerator pedal (ASR).
The New Automatic Transmission II shift points are delayed and the reverse gear "2" is activated (onroad
program Br, B3, K3; offroad program BR, B1, K3).
Standard components
Transfer case
This is a single-stage transfer case with an open differential flanged directly
onto the automatic transmission. The power is distributed 50:50 between the
front and rear axles.
Power flow
The input torque to the transfer case is transferred to the bevel-gear
differential (3) by the input shaft (1). The rear differential bevel wheel (3b) is
directly connected to the rear axle output flange (4). This transfers the output
torque directly to the rear axle through the driveshaft.
The front differential bevel wheel (3a) is connected with the sprocket wheel
on the input shaft (2). As a result, the front differential bevel wheel is
connected to the sprocket wheel on the front axle output flange (5) by the
chain (7). The output torque is transferred to the front axle by the front axle
output flange (6) and the driveshaft.
Rear axle
A traditional rear axle center assembly with a non-locking bevel-gear
differential is used.
Front axle
A front axle center assembly with a non-locking bevel-gear differential is used.
P28.10-2218-82
Operation of Offroad Pro technical package (code 430)
DSR switch (N72/s30)

Function as with standard equipment
Start-off assist
Function as with standard equipment
Low-range switch (N72/s31)

GF28.60-P-1000GZ
Shifting from High to Low (offroad gear)
Using the LR button located in the lower control
panel control unit (N72), the driver can shift from
onroad (High) to offroad ratio (Low). P28.60-2076-04
Once all shifting conditions have been met, gear

ratios (from High to Low) are changed in the
transfer case. A red LED integrated into the button
displays the current operating condition.
There is also a so-called preselection function. If the driver presses the LR button before all of the function's prerequisites have been met,
the LED in the LR button begins blinking. If the function prerequisites have been met, the gears are shifted in the transfer case. The LR
symbol appears in the multifunction display.
If the button is pressed again during preselection, the shift request (preselection) is aborted. During the preselection process, notes and
warning messages are displayed in the multifunction display (A1p13) in the instrument cluster (A1).
This function is also known as Shift on the Move (SOM) since it can also be carried out while driving.
Shifting from Low to High (onroad gear)

The shifting function and logic is the same as shifting from High to Low.
Notes on diagnosis (operation)

Shifting from High to Low or from Low to High
If the selector lever is brought into the D drive position during shifting, the transfer case control unit (N15/7) holds the VGS-NAG II control
unit (N15/11) in neutral until the shift from High to Low is complete.
If a failure (e.g. butting) occurs while shifting, the process is repeated. If shifting cannot finish successfully, the transfer case is shifted to
the previous gear.
If the gear cannot be engaged due to other reasons, the transfer case is shifted to neutral. The driver is made aware of this by audio and
visual warning signals.
Offroad package (N72s34) differential lock
selector wheel
The driver can select three levels using the
differential lock selector wheel located in the
lower control panel (LCP) control unit (N72):
1. level: transfer case (interaxle differential lock)
locks automatically, rear axle does not lock
2. level: the transfer case differential locks
(100%), the rear axle differential does not lock
3. level: the transfer case and the rear axle
differential are locked manually (100 %)
Each level has a red function illumination which shows the switched-on status.
If the ignition is on or off for more than 10 seconds, the first level activates automatically. The level does not change if the interval is shorter than 10 seconds.
In the automatic position, the transfer case control unit attempts to prevent the wheels from slipping. It first pre-loads the interaxle lock. The pre-load force is
primarily dependent on the engine torque, gear, driving speed, and steering angle. If a wheel still slips, the system readjusts and the locking force is raised to
100% max.
Axles
Along with the engine and transmission, the front axle major assemblies
including steering gear are attached to the front axle carrier, which is
constructed as a welded structure. The front axle carrier has been decoupled
from the body via four rubber mounts to lessen the transfer of front axle
vibrations to the body.
The front suspension was designed as a double wishbone axle.
Both the standard variant and the Offroad package have a front-axle center
assembly with non-locking bevel-gear differential.
Locking is simulated by 4-ETS.
The rear axle major assemblies are attached to a rear axle carrier which is
decoupled from the body by rubber and hydro-mounts. The rear suspension
was designed as a four-link suspension.
Coil springs and shock absorbers are arranged in tandem.
Telematics 24.05.2005
The Audio 20 CD radio, eight standard loudspeakers, and the AM/FM antenna
come as standard equipment.
Audio 20 CD (A2) features

∗ Radio with AM/FM tuner (with FM diversity)
∗ CD Audio drive
∗ Basic audio amplifier (4-channel amplifier with audio processing)
4 x 25 W at 4 ohm
∗ CAN B and MOST interface (Gateway)
∗ Traffic radio decoder (TP/TA)
∗ Controllable via multifunction steering wheel
∗ Installed in 2 DIN slots
∗ Monochrome display (12-point matrix display)
Controls or supports
∗ the single-slot CD changer (A2/6)
∗ the Universal Portable CTEL Interface (UPCI) control unit (N123/1)
∗ the sound amplifier (N40/3)
Note: The radio does not support Bluetooth P82.86-5141-11
Telematics 84
The Audio 50 APS (code 525) is available as special equipment.
Audio 50 APS (A40/3) features

The Audio 50 APS is the navigation entry-level model.

∗ 4.9" color display (TFT)
∗ Dual-tuner radio (RDS/TMC)
∗ CD-ROM drive for audio and navigation data
∗ Navigation display with arrows
∗ Gateway between interior CAN (CAN B) and MOST
∗ Amplifier output stages (for basic sound) 4 x 25 W
∗ The sound system is available as special equipment
∗ Sound amplifier (N40/3)
∗ CD changer (A2/6)
∗ UPCI control unit (N123/1)
∗ External analog audio sources (e.g. MP3 player) which can be connected
P82.86-5138-11
to the AUX connection in the glove box
∗ Recognition of the bluetooth headset
Telematics 85
The COMAND APS (code 527) is also offered as special equipment.
COMAND APS (A40/3) features

∗ 6.5" TFT color display
∗ Dual-tuner radio (RDS/TMC)
∗ DVD-ROM drive for audio and navigation
∗ Arrow and map navigation display
∗ Basic signal amplifier (4 x 20 W)
∗ Bluetooth-enabled in connection with a UPCI (a Bluetooth headset can be
used)
∗ Gateway between interior CAN (CAN B) and MOST
∗ Sound amplifier (N40/3)
∗ CD changer (A2/6)
∗ UPCI control unit (N123/1)
∗ External analog audio sources (e.g. MP3 player) which can be connected
to the AUX connection in the glove box
P82.86-4685-11
∗ Recognition of the bluetooth headset
Telematics 86
Loudspeakers
P82.62-2801-00 P82.62-2802-00
A modular head unit with eight loudspeakers is installed as the basic version. Surround Sound system (code 810)
For dynamic interior volume adjustment, a microphone in the overhead A sound system with eleven loudspeakers and a subwoofer including surround
control panel measures the interior volume. Based on these measurements, sound and digital sound editing (CD changer required) is available as special
the volume dynamically adapted to the background noise in the interior of the equipment for all radio variants. All amplifier channels have a frequency
vehicle. response individually adapted to the respective vehicle acoustics. Bass,
treble, volume, balance, and fading can be adjusted separately.
Telematics 87
Antenna module (A2/93)
The antenna module contains the

antennas for the:
∗ AM and FM1 radio reception
∗ Central locking
∗ Keyless Go
∗ GPS navigation
∗ Includes the necessary GPS
antenna module
∗ Telephone antenna for the
UPCI
The antenna module (A2/93) is

installed in the rear of the
vehicle's roof. Replacing or
repairing it is only possible if the
headliner is lowered.
Additional antennas for FM
reception (FM2, FM3) are
integrated into the heated rear
window and connected to the
antenna module by the antenna P82.62-2828-11 GT82_62_0011_C02
amplifiers (A2/19).
Telematics 88
CD changer
∗ CD changer accommodates six CDs (A2/6) (single slot version as in
W/S211)
∗ Only available with the Entertainment package (code 320)
∗ Installed in the upper part of the glove box
∗ The CDC button on the left unlocks and lowers the CD changer.
∗ Plays audio and MP3 CDs
∗ MOST bus participant controlled by the head unit
AUX input
∗ Additional audio devices such as a cassette player, Walkman, and MP3
players can be connected using the supplementary 3.5 mm input jack.
∗ Select the audio input in the audio main menu in the head unit.
∗ Set the volume of the audio device on the head unit (if necessary).
GT82_64_0007_C11
Telematics 89
Telephone
There are several options for installing cellular mobile phones:
∗ The standard telephone equipment for installing non-networked

telephones consists of:
− Wiring and telephone antenna in the antenna module (up to now VDA)
∗ The UPCI preinstallation special equipment (code 386) consists of:
− UPCI control unit beneath the rear bench seat
− Wiring with connection for the portable CTEL cradle
− Antenna in the antenna module
− Compensator
∗ The portable CTEL special equipment (code 388) also contains a
Bluetooth-enabled portable CTEL
1 Cradle
2 Insert
3 Interface connector
4 Antenna connection
A34/15 Contact plate
P82.70-5378-06
Telematics 90
The UPCI control unit (N123/1) is installed
beneath the left rear seat.
Located on the upper armrest, the contact plate
for the cradle bracket is made for a specific
telephone bracket.
The microphone system (B25/12) contains four

microphones located in the vehicle's inside
rearview mirror. The microphones are individually
read in and evaluated by the UPCI telephone
control unit N123/1.
At market launch, the following cradles are

available for code 386 as accessories (not from
the factory):
P82.70-5377-09
Siemens CX65, CTX65, CX65V B6 787 58 31
Siemens S65 B6 787 58 34
Nokia 6210, 6310, 6310i B6 787 58 22
Nokia 6220, 6230 B6 787 58 32
Nokia 6100, 6610, 6610i, 7250i B6 787 58 35
SonyEricsson T610, T630 B6 787 58 30
SonyEricsson K700i B6 787 58 36
Telematics 91
Vehicle shell 24.05.2005
Vehicle shell
All body components were completely redesigned versus the predecessor
model series. In place of the 163 model series frame construction, a rigid
unitized body was developed. As opposed to the predecessor model series,
passenger compartment stability was also increased. The front structure was
kept compatible with potential collision objects through the use of an adapted
deformation resistance level as well as low longitudinal and crossmembers.
In addition to improving passive safety, the more rigid body structure
increases ride comfort and driving safety, especially while offroading. Fatigue
strength and directional stability were enhanced for offroad operation. The
points of load application between the suspension and shell were also
redeveloped to meet the high demands of the shell while offroading. Shell
development focused on:
∗ balancing the tolerance when joining individual shell parts (stress-relieved
joining) using appropriate flanges.
∗ reducing shell tolerances using a closed full-perimeter support structure in
front of the liftgate (D-ring).
∗ omitting most of the MAG weld seams to improve production quality.
Sheet steel was used as the body shell material. In particular, dual-phase steel
was selected, which features extremely high dynamic resistance and good
P60.00-2658-00
deep-drawing capability. Repairs are simpler to perform through easily
removable front and rear end modules.
Vehicle shell 92
Safety
There is now even less risk of passenger injury. To meet the demands placed
on the body, each individual body element was developed further with regard
to geometry, material thickness, joining technology, and material quality
(increased-strength and highest-strength sheet steel). The 164 model series
passive safety concept encompasses:
∗ A body structure without a framework system similar to a passenger car,
featuring an energy-absorbing front and rear structure
∗ A highly rigid passenger cell
∗ The compatibilty of the
∗ To ensure a large deformation distance for better safety in head-on
collisions, the following front-end design was implemented:
∗ Compact V6 and V8 engines mounted on stable subframes (deformable in
crash direction in case of head-on collision)
∗ Breakaway wishbone control arms
∗ Driveshaft and transmission mount are controllably deformable.
∗ A double-walled front structure for better load distribution in a partial
head-on collision (offset).
∗ The seating height is 250 mm higher than a conventional passenger
vehicle.
∗ A straight-line cockpit crossmember between the A-pillars
∗ A telescopic steering wheel with a corrugated tube P60.00-2657-00
∗ Doors with a solid reinforcement beam
Vehicle shell 93
Front end
The front end structure consists of a firewall, both front longitudinal In severe head-on collisions, the front axle carrier may deform and absorb
members, and both wheelhouses. As opposed to the predecessor model high impact energies. The following were used to improve impact energy
series, the 164 front end structure was designed in a manner similar to absorption during head-on collisions:
passenger cars. The front cross connection is designed as a front end and ∗ Both front longitudinal members with an additional enclosed third
consists of: shell
∗ An aluminum extruded section to carry the bumper components ∗ Additional lengthwise outboard members on left and right carriers with
∗ Two crash boxes made from high-strength steel as easily removable support on the A-pillars (second longitudinal member level)
connections to both front longitudinal members ∗ A solid firewall crossmember between the A-pillars
∗ A bolted double-wall steel structure to support both lamp units ∗ An outboard right and left pedal floor carrier
∗ A steel radiator crossmember. The entire front end is bolted to the
front end structure, as are the individual components of the front end. The 164 model series also has major assembly space which is separated
If an accident occurs, this allows parts or whole assemblies to be from the engine compartment by a multi-piece paneled partition wall
exchanged or replaced inexpensively without welding. running left to right. This ensures good sound absorption and thermal
insulation to the passenger compartment.
The front axle major assemblies including the steering gear are installed on
the front axle carrier along with the engine and transmission. The front axle
carrier is connected to the shell via four rubber mounts. The extremely
rigid front axle carrier is a welded structure made from high-strength sheet
steel.
Vehicle shell 94
Passenger cell Corrosion protection
The main floor panel consists of three assemblies. The middle assembly is Galvanizing the shell ensures long-term corrosion protection and helps
made of thicker sheet metal and constitutes the floor backbone through retain the vehicle's worth.
the form of the tunnel. Additional solid tunnel reinforcements have been The body shell is coated by four different technologies:
attached. The floor to the left and right of the tunnel has been stiffened ∗ hot-dip galvanized on both sides
with: ∗ electrolytically and organically coated on both sides
∗ A stable crossmember to support seats and to provide lateral support ∗ electrolytically coated on both sides and organically coated on one
to the tunnel in case of a side impact side
∗ A diagonal member running from the firewall to the side longitudinal ∗ electrogalvanized on both sides
member/B-pillar node. The crossmember for the rear seats with its
additional reinforcement forms the separating line between the center Additionally, a resistant, scratch-proof clear varnish is also applied.
and rear floors.
Crossmember beneath the instrument panel

The structural element of the cockpit assembly module is a tube-shaped
assembly carrier made from steel and is bolted to both A-pillars. In
addition, there is also a connection to the tunnel, to the crossmember
beneath the windshield, to the wind deflector, and to the firewall.
Vehicle shell 95
Door module
The doors have essentially the same door modules as the new A-Class. The M-
Class door modules, however, are screwed onto the door with 9 screws per
door.
GT72_10_0070_C81
Vehicle shell 96
Supplemental restraint systems 24.05.2005
Overview
In addition to the structural safety features of the W164, the following SRS
safety functions have been integrated:
∗ Dual-stage driver and front passenger airbags
∗ Front seat buckle emergency tensioning retractor
∗ Front seat belt with dual-stage belt force limiter
∗ Seat belt buckle detection in rear
∗ Emergency tensioning retractor with one-stage belt force limiter for rear
outboard passengers
∗ Front sidebags
∗ Rear sidebags (special equipment)
∗ Crash-active NECK-PRO head restraints (special equipment)
∗ Left and right windowbags
∗ Seat occupied recognition film in the front passenger seat
∗ Upfront and side impact sensors
∗ Rollover sensors integrated into the Armada SRS control unit
∗ PRE-SAFE (special equipment)
Supplemental restraint systems 97
Component arrangement
P91.60-3053-09 P91.60-3054-09
A1 Instrument cluster N93 Central gateway (CGW)
A53 Left front sidebag sensor R12/4..5 Right airbag stage 1 + 2 squib
A54 Right front sidebag sensor R12/6..7 Left and right rear emergency tensioning retractor squib
B48 Seat occupied recognition with ACSR R12/9..10 Left and right front sidebag squib
B48/1..2 Left and right front upfront sensors R12/11..12 Left and right rear sidebag squib
N2/7 ARCADE control unit R12/13..14 Left airbag stage 1 + 2 squib
N3/10 Engine control unit (ME) R12/16..17 Left and right windowbag squib
N10 Front SAM R12/26..27 Left and right front emergency tensioning retractor squib
N10/8 Rear SAM R46 Left front buckle emergency tensioning retractor
N69/1 Left front door control unit R46/1 Right front buckle emergency tensioning retractor
N69/2 Right front door control unit S68/1..2 Left and right front seat belt buckle switch
N72/1 Upper control panel (UCP) S68/11..12..14 Rear left, right, and middle seat belt buckle switch
N73 Electronic ignition switch (EIS)
ARCADE control unit (N2/7)
∗ Recognizes and differentiates between head-on and rear-end collisions and side impacts using internal and external sensors
∗ Integrated rollover sensor
D Always comply with WIS/DAS safety measures when working on SRS systems. Never turn the control unit around as long as it is connected to the
vehicle or right after it has been disconnected from the on-board electrical systems (power reserve).
∗ The following sensors are involved in triggering the SRS system:

− Upfront sensors
− Sidebag collision sensors
− Seat occupied recognition foil
− Seat belt buckles on the front seats and rear outboard seats
P91.60-2959-01 P91.60-2964-01
External sensors
∗ Upfront sensors (B38/1, B38/2)
− measure the acceleration values in the left and right front section
− help trigger the SRS control unit (N2/7) in a head-on collision
− installation location: on each side of the radiator mount
Note:
The SRS module can also be triggered without upfront sensors. If a sensor fails, the signal of the second sensor is still evaluated.
∗ Sidebag collision sensors (A53, A54)

− measure the acceleration values in the left and right B-pillar area
− help detect a side impact early
− Installation location: lower B-pillar
P91.60-2949-01 P91.60-2946-01 P91.60-2947-01
Front seat belts and buckle emergency tensioning retractor
∗ The driver and front passenger seat belt is equipped with a reel mechanism and dual-stage belt force limiter, both of which are controlled by the SRS control
unit.
∗ The belt force limiter prevents injuries caused by excessive restraint force as a result of the taut belt.
∗ The second stage of the belt force limiter is also triggered by the SRS input values (pyrotechnical unit) once the second airbag is deployed, for instance,
during a severe head-on collision.
∗ Buckle emergency tensioning retractor customary to other MB vehicle models (solid fuel propellant)
∗ Buckle emergency tensioning retractor notifies the SRS control unit whether the seat belt has been buckled.
S68/1
S68/2
GT91_40_0020_C71 GT91_40_0021_C71
Rear selt belts and seat belt buckle
∗ Outboard seats have a reel mechanism and tensioning ignition (solid fuel propellant); rack-and-pinion operation known from the predecessor model
∗ The center seat has a 3-point seat belt with a reel mechanism and a one-stage belt force limiter on the seat backrest.
∗ Seat belt buckle recognition for all three rear seats
GT91_40_0022_C71 GT91_40_0023_C71 GT91_40_0024_C71
Airbags
∗ Dual-stage driver and front passenger airbags, as known from other MB vehicle models
∗ Windowbags for the left and right side installed in the roof area. Squib is located below on the lower A-pillar.
∗ Front sidebags are located in the lateral backrest frame and can be recognized by a small patch on the exterior seat trim.
P91.60-2933-06 GT91_60_0019_C01 P91.60-2968-01

1 Retaining strap
2 Windowbag
3 Ignition device
∗ Rear sidebags (special equipment) are located in the lateral backrest frame and can be recognized
by a small patch on the exterior seat trim.
P91.60-2948-01
Side impact
As of model year 2007
The SRS airbag control unit (N2/11) evaluates the air pressure values measured by the pressure sensors for the driver/front passenger door airbag system
(B48/7, B48/8) as well as the rear sensors for this airbag system (B48/9, B48/10) to recognize a side impact to the door. If air pressure values rise on one
side (e.g. a door is being pressed inwards), the front/rear airbag and the windowbag are deployed on the appropriate side.
GT91_60_0020_C71 GT91_60_0021_C71 GT91_60_0022_C71
NECK-PRO (special equipment) 24.05.2005
Driver and front passenger crash-active head restraint triggering unit
Using a solenoid, the triggering unit swivels the rotatable head restraints approx. 44 mm forwards and approx. 30 mm upwards. A holding solenoid fixes the
head restraint into position. This puts the head in a better position relative to the headrest during a collision.
GT91_16_0005_C71 GT91_16_0002_C11 GT91_16_0003_C11

Direction Taut position Triggered position
NECK-PRO (special equipment) 106
This is a reversible system
GT91_16_0004_C02 GT91_16_0006_C02 GT91_16_0007_C02

Procedure
The head restraint can be returned to its standard After that, the head restraint must be pressed Final position
position using a normal 4 mm thick tool together with the taut spring and brought into the
(e.g. T-Grip T20). original position.
NECK-PRO (special equipment) 107
Power liftgate 24.05.2005
∗ The optional Power Liftgate enables remote opening and closing of the liftgate:
− Remote key
− Liftgate switch on the driver door c
∗ The liftgate can also be opened with the liftgate contact switch on the liftgate outer handle.
∗ The liftgate can also be closed with the equivalent switch on the underside of the liftgate. (If the vehicle is equipped with Keyless Go, the liftgate can be
closed and the vehicle locked by pressing the Keyless Go switch once.)
Power liftgate 108
Limiter/Intermediate position
The liftgate opening can be limited if opening it
further would damage the liftgate (e.g. in a garage
with insufficient height clearance or if a roof rack
system is used).
The opening can be limited using the multifunction
buttons on the steering wheel and the instrument
cluster multifunction display.
The opened liftgate is at the same level as the roof

and roof rack.
GT72_20_0003_C71
The power liftgate control unit (N121/1) controls

this process.
∗ The system uses a hydraulic pump and an

actuating cylinder.
∗ The hydraulic pump is located beneath the
liftgate control unit.
∗ The actuation cylinder is installed in the right
roof area above the rear side window. The
hydraulic system is a closed unit and must be
replaced as a whole.
GT72_20_0008_C71 GT72_20_0007_C71
Power liftgate 109
Obstruction sensor strips
In addition to the position potentiometer on the right liftgate hinge, there are obstruction sensor
strips on each side of the liftgate opening.
The potentiometer calculates the position and number of movements while controlling opening,
closing, and reverse motions.
The sensor strips indicate if there is an obstruction between the liftgate and the liftgate opening. In
such cases, the latch is unlocked even when it is not engaged.
GT72_20_0004_C71
The right and left obstruction sensor strips are

conventional contact strips which -- depending on
resistance -- can take on one of three modes. The
strips are recognized by the power liftgate control
unit while the liftgate is in motion:
∗ Ready for operation
∗ Defective strips (interruption or short circuit)
∗ Something is caught
If the strips are defective, the liftgate does not

close automatically.
GT72_20_0005_C71 GT72_20_0006_C71
Power liftgate 110
Normalizing the power liftgate mechanism
The liftgate must be normalized if Normalizing the liftgate upstop position:
∗ it is being used for the first time. ∗ The opening limiter in the instrument cluster (A1) must be
∗ one of the system components (potentiometer, hinge, tailgate, etc.) deactivated.
was replaced or adjusted. ∗ The closed position must have been normalized.
The liftgate-close potentiometer must reach the limit values during The liftgate can now be opened and closed using the liftgate open/close
normalization. The limit values are the upper and lower liftgate stops. If the button. In this instance, power opening is possible up to the middle
closed liftgate position is not normalized, the active liftgate function is position only.
unavailable.
Programming the upstop:
Normalizing the downstop position: The liftgate must be completely opened. To do this, pull the open/close
∗ The liftgate must be completely closed. button and hold it.
∗ The power liftgate control unit must recognize the position, i.e. the lock If the liftgate control unit (using the locking recognition) determines that
must remain closed for at least 0.5 seconds. the limit position has been reached, the power liftgate hydraulic closing
pump is automatically actuated for 2 seconds as well, without the need
Note for any other button being pressed. The value (position) reached by the
After the first normalization, necessary normalizations are only possible potentiometer sensor is adopted as the normalization value.
once STAR-Diagnosis (DAS) has undone the normalization.
Power liftgate 111
Removing and installing the instrument cluster 24.05.2005
Use a pulling hook to remove the instrument

cluster (A1).
Unlock the instrument cluster by inserting the

pulling hook into the release holes (1) and then
turning the tip down and pulling it back. Pulling
lightly on the upper area also undoes the middle
clip.
P54.30-8243-04
Removing and installing the instrument cluster 112
Emergency operation 24.05.2005
Unlocking the vehicle

∗ Push the mechanical key all the way into the driver door lock.
∗ Turn the mechanical key counterclockwise to position c.
∗ Pull on the door handle until the lock button pops up. The driver door is now unlocked.
∗ Pull on the door handle again to open the driver door.
Liftgate
If the liftgate cannot be opened using the SmartKey, it must be opened from the liftgate interior using the
emergency release lever c.
Remove the liftgate cover d to access the release lever.
WARNING
Make sure that there is sufficient room behind the vehicle since the liftgate will swing up.
Emergency operation 113
Gearshift lever
The park position can only be taken out if the battery is jumpered through the engine compartment or
directly at the battery.
Fuel filler flap

∗ Open the liftgate.
∗ Open the cover in the load compartment in the ride side paneling.
∗ Pull the release cable backwards in the direction of the arrow.
∗ The fuel filler flap can now be opened.
Sliding roof
∗ The tilting/sliding roof can be opened or closed manually during electric malfunctions.
∗ The tilting/sliding roof actuation motor is located behind the cover c on the overhead control panel.
∗ Take the SmartKey out of the starter switch.
(Vehicles with SmartKey with Keyless Go)
∗ Turn the motor off by pressing the Keyless Go button on the selector lever once.
∗ Open the driver door (this sets the starter switch to 0; equivalent to removing the SmartKey). Now the
driver door can be closed again.
∗ Pull off the cover c on the spot marked by the arrow.
∗ Take the crank d out of the pouch for manual operation.

∗ Push the crank d through the hole.
∗ Turn the crank d clockwise to
− open the sunroof
− tilt up the back of the sunroof
∗ Turn the crank d counterclockwise to
− tilt down the sunroof
− tilt lower the back of the sunroof
Notes:
Turn the crank d slowly and carefully.
The tilting/sliding roof must be synchronized after it has been manually operated.
Automatic transmissions with DIRECT SELECT 24.05.2005
The M-Class uses the

automatic transmission model
722.9.
Mechanical, hydraulic, and

electrical components are
located in the same places as
in the passenger car variant.
The transmission housing was

modified to support the
transfer case. The selector
lever's connection to the
transmission (P, R, N, D, +, - )
and the position indicator in
the multifunction display were
also fundamentally changed.
Automatic transmissions with DIRECT SELECT 116
Let's take a close look at the changes.
The operating system is known as DIRECT SELECT or Shift-by-Wire.

The following control units play a larger role in operation:
∗ Instrument cluster (A1)
∗ Intelligent servo module ISM (A80)
∗ VGS-NAG2 control unit (N15/11)
∗ Electronic ignition switch control unit EIS (N73)
∗ Steering column module (N80) with selector lever
Until now, the driver has selected the drive position (P, R, N, D) by means of a mechanically connected
shift rod which joins the selecter lever to the automatic transmission. An electric connection replaces the
mechanical one. The electrical connection consists of a control (selecter lever integrated into the steering
column module), left (S110/1) and right (S111/1) steering wheel gearshifts located on the back of the
multifunction steering wheel, and an intelligent servo module ISM (A80) attached to the automatic
transmission.
The kickdown and SOG functions are always available.
Function
The steering column module (N80) uses CAN C to relay the transmission positions P, R, N, and D through
the VGS-NAG2 control unit (N15/11) (plausibility check of signals) to the ISM. If circuit 15 is OFF or if the
VGS-NAG2 control unit (N15/11) is experiencing a disruption, the ISM (A80) receives the information
(CAN C signals) directly from the steering column module (N80). The ISM then processes the signals if
they are plausible.
After the DIRECT SELECT selector lever is
released, it spring-centers back into the "0"
position (basic position). The "N1" and "R"
positions as well as the "N2" and "D" positions are
differentiated by force levels. For example, putting
the transmission into R requires almost twice the
force needed to put the transmission into N1. The
same applies to N2 and D. To shift from D to N,
N1 must be actuated. To shift from R to N, N2
must be actuated.
A button attached to the exterior of the DIRECT

SELECT selector lever is labeled "P" and triggers
the activation of P (park lock) once all conditions
P27.60-2681-01
have been met.
In D on the DIRECT SELECT selector lever, the

shift ranges can be shifted back and forth ("+" or
"-") by using the left (S110/1) and right (S111/1)
steering wheel shift buttons on the back of the
multifunction steering wheel. The selected shift
range is displayed in the instrument cluster (A1).
P54.30-8533-02
Sport/Manual switch (only in the Offroad Pro technical package)
The driver can govern the basic shift program by pressing the Sport/Manual switch in the upper control
panel (UCP) control unit (N7/21). There are two transmission modes to choose from: "S" (sport) and "M"
(manual).
Each mode features a different shift strategy. While in M, the driver can shift gears manually using the left
(S110/1) or right (S111/1) steering wheel shift buttons. The mode (S or M) selected by the driver for
forward driving remains active when drive position "R" (reverse) is engaged. Vehicles featuring the
Offroad Pro technical package (code 430) and built to USA specifications do not feature an S/M switch.
The kickdown and SOG functions are not available in Low range.
Restarting the vehicle automatically engages mode S.
Key-P function
The Key-P function replaces the well-known Shift-Lock function. The Key-P
function combines all of the functions in addition to the parking brake which
prevent the vehicle from rolling away unintentionally.
The park lock prevents the vehicle from rolling away unintentionally. It must
always be selectable by the driver or reliably engaged right after the key has
been removed (or after the driver door has been opened with special
equipment Keyless Go). Once the key is removed, the electronic ignition
switch (EIS) N73 sends the command to engage the park pawl via CAN C.
The Key-P function allows moving out of position "P" into a drive gear via the
selector lever only when the ignition is on and the brake pedal is pushed.
Intelligent servo module (A80) “Emergency-P” path

The intelligent servo module's "Emergency-P" path is triggered by an error in
the EIS control unit (N73) or a failure of the on-board electrical system
battery. An additional battery (G1/7) is installed to safeguard this function.
The EIS control unit (N73) controls the intelligent servo module's (A80)
"Emergency-P" path using a switch. This path then releases a spring
mechanism which engages "P" in the transmission.
GT27_60_0009_C81
Gear and transmission mode display in the instrument cluster (A1)
The multifunction display is integrated between the electronic speedometer and the tachometer. The
lower status display shows the current transmission modes Sport and Manual as well as the following
information: 1, 2, 3, 4, 5, 6, D, P, N, and R.
Note
The current gear in Manual is displayed on a white background. The current gear range (P, R, N, D) is
displayed in Sport or in vehicles without the Offroad Pro technical package.
P54.30-8532-02
AKUBIS online 24.05.2005
Welcome to akubis® online, the interactive “add-on”

and electronic program which supplements the AKUBIS® service mailing.
It provides general information on AKUBIS® and helpful
additional information on the current program.
Wishing you much success with what you have learned.
http://global-training.daimlerchrysler.com/akubis
Participant login
AKUBIS service mailing
“M-Class Market Launch”
PMRA-HF067 CW 23 (2005)
User name: tn_hf067
Password: pkw_kw23
AKUBIS online 122
» ... Die Mitarbeiter werden zukünftig in die Rolle persönlicher Wissensmanager hineinwachsen
müssen, die aktiv die Verantwortung für ihre Qualifizierung übernehmen ... « Jürgen E. Schrempp
» ... Staff must in future assume the role of personal knowledge managers, who actively take
responsibility for their own qualification ... « Jürgen E. Schrempp
123456789
!"§$%&
DaimlerChrysler AG
Global Training
HPC Z480
D-70546 Stuttgart
Intranet: http://intra-gt.daimlerchrysler.com
1511 1638 02 1st edition 05/05 128

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Cars complete vehicle M-Class (164

model series) AKUBIS Initial training

Cars • complete vehicle

Printed in Germany Note:

1511 1638 02 - 1st edition 05/05 128 As at 05/05

Vehicle weight ML 350 ML 500 ML 280 CDI ML 320 CDI

Towing capacities ML 350 ML 500 ML 280 CDI ML 320 CDI

The vehicle identification number is located:

The model plates on the engine hood and the rear

Offroad styling package

Chrome package (standard for ML 500)

Sport package (interior)

Trim parts package

"Fineline" bird's-eye maple paneling

Offroad Pro technical package

Electric front seats

Electric seats with memory

Heated front seats

Installation location: beneath the left rear seat

∗ Fuse box (F3)

Fuse and relay assignment diagram located

A32n1 Blower motor

The M-Class features a two-battery arrangement.

∗ Installed underneath the front passenger seat:

Main functions of the front SAM (N10)

∗ Front windshield wipers

∗ Heated rear window

The entire communication network in the W164 consists of:

Central gateway (N93)

Installation location: beneath the left front seat

As in many other passenger model series, several

If the vehicle is equipped with Keyless Go and an

Special equipment for interior protection (code 882)

Thermatic air conditioning

Dual-zone air conditioning

Comfort Thermotronic air

Tri-zone air conditioning with

∗ The glove box must be removed in order to

B10/31 Left side temperature sensor

The pollutant sensor (air quality) (B31) is located

Rear air conditioner housing

VRV: overview and background

Notes on replacing the instrument cluster

V6 diesel engine V6 gasoline engine V8 gasoline engine

P01.10-2564-50 P01.00-2479-50 P01.10-0387-50

ML 280 CDI ML 320 CDI ML 350 ML 500

Essential highlights of the OM642 Main innovations of the CDI 4 system

The most important highlights of the new V6 engine:

F58 Engine compartment fuse and relay box

F4 Rear fuse and relay box

57 Fuel pump fuse

The M272 uses a new fuel injection and ignition

Rubber mounts help suppress vibration. Cooling

The electronic engine management is a further

The engine control unit was placed beneath the

For thermal reasons, the engine control unit was

The connectors are attached to the control unit

Component dimensions and versions depend on cooling needs. The chart

Suction fan Radiator AC condenser

Fully electric seats

Partially electric seats

B Information Transfer case

Rear axle center assembly