Model Series 166 2011 - 06 - 002 - 004 - en

Mercedes-Benz Service
Introduction of the New M-Class

Model Series 166
Daimler AG Technical Information and Workshop Equipment (GSP/OI) D-70546 Stuttgart
This printout will not be recorded by the update service. Status: 07 / 2011
Information and copyright

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can also be found at our Internet Portal.
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or alternatively
Address: Daimler AG
GSP/OIS
HPC R822, W002
D-70546 Stuttgart
2011 by Daimler AG
This document, including all its parts, is protected by copyright.
Any further processing or use requires the previous written consent of
Daimler AG, Department GSP/OIS, HPC R822, W002, D-70546 Stuttgart.
This applies in particular to reproduction, distribution, alteration, translation,
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databases and online services.
Image no. of title image:
Image no. of posters:
P00.01-4194-00
P00.01-4195-00, P00.01-4196-00
Order no. of this publication:
6516 1383 02 HLI 000 000 02 72
07/2011
Contents
Preface
Overview
Models and major assemblies
Brief description
Equipment
Overall vehicle
Exterior
17
Dimensions
21
Technical data
23
Interior
25
Maintenance
ASSYST PLUS
32
Drive
Engine data for gasoline engines
34
Engine data for diesel engines
35
Gasoline engines M 276 and M 278
36
Diesel engines OM 651 and OM 642
38
Engine mounts
40
Engine cooling
41
Exhaust system
42
Fuel system
44
Introduction of the New M-Class, Model Series 166 n

Contents
Transmission
7G-Tronic Plus transmission
48
Transfer case
50
Chassis
Axles
52
Suspension
54
ON&OFFROAD package
55
Steering
58
ACTIVE CURVE SYSTEM
59
Brake system
61
Wheels and tires
63
Networking
Overall network
65
Batteries and alternator
69
Lights
Exterior lights
70
Interior lights
72
Safety
Active/passive safety
73
Restraint systems
75
n Introduction of the New M-Class, Model Series 166

Contents
Driving assistance systems
Overview of systems
76
Reversing camera
79
Comfort
Climate control
83
Audio and communications

Telematics
85
Sound system
87
Body
Bodyshell
88
Corrosion protection
94
Special tools
Suspension
97
Engine
99
Workshop equipment
Body repair systems
100
Annex
Abbreviations
101
Index
103

Preface
Dear Reader,
This Introduction into Service Manual presents the
new M-Class in model series W 166.
The purpose of this brochure is to acquaint you with
the technical highlights of this new vehicle in advance
of its market launch. This brochure is intended to
provide information for people employed in service or
maintenance/repair as well as for aftersales staff. It is
assumed here that the reader is already familiar with
the Mercedes-Benz model series currently on the
market.
In terms of the contents, the emphasis in this Introduction into Service Manual is on presenting new and
modified components and systems.
This Introduction into Service Manual is not intended
as an aid for repairs or for the diagnosis of technical
problems. For such needs, more extensive information
is available in the Workshop Information System (WIS)
and Xentry Diagnostics.
WIS is updated continuously. Therefore, the information available there reflects the latest technical status
of our vehicles.
This Introduction into Service Manual presents initial
information about model series W 166. The Introduction into Service Manual is not stored in this form in
WIS. The contents of this brochure are not updated.
No provision is made for supplements.
We will publicize modifications and new features in the
relevant WIS documents. The information presented in
this Introduction into Service Manual may therefore
differ from the more up-to-date information found in
WIS.
All of the information relating to specifications, equipment and options are valid as of the publication deadline in June 2011 and may therefore differ from the
current production configuration.
Daimler AG
Technical Information
and Workshop Equipment (GSP/OI)
i Note
Information about the vehicles and about operating the vehicle functions can also be found in the
interactive owner's manual on the internet at:
www.mercedes-benz.de/betriebsanleitung

BR 166
Model
Engine
Automatic
7-speed transmission
Market launch
ML 350 4MATIC
166.057
276.955
722.906
09/2011
ML 350 4MATIC
Flexible Fuel1
166.057
276.955
722.906
02/2012
ML 550 4MATIC1
166.073
278.928
722.909
02/2012
ML 250 CDI
BLUETEC
4MATIC2
166.004
651.960
722.908
11/2011
ML 350 CDI
BLUETEC 4MATIC
166.024
642.826
722.903
09/2011
1
2
Overview
Models and major assemblies
USA only
ECE only
P00.00-4737-00
Model series 166

Overview
Brief description
Vehicle concept
New features
As the successor to model series W 164, model series

W 166 is the latest vehicle in the SUV (Sport Utility
Vehicle) category. The interior and exterior styling set
new trends. The vehicle's dynamic styling coupled
with the newly developed and more advanced technology make it an even more attractive option.
Dimensional concept
With a vehicle length of 4804 mm and a vehicle width
of 1926 mm, model series W 166 exceeds the length
of the predecessor model series by 23 mm and the
width by 15 mm. The maximum height has been
reduced by 19 mm in the interests of a more dynamic
vehicle design and better aerodynamics.
Environmental compatibility
A major focus of the development of the new M-Class
was, in addition to its key performance values and
driving characteristics, lower fuel consumption both
on-road and off-road.
The consumption of the vehicle has been reduced
compared to the predecessor model series, in particular through engine developments and other
consumption-reducing measures on the vehicle and
drivetrain.
By selecting materials with excellent recycling properties, a recycling rate of 85% has been achieved. In
addition, a recoverability rate of 95% has been
achieved in accordance with the calculation model of
ISO 22628.
New Telematics Generation 4.5 with USB interface

Intelligent Light System (ILS)1
Partially electric trailer hitch
New generation of gasoline engines M 276/M 278
New diesel engine OM 651
Uprated diesel engine OM 642 with reduced
consumption
Radiator shutters
ECO start/stop
Switchable engine mounts on diesel models
BLUETEC with external filling
ON&OFFROAD package
ACTIVE CURVE SYSTEM
Electric power steering
Electric parking brake
New digital reversing camera
Active Park Assist
DISTRONIC PLUS incl. Brake Assist System PLUS
(BAS) and PRE-SAFE brake
Attention assistance system (ATTENTION ASSIST)
Speed Limit Assist
PRE-SAFE
Blind Spot Assist and Active Blind Spot Assist
Lane Keeping Assist and Active Lane Keeping
Assist
Adaptive Highbeam Assist
Night View Assist (Intelligent Night View)1
Cooled/heated cup holders
Active engine hood (ECE only)
Further developed NAG2FE PLUS automatic
transmission
Not for market launch
i Note
Further details on the electrical systems of model
series 166 (e.g. function descriptions) are available in the Workshop Information System (WIS)
under information type "Basic knowledge/functions" (GF).

ML 350
4MATIC
ML 550
4MATIC1
Code P31
Standard
ML 250 CDI
BLUETEC
4MATIC
ML 350 CDI
BLUETEC
4MATIC
Overview
Equipment
Equipment variants
AMG exterior sport package
Interior sport package
Code P31
Code P95
designo Exclusive package2
Code X27, X11, X06
Edition 1 (ECE only)3
Code P19
Powerplant, engine, suspension, brakes

Off-road transmission mode with
off-road button (ECE only)
ECO start/stop function
Diesel particulate filter (DPF)
Standard
Standard
Standard
Standard
Standard4
AIRMATIC package
Code 489
ACTIVE CURVE SYSTEM

BLUETEC diesel emission control
system with SCR technology (Selective Catalytic Reduction) and
AdBlue tank (except Japan)
Code 468
Code 468
Standard5
ON&OFFROAD package6 (except

Japan)
Code 430
Standard
ML 550 only in USA und ROW (not ECE)

As of model year 2013
3
Up to model year 2013
4 Country-dependent
5
As of 03/2012 also available without diesel emission control system
6
In USA as of model year 2013
2

Overview
Equipment
ML 350
4MATIC
ML 550
4MATIC
ML 250 CDI
BLUETEC
4MATIC
ML 350 CDI
BLUETEC
4MATIC
Powerplant, engine, suspension, brakes

70l diesel tank (ECE only)
78l gasoline tank (ECE only)
Standard
93l tank (standard in USA)
Code 915
Standard
93l tank (Flexible Fuel)
Standard1
Standard
Code 915
Wheels, tires, light alloy wheels

43.2 cm (17") light alloy wheel
(except USA) weighted wheel
235/65; 7.5 J x 17 ET 53
Standard
Code 25R

(except USA) Aero wheel
235/65; 7.5 J x 17 ET 56
Code R24

(except USA) 255/55;
8 J x 18 ET 56
Standard
Code R41

255/55; 8 J x 18 ET 56.5
Code 03R
Code 03R

255/50; 8 J x 19 ET 56
Code R552

255/50; 8.5 J x 19 ET 59
Code R53
Code R533
Code R55
With Code 929 Flexible Fuel (USA only)

Standard in USA
3
Except USA
2
10

Code R552
Code R53
ML 350
4MATIC
ML 550
4MATIC
ML 250 CDI
BLUETEC
4MATIC
ML 350 CDI
BLUETEC
4MATIC
Code R39
Code R391
Code R39
Standard
Code 780
Code R33
Code R331
Code R33
Overview
Equipment
Wheels, tires, light alloy wheels

255/50; 8.5 J x 19 ET 59
48.3 cm (19") AMG light alloy wheel
255/50; 8.5 J x 19 ET 59
265/45; 9 J x 20 ET 57
265/45; 9 J x 20 ET 57
265/45; 9 J x 20 ET 57
Code 50R
Code 758
Standard in
USA
Code 7572

265/40; 9 J x 21 ET 53
Tire pressure monitor (TPM)3
(except Japan)
Code 758
Code 475
Standard
MOE run-flat tires
Code 475
Code R66
Tire pressure loss warning (except

USA)
Standard
Standard
TIREFIT tire sealant with electric air

pump (ECE only)
Standard
Emergency spare tire in trunk floor
Code 6904
Except USA
Except USA and Japan
3
Standard in USA
4
Standard in USA and Japan
2

11
Overview
Equipment
ML 350
4MATIC
ML 550
4MATIC
ML 250 CDI
BLUETEC
4MATIC
ML 350 CDI
BLUETEC
4MATIC
Light systems
Ambiance illumination
Code 876
Light package:
Bi-xenon headlamps
Intelligent Light System
Position lamp (USA only)
Headlamp cleaning system
Code P351
Roof systems
Sliding roof2
Code 414
Panoramic sliding sunroof
Standard
Code 413

Driver assistance package Plus:
DISTRONIC PLUS
Active Blind Spot Assist
Active Lane Keeping Assist
Automatic child seat recognition in
front passenger seat (not in USA)
Code 23P
Active Park Assist (except Japan)
Code 235
Downhill Speed Regulation (DSR)
Standard
Night View Assist

(Intelligent Night View)
1
2
12
Code 6101
As of 03/2012
Standard in USA

Code 414
ML 350
4MATIC
ML 550
4MATIC
ML 250 CDI
BLUETEC
4MATIC
ML 350 CDI
BLUETEC
4MATIC
Overview
Equipment

LANE PACKAGE:
Blind Spot Assist
Lane Keeping Assist
Code 22P
Speed Limit Assist

(ECE only) only with COMAND
Code 513
Reversing camera with guide lines1
Code 218
Attention assistance system

(ATTENTION ASSIST)
Standard
Safety and theft protection

Sidebag for driver and front
passenger
Standard
Code 2932
Sidebags in rear
Windowbag for all seat rows
Standard
Kneebag on driver side
Standard
PRE-SAFE system
Standard
Automatic child seat recognition in

front passenger seat (except USA)
Code U181
Front passenger seat with weight

detection (USA only)
Code U10
Active engine hood (except USA and

Japan)
Standard
1
2
Standard in Japan

13
Overview
Equipment
ML 350
4MATIC
ML 550
4MATIC
ML 250 CDI
BLUETEC
4MATIC
ML 350 CDI
BLUETEC
4MATIC
Safety and theft protection

KEYLESS-GO
Code 889
Anti-theft alarm system (ATA) (USA

only)
Standard
Theft protection package (except

USA)
Code P54
Climate control
2-zone automatic air conditioning
Standard
3-zone comfort automatic air conditioning (THERMOTRONIC)
Code 581
WINTER PACKAGE:
Stationary heater
Remote control (feedback and timer
incl. antenna)
Heated windshield washer system
Front seat heaters (except USA and
Japan)
Code 228
Temperature-controlled cup holder
Code 311
Comfort systems
MEMORY PACKAGE
Code P64
Seat heaters for 1st seat row1
Code 873
Seat heaters for 2nd seat row

1
14
Standard
Code 873
Code 872

Code 873
ML 350
4MATIC
ML 550
4MATIC
ML 250 CDI
BLUETEC
4MATIC
ML 350 CDI
BLUETEC
4MATIC
Overview
Equipment
Comfort systems
Seat climate control
Code 401
Multifunction steering wheel in

Nappa
Standard
Multifunction steering wheel in

Nappa leather/wood finish
Code 289
Heated multifunction steering wheel

in Nappa leather
Code 443
Through-loading feature over

armrest in rear
Code 282
Automatic rear-end door (standard

in USA)
Code 890
Telephone, audio and communications

Audio 20 (ECE only)
Standard
Audio 20 with CD changer (ECE

only)
Code 510
Preinstallation for Becker MapPilot

(ECE only)
Code 508
COMAND Online (except USA)
Standard in Japan
Code 527
COMAND (USA only)
Standard
Code 528
COMAND Online with DVD changer

(except Japan)1
Code 512
COMAND APS in USA

15
Overview
Equipment
ML 350
4MATIC
ML 550
4MATIC
ML 250 CDI
BLUETEC
4MATIC
Telephone, audio and communications

Becker MapPilot (ECE only)
Code 509
harman/kardon sound system
Code 810
Rear entertainment
Code 864
SIRIUS satellite radio (USA only)
Code 536
Media interface (UCI)
Code 518
Digital Audio Broadcasting (DAB)

radio operation (ECE only)
Code 537
Comfort telephony (ECE only)
Code 386
USB interface in center console
Standard
Miscellaneous
16
115 V socket (USA only)
Code U80
Trailer hitch with electric release

(ECE only)
Code 550
Trailer hitch (USA only)
Code 550

ML 350 CDI
BLUETEC
4MATIC
Front view
Rear view
The front is dominated by a powerful radiator grille

with central star in the style typical of the M-Class. The
design of the engine hood fits harmoniously into the
overall picture and meets the increased requirements
resulting from legislation on pedestrian protection.
The harmonious rear end with newly designed twopiece LED/fiber-optic rear lamps and the lowered roof
with large roof spoiler emphasize the width of the
vehicle and give it the appearance of sitting securely
on the road. The bumper with integrated chrome-style
loading sill protector and new "wing design" shapes
the appearance of the rear of the SUV.
The headlamps have a high-quality, exclusive and

innovative appearance. The higher, generously proportioned underbody protector in chrome design extends
up below the radiator grille to support the impressive
appearance of the vehicle.
Overall vehicle
Exterior
P00.00-4738-00
Rear view (model series 166)

17
Overall vehicle
Exterior
Side view
The stretched linear design of the side view emphasizes the on-road nature of the vehicle, whose
compact proportions are underlined by a large wheelbase and short overhangs. The C-pillar, which is characteristic of this model series, follows the example of
earlier generations of the M-Class and clearly differentiates the vehicle's styling from that of its competitors.
The roof line, which drops towards the rear end, underlines the sportiness of the new M-Class.
Running boards with sturdy stainless steel inserts are

available optionally to give the vehicle a more "SUVstyle" appearance.
The rear side windows transition into the rear window
without a visible column and, together with the wraparound rear lamps, create a well-integrated design.
The high beltline with high-quality stainless steel trim

strip and the dynamic, rising character line create a
harmonious and coherent overall picture.
Side view (model series 166)
18

P00.00-4739-00
Sliding roof, panoramic sliding sunroof

As previously, an electrically powered sliding roof in
glass is available as special equipment. An automatic
reversing function increases the operating safety
during closing.
In addition, a top sliding roof in glass (full-glass roof) is
also available. This provides a continuous glass
surface extending from the windshield to the C-pillar
with a trim strip on each side that blends with the allglass look.
The external skin of the full-glass roof with top sliding

roof consists of three separate glass panels made of
safety glass:
Overall vehicle
Exterior
A fixed glass panel at the front

A moving glass panel in the middle
A fixed glass panel at the rear
The movable glass panel can be tilted electrically (tilt
position), raised and moved back towards the rear of
the vehicle (slide position).
The entire module is based on a steel frame as the

major assembly carrier. After the body shell is painted,
this steel frame is fitted onto the roof frame of the
bodyshell from above and bonded in place.
P77.20-2299-00

19
Overall vehicle
Exterior
Aerodynamics
Aeroacoustics
Aerodynamics is a development discipline of

increasing significance. It has a decisive influence on
fuel consumption and noise-related comfort. Through
the use of the latest development and test procedures, the coefficient of drag (Cd value) of the new
M-Class has been further reduced. In this market
segment, it is the most drag-reducing SUV in the
world.
The already excellent value of the predecessor model
of down to 0.34 has been further reduced.
Compared with the predecessor model, model series

166 features a highly noise-insulating acoustic windshield and additional seals in the upper and side rearend door joints to further reduce wind noises.
The newly developed outside mirror meets both of
these requirements. It has very low aerodynamic drag
and excellent aeroacoustics. In addition, the housing
has been designed so that rainwater flows to the
outside and drips off through a narrow channel around
the outside.
P88.70-2644-00
Outside mirror
20

Vehicle dimensions of ML 350 CDI BLUETEC 4MATIC

Dimensions unloaded
The ML 250 CDI BLUETEC is equipped with suspension lowered by 10 mm as standard (ECE only)
Overall vehicle
Dimensions
P00.10-5071-00
1 Vehicle without license plate adapter (5 mm)

21
Overall vehicle
Dimensions
Vehicle dimensions (garage dimensions) of ML 350 BLUETEC 4MATIC

Dimensions unloaded
The ML 250 CDI BLUETEC is equipped with suspension lowered by 10 mm as standard (ECE only)
1
2
3
4
22
Loaded ready to drive (EC) with driver of 68 kg, 7 kg luggage, tank 90% full
At permissible gross vehicle weight
Incl. license plate adapter (5 mm)
With trailer hitch (special equipment)

P00.10-5072-00
Comparison of model series 164 against model series 166

Unit
W 1661
W 164
Difference
Overall vehicle
Technical data
Dimensions
Vehicle length
mm
4781
4804
+23
Vehicle width
mm
1911
1926
+15
Vehicle width
(with outside mirrors folded out)
mm
2170
2141
-29
Vehicle height with detachable parts
mm
1815
17882
-27
Vehicle height of bodyshell
mm
1767
1759
-8
Wheelbase
mm
2915
2915
Front overhang length
mm
866
880
+14
Rear overhang length
mm
1000
1009
+9
Front track width
mm
1627
16532
+26
Rear track width
mm
1629
16672
+38
Front approach angle
28
27
-1
Rear overhang angle
26
26
Ramp angle
17
17
0.34
0.322
-0.02
Coefficient of drag Cd
1
2
Based on example of ML 250 CDI BLUETEC 4MATIC with steel suspension

Values depend on model, suspension and country variant

23
Overall vehicle
Technical data
Unit
ML 350
4MATIC
ML 550
4MATIC
ML 250 CDI
BLUETEC
4MATIC
ML 350 CDI
BLUETEC
4MATIC
Dimensions and weights

Curb weight (EC)
kg
2130
2150
2175
Permissible gross vehicle

weight
kg
29002
28503
2950
2950
Maximum payload (EC)
kg
770
800
775
Open cargo area volume

behind driver seat
1210
Open cargo area volume

behind rear seat
690
Maximum luggage compartment volume behind driver

seat
2010
Maximum luggage compartment volume behind rear seat
1025
Turning circle
11.80
Fuel tank4
Including reserve
l
l
78
10
93
12
70
11
70
11
Fuel tank4 with increased

capacity
Including reserve
l
l
93
12
93
12
93
12
Not yet available by copy deadline

ECE
3
USA
4 93 liters standard in USA
2
24

Interior design
The interior has an impressive, coherent design which
makes use of very fine materials and it has been
crafted with great attention to detail. The emphasis on
the wide appearance of the vehicle is continued in the
cockpit. The large central display is flanked by two air
outlets. The controls for the air conditioning are
located underneath the head unit whose frame, like all
other trim pieces, features the new Silver Shadow
surface design.
The modern instrument cluster impresses with its
excellent legibility and high-quality appearance.
The following features, in particular, contribute to the

high perceived quality of the cockpit:
The sprayed polyurethane skin with dual-gloss
grained surface for the upper and lower section of
the instrument panel and glove box lid. Compared
to the predecessor model series, this has a more
pleasant feel and greater resistance to dirt.
The integrated hood of the instrument cluster (no
joints)
The invisible airbag flap
Harmoniously embedded operating units
Optional dual-color design with leather special
equipment in the color combinations alpaca gray/
black, almond beige/black or maroon/black.
Overall vehicle
Interior
P68.10-4444-00
Instrument panel

25
Overall vehicle
Interior
Instrument cluster
P54.32-9575-00
Instrument cluster, USA version

Shown on model 166.023
A1
A1e1
A1e2
A1e3
A1e4
A1e9
A1e10
A1e11
A1e15
A1e16
A1e17
A1e18
A1e20
A1e32
A1e41
26
Instrument cluster
Left turn signal indicator lamp
Right turn signal indicator lamp
High beam indicator lamp
Fuel reserve warning lamp
Seat belt warning lamp
Parking brake indicator lamp
Parking brake warning lamp
Supplemental restraint system indicator lamp
Preglow indicator lamp (with diesel engine)
Antilock brake system indicator lamp
Rear fog light indicator lamp
Regenerative braking system indicator lamp
ESP/ASR OFF warning lamp
Electronic Stability Program warning lamp
A1e51
A1e54
A1e58
A1e59
A1e66
A1e67
A1e75
A1p1
A1p2
A1p5
A1p8
A1p12
A1p13
A1p16
Brake system warning lamp

Coolant temperature warning lamp
Engine diagnosis indicator lamp
DISTRONIC warning lamp (with (code 233)
Distronic Plus)
Tire pressure monitor warning lamp (with code
(475) Tire pressure monitor (Premium))
Low beam indicator lamp
Brake force distribution warning lamp
Coolant temperature gauge
Fuel level indicator
Tachometer
Speedometer
Gear indicator
Multifunction display
Transmission mode display

Center console
The new center console can optionally be equipped
with temperature-controlled cup holders. These are
located under a roller blind which, together with the
controls of the center console and the comfortable
armrest with integrated palm rest, forms a unit in front
of/above the large stowage compartment.
Pressing the button twice starts the warming process.

This is indicated by illumination of a red LED. As of a
temperature of approx. T = 40 C, the residual heat
indicator lamp indicates the elevated temperature to
the vehicle occupants. Pressing the cup holder button
again stops the warming process.
Overall vehicle
Interior
Faults which occur during operation are indicated by

flashing of the LEDs.
Temperature-controlled cup holder

For the first time, a temperature-controlled cup holder
is available as special equipment. It allows drinks to be
cooled or heated by means of a heating/cooling
element. This consists of an electrothermal converter
(Peltier element), which creates a temperature difference through the flow of electric current. Heating is
possible up to approx. T = 55 C and cooling is
possible down to approx. T = 8 C.
The cooling process is activated by pressing the cup
holder button once. A blue LED in this button indicates
that the cooling process is active and this process can
be stopped by pressing the cup holder button again.
Temperature-controlled cup holder (special

equipment)
R5/1
R5/1e1
R5/1 s1
P68.00-6827-00
Cupholder
Residual heat indicator lamp
Cupholder button

27
Overall vehicle
Interior
Seats
There are a total of 4 different seat cover variants
available (fabric, Artico, leather, Edition One/designo)
in up to 6 different color combinations.
The required high strength of the backrest is achieved

through a sheet steel frame with sturdy connections
to the side seat fittings.
The driver and front passenger seats are equipped

with electric seat adjustment as standard. This allows
electric adjustment of the seat height, backrest inclination and cushion angle as well as the fore/aft position. The head restraint is manually adjustable, both
vertically and longitudinally. A memory package is
available optionally as special equipment.
Pullmaflex supporting springs are secured in the

frame. These support the foam padding. There is a
luggage net on the rear of the backrest. A sidebag is
also integrated in the backrest under a seam at the
side.
The seat cushion shell, which is made of sheet steel

with supporting springs (sine springs), is connected to
the seat adjustment fittings. There is a molded foam
part over the supporting springs. The mechanical seat
components are covered by panels in the interior
equipment color.
The rear seat cushions are made of solid foam. The

seat cushion and backrest are split in the ratio 60:40.
The narrow part of the seat is behind the front
passenger seat. The wide part contains a folding
armrest with compartment and cup holder. The three
rear seats are each equipped with L-shaped head
restraints with manual vertical adjustment. Backrest
angle adjustment (comfort position) of the rear backrests is a new feature.
P91.00-2296-00
Seats
28

Storage and stowage compartments

In addition to the glove compartment, there are
4 stowage compartments in the center console. Both
in the front area below the A/C operating unit and in
the rear area in front of the second seat row there is
either a stowage compartment or, optionally, an
ashtray.
Furthermore, there is a roller blind compartment in
front of the armrest next to the hand rest which
optionally serves as a temperature-controlled
beverage holder.
There is also large stowage compartment under the

armrest, providing for a wide range of stowage
options.
Overall vehicle
Interior
Additional beverage holders are located in the armrest

of the second seat row. There are nets on the rear of
both front seats.
Extra stowage compartments can be found in the load
compartment, depending on the equipment of the
vehicle. There is also stowage space under the removable load compartment floor.
P68.00-6826-00
Overview of stowage areas and compartments

1 Glove compartment
2 Front center console stowage compartment
(SA: smoker package)
3 Center console center stowage compartment
(SA: cup holder)
4 Center console stowage compartment (front armrest)
5 Rear center console stowage compartment
(SA: smoker package)
6 Net in front passenger footwell
7 Door pockets
8
9
10
11
12
13
14
Net on rear panel

Cup holder in second seat row
Net
Stowage box (depending on equipment installed)
Load compartment
Spare wheel well (depending on equipment installed)
Lockable loading floor handle/laptop compartment
(depending on equipment installed)

29
Overall vehicle
Interior
Load compartment
The passenger compartment and load compartment
are separated by a rear bench seat with a 60:40 split,
whose seat cushions can be raised vertically towards
the front and backrests can be folded down towards
the front. This provides simple operation, a flat loading
floor and a low loading height.
With a load compartment depth of 1046 mm, at least
six full plus two half bottle crates or four large golf
bags can be stowed in one layer under the optional
load compartment cover even when the backrest is
not folded down. In the cargo position (12), the load
compartment volume is 690 liters. With the rear seat
cushions folded up and backrest folded down, a
loading volume of 2010 liters is available as per VDA
specification. In total, the inclination of the 2nd seat
row can be set to ten different notch positions.
A luggage compartment cover, twin roller blinds

behind the 2nd seat row and a cargo strap rail are
available as special equipment. Four anchoring lugs
on the loading floor and a folding bag hook are
installed as standard. In contrast to other model
series, the net of the twin roller blinds cannot be used
behind the first seat row. If necessary, this net can be
retrofitted through Mercedes-Benz Accessories.
Trunk, 2nd seat row folded down completely
30

P68.80-2098-00
Cargo area variants as per VDA DIN 70020
Open cargo area

Loaded up to top edge of rear backrest
Volume: 690 liters1
Overall vehicle
Interior
Open cargo area behind rear backrest

Loaded up to roof
Volume: 1025 liters1
Open cargo area

Rear backrest folded down, rear cushions raised
Loaded up to top edge of driver seat backrest
Volume: 1210 liters
Open cargo area

Rear backrest folded down, rear cushions raised
Loaded up to roof
Volume: 2010 liters
Largest rectangular object

Dimensions: 1500 x 900 x 760 mm
Volume: 1026 liters
Longest board
Dimensions: 3180 x 400 x 30 mm
Cargo area variants
P00.00-4740-00
Upright backrest position

31
Maintenance
ASSYST PLUS
New technical features
Use of NAT2 FE+
The M-Class is based on the tried-and-tested technology of the predecessor model.
Due to development of the NAT2 transmission and the

increased durability of the new fluid, the fluid and filter
change intervals have changed from a one-off change
at 60,000 km (old) to every 125,000 km/5 years
(new).
Technical innovations include the maintenance-free

electromechanical steering and external AdBlue
filling on the BLUETEC diesel vehicles.
Model series W 166 is also the first vehicle to be
equipped with a dust filter in addition to the interior air
filter/combination filter. The change interval of the
dust filter is "every 25,000 km/12 months". The dust
filter is thus replaced as part of Service A or Service B.
The existing change interval for the interior air filter/
combination filter of "every 50,000 km/24 months" is
not affected by the introduction of the dust filter.
Extended maintenance strategy

As on the predecessor model series, the tried-andtested extended maintenance strategy is also used for
model series W 166. Both workshops and the
customer will benefit from the extended maintenance
scopes from the very first kilometer driven.
By making maintenance less complicated and introducing the basic service which covers the technically
essential items, we are able to offer maintenance that
is more cost-efficient and competitive without
compromising the usual Mercedes-Benz service
quality.
As with the current model series, there is a basic
service and a supplementary PLUS package.
32
NAT2 Fuel Economy Plus
P27.00-2345-00
PLUS package
The service advisor must offer the PLUS package to
the customer during a consultation because it is no
longer included in the conventional maintenance
scopes.
The aim of this consultation is to offer the customer
the package best suited to him or her.

Workshop display
still to be replaced
The workshop code is stored in the maintenance

computer and is read out by the service advisor via the
instrument cluster or Xentry Diagnostics.
Maintenance
ASSYST PLUS
The customer has no access to this workshop code.

The workshop code contains all vehicle-specific
service items which currently need to be performed on
the vehicle, depending on mileage, time and equipment.
The workshop code can have 3 to 6 digits. It consists
of numbers and/or letters.
P54.32-9578-00
Display on multifunction display (shown for ECE)

Service (time-based servicing scheme)
Decoding of the workshop code

After the workshop code is entered in the Workshop
Information System (WIS), the system outputs a
vehicle-specific service sheet containing the service
items for the pending service.
Maintenance-relevant special equipment must be
determined by the service advisor.
If the workshop code is entered with the complete
vehicle identification number (VIN), service-relevant
special equipment is also included.
Digital Service Booklet

P54.32-9579-00
All service, body and major assembly operations are

documented in a central database using the Digital
Service Booklet (DSB) aftersales system. The customer receives a service report which he/she stores
in the service booklet as evidence of the service.
Display on multifunction display (shown for ECE)

Workshop code
The Digital Service Booklet is available for Europe, the

Middle East, North Africa and Russia.
Display of Digital Service Booklet
P00.01-4190-00

33
Drive
Engine data for gasoline engines

Unit
Engine data
Engine designation
Engine configuration/no. of cylinders
ML 350 4MATIC
ML 550 4MATIC
276.955
278.928
M 276 DE 35
M 278 DE 46 LA
V6
V8
3498
4664
Displacement
cm3
Bore
mm
92.9
Stroke
mm
86
Premium1
Premium
7.6
km/h
235
l/100 km
8.5-8.8
g/km
199-206
Standard
EU 5/ULEV II
Fuel
Performance
Acceleration 0 ... 100 km/h
Maximum speed
Fuel economy/CO2 emissions
Fuel economy, overall (NEDC)
CO2 emissions
Exhaust emission standard ECE/USA
1
2
34
With code 929 Flexible Fuel premium gasoline with a methanol/ethanol content of up to 85% (e.g. E85) (USA only)
Not yet available by copy deadline

Unit
Engine data
Engine designation
Engine configuration/no. of cylinders
ML 250 CDI BLUETEC

4MATIC
ML 350 CDI BLUETEC

4MATIC
651.960
642.826
OM 651 DE22 LA
OM 642 DE30 LS
Inline 4
V6
Displacement
cm3
2143
2987
Bore
mm
83.0
72.0
Stroke
mm
92.0
92.0
Fuel
Drive
Engine data for diesel engines
Diesel
Performance
Acceleration 0 ... 100 km/h
Maximum speed
9.0
7.4
km/h
210
224
l/100 km
6.0-6.5
6.8-7.4
g/km
158-170
179-194
Standard
EU 6/BIN 5
EU 6/BIN 5
Fuel economy/CO2 emissions

Fuel economy, overall (NEDC)
CO2 emissions
Exhaust emission standard ECE/USA

35
Drive

In model series W 166, the newly developed V6/V8
engine family of M 276/M 278 engines is being used
as of the market launch in 2011. This replaces the
previous V6/V8 engine family of M 272/M 273
engines.
The 6-cylinder M 276 engine is used in the
ML 350 4MATIC. The 8-cylinder M 278 engine is
installed in the ML 550 4MATIC (USA and Russia only).
i Note
Introduction into Service Manual "Introduction of
the New 6 and 8-Cylinder V-Engine Generation
M 276/M 278" is available for the new V-engines.
Order No. 6516 1379 02
Both engines meet the EU 5 and ULEV II emissions

standards.
In the USA, the ML 350 4MATIC is being offered as a
Flexible Fuel Vehicle, which can be operated with a
fuel alcohol content (methanol and/or ethanol) of up
to 85%.
M 276 DE 35 and M 278 DE 46 LA
36

P01.10-3076-00
Unit
Engine data
ML 350 4MATIC
ML 550 4MATIC
M 276 DE 35
M 278 DE 46 LA
Rated output
at engine speed
kW
rpm
225
6500
300
5000-5750
Rated torque
at engine speed
Nm
rpm
370
3500-5250
600
1600-4750
12.2
10.5
Compression ratio
Performance graph M 276.955
P01.00-3307-00
Drive
P01.00-3308-00
Torque
Power output
Rpm

37
Drive

OM 651
OM 642
There are numerous new technical features and developments in the OM 651 diesel engine installed in
the ML 250 CDI BLUETEC 4MATIC, which improve, for
example, the specific consumption as well as emission
and noise-related characteristics.
The most important new technical features of the

6-cylinder OM 642 diesel engine offered in the ML 350
CDI BLUETEC 4MATIC include:
The most important technical features include:

Common Rail technology of the 4th generation
with an injection pressure of up to 1800 bar
NVH optimization (Noise-Vibration-Harshness)
Compact design through rear camshaft drive
Lanchester balancer
Dual-stage turbocharger without variable turbine
geometry
ECO start/stop function (ECE)
Compliance with EU 6 and BIN 5 emissions
standards
Increased power and torque

Further developed cylinder head
Reduced compression ratio in combination with an
optimized, roller bearing-mounted turbocharger
Friction-optimized crank assembly with TWAS
(twin-wire-arc-sprayed) cylinder barrel coatings
(ECE)
ECO start/stop function (ECE)
Regulated oil pump
Friction-optimized vacuum pump
Switchable water pump
Improved EGR cooling path with switchable bypass
Ceramic glow system
Modified air ducting
Compliance with EU 6 and BIN 5 emissions
standards
OM 651 DE22 LA and OM 642 DE30 LS
38

P01.10-3077-00
Unit
Engine data
ML 250 CDI BLUETEC

4MATIC
ML 350 CDI BLUETEC

4MATIC
OM 651 DE22 LA
OM 642 DE30 LS
Rated output
at engine speed
kW
rpm
150
4200
1901/1792
3600
Rated torque
at engine speed
Nm
rpm
500
1600-1800
6201/6172
1600-2400
16.2
15.5
Compression ratio
1
2
Drive
ECE
USA
P01.00-3309-00
Performance graph M 642.826 (ECE)
P01.00-3310-00
Torque
Power output
Rpm

39
Drive
Engine mounts
Switchable engine mount
Another new technical feature of the W 166 are the
switchable engine mounts on the diesel models. These
are located at the rear of each integral carrier and
prevent the transmission of low-frequency natural
vibrations from the engine during idling.
During driving operation and when the engine is
switched on/off, the engine control unit controls a
solenoid. Depending on the operating condition, this
opens or closes the bore. When the solenoid is
switched, the enclosed air acts as an air spring and the
hydraulic system builds up the dampening effect.
The operating conditions are switched depending on
the rpm, torque and vehicle speed.
Engine mount design

1
2
3
4
5
6
7
8
9
10
11
P22.10-2378-00
Flange
Seal bellows
Diaphragm
Check ball
Buffer stop
Protective cap
Hub
Retaining ring
Cover
Bore
Solenoid
P22.10-2377-00
Integral carrier from front

Y123
Y123/1
40
Left switchable engine mount

Right switchable engine mount
A
B
Integral carrier
Electrical connector

General
Adjustable radiator shutters
All gasoline and diesel engines of the new M-Class

come with a cooling module with cross-flow radiator,
a transmission oil heat exchanger, a condenser with
attached refrigerant accumulator and drier and a
continuously variable fan motor.
The models with engine variants M 276, OM 651 and

OM 642 are equipped with adjustable radiator shutters in combination with a 600 W radiator fan. This
allows the air flow through the cooling module of the
engine and through the engine compartment to be
regulated. On vehicles with diesel engine and with the
trailer hitch special equipment option, radiator shutters are not installed.
The cooling equipment on the CDI engines also

includes a charge air cooler. This is located ahead of
the condenser above the crossmember and attached
to the front end module.
On the V8 engine, charge air cooling is carried out via
a low-temperature circuit. As with the charge air
cooler on the CDI engines, the low-temperature cooler
is attached to the front end module.
The cooling requirements are met by a varying number
of radiator fins and different fan motors with powers of
400 W and 850 W.
The electric control unit for the fan motor is integrated
into the electric motor on all variants.
All cooling circuits are filled via an external coolant
expansion reservoir. The cap has a 2-stage valve
which, when heated, temporarily increases the system
pressure to approx. 2 bar to prevent the evaporation
of coolant.
The air ducting (sealing of radiator section) is integrated in the front end module. All components of the
cooling module are connected to each other with clips
and quick couplings to allow for easy assembly and
service access.
Drive
Engine cooling
Shutters consisting of a number of slats are arranged

in a circular shape between the radiator and fan.
These slats can be turned jointly by an actuator
attached to the cooling module and they influence the
flow path of the cooling air.
One of the most important advantages of adjustable
radiator shutters currently is the positive effect they
have on the aerodynamics of the vehicle at elevated
vehicle speeds, which in turn makes a reduction in fuel
consumption possible as well as emissions improvements.
i Note
The radiator shutters are not installed on vehicles
with diesel engine if they are fitted with a trailer
hitch.
P20.20-2414-00
Radiator shutters
Y84
Radiator shutters actuator

41
Drive
Exhaust system
Gasoline engines
The catalytic converter system of the ML 350 4MATIC
(M 276) and ML 550 4MATIC (M 278) consists of a
firewall and a NOx storage catalytic converter
(M 276 DES) for both the left and right cylinder banks.
The muffler system consists of two center mufflers
each with 5.3 liter volume (M 276), or a center muffler
of approx. 12 liter volume (M 278) and a transversemounted rear muffler at the rear end of the vehicle
with a volume of approx. 33 liters. The center and rear
mufflers consist of a combination of absorption and
reflection chambers.
On the M 276, the connecting points are located

directly ahead of the center mufflers. The M 276 DES
also has a service connecting point between the firewall and NOx storage catalytic converters. In the event
of a repair, it is also possible to make connecting
points ahead of the rear muffler so that the center and
rear mufflers can be replaced separately.
The tailpipes are located behind the bumper in a nonvisible area.
The connecting points of the exhaust system of the

M 278 are located directly ahead of the firewall catalytic converters and the center muffler.
Gasoline engine exhaust system (M 276 DES)
42

P49.00-2150-00
Drive
Exhaust system
Diesel engines
The catalytic converter system of the 4 and 6-cylinder
diesel engines (OM 651/OM 642) consists of an
oxidation catalytic converter, a diesel particulate filter
and an SCR catalytic converter. The muffler system
consists of just one rear muffler of approx. 15 liters
volume in the vehicle rear with two reflection chambers.
In order to meter the AdBlue urea solution into the
SCR catalytic converter, an injection nozzle specially
designed for the AdBlue urea solution is attached to
the exhaust pipe directly after the DPF.
The connecting points of the exhaust system are

located directly ahead of the oxidation catalytic
converter in the area of the firewall and ahead of the
SCR catalytic converter in the underfloor. In the event
of repair, it is possible to subsequently make a
connecting point ahead of the rear muffler so that the
SCR catalytic converter and rear muffler can be
replaced separately.
As of the connecting point ahead of the oxidation catalytic converter, the exhaust system of the OM 651 and
OM 642 is identical. It consists of one continuous
tract with air gap insulation up to the SCR catalytic
converter.
The rear muffler has two tailpipes located in a nonvisible area behind the bumper.
P49.10-2961-00
Diesel engine exhaust system (OM 651)

1
B16/15
B19/7
B19/9
B28/8
G3/2
Pressure lines
Temperature sensor upstream of SCR catalytic
converter
Temperature sensor upstream of catalytic converter
Temperature sensor upstream of diesel particulate filter
Diesel particulate filter differential pressure
sensor
Oxygen sensor upstream of catalytic converter
NOx control unit sensor downstream of diesel

particulate filter
N37/7b1 NOx sensor downstream of diesel particulate filter
N37/8
NOx control unit sensor downstream of SCR
catalytic converter
N37/8b1 NOx sensor downstream of SCR catalytic converter
Y129
AdBlue metering valve
N37/7

43
Drive
Fuel system
Gasoline engines
The electronically commutated gasoline fuel pump is
actuated via a fuel tank control unit. The fuel tank
control unit regulates the fuel pump based on the fuel
pressure specifications from the engine control unit.
Via the low-pressure circuit (4.0-6.7 bar), the fuel
moves from the tank and through the fuel filter to the
high-pressure pump (M 276) or to the two high-pressure pumps (M 278).
In the high-pressure circuit, the high-pressure pumps
are protected by pressure relief valves and each have
one quantity control valve. This regulates the quantity
of fuel fed to the pump element depending on the
specified fuel pressure.
Via the high-pressure pumps, the fuel pressure is

brought up to the pressure required for spray-guided
direct injection (up to 200 bar depending on the operating condition) and the fuel is fed into the rails via the
high-pressure line where it is stored.
The fuel pressure and temperature sensor registers
the current fuel high pressure (rail pressure) and the
fuel temperature in the left rail (M 276) or in the right
rail (M 278). The rail pressure is regulated by the
ME-SFI [ME] (motor electronics) control unit, which
actuates the quantity control valves on the high-pressure pumps with a PWM signal until the specified pressure is obtained in the rail.
The fuel injectors in each cylinder bank are supplied
with fuel directly from the corresponding rail.
Fuel system in ML 350 4MATIC
44

P47.00-2205-00
Diesel engines
Fuel preheating
The diesel fuel pump is actuated by a fuel tank control

unit. The fuel tank control unit regulates the fuel pump
based on the fuel pressure specifications from the
engine control unit.
In order to ensure the flowability of the fuel at low outside temperatures, a condensation sensor with heating element is integrated in the fuel filter to monitor
the water level.
The fuel reaches the high-pressure pump from the

tank via the low-pressure circuit. When actuated, the
fuel pump draws the fuel out of the fuel feed module
and pumps it through the fuel filter to the high-pressure pump. Depending on the fuel requirements, the
fuel pressure is regulated to approx. 3.0-5.0 bar.
The heating element is energized by the glow output

stage and warms up the fuel in the fuel filter. The
current condensation level is transmitted to the CDI
control unit via the condensation sensor in the fuel
filter. As of a condensation level of approx. 100 ml,
the CDI control unit transmits a message to the instrument cluster, which displays this on the multifunction
display as a warning message.
In the high-pressure fuel circuit, the fuel is pumped

into the rail (OM 651) or into the left-hand rail and
from there simultaneously into the right-hand rail
(OM 642) by the high-pressure pump depending on
the accelerator pedal signal, the engine speed and the
fuel temperature. The fuel pressure in the rails is
controlled by the pressure regulating valve and quantity control valve depending on the specified pressure
and fuel temperature. The fuel pressure actually
present in the rails is recorded by the rail pressure
sensor, continuously forwarded onto the CDI control
unit and limited to max. 1800 bar by the pressure
regulating valve.
Drive
Fuel system
The fuel reaches the fuel injectors from the respective

rail via the high-pressure lines. Based on a performance map, the CDI control unit calculates the
cylinder-selective injection quantity for the respective
operating condition. This is dependent on the fuel
pressure in the rails and the actuation duration of the
fuel injectors.

45
Drive
Fuel system
Fuel tank
i Note
The newly developed, blown fuel tank made of HighDensity Polyethylene (HDPE) with multi-layered walls
is located ahead of the rear axle under the rear bench
seat. This means that the opening between the load
compartment and passenger compartment remains
as large as possible when the rear seat backrest is
folded down.
The Flexible Fuel special equipment option offered in
the USA includes a separate fuel tank variant with
modified components. Here, an additional fuel quality
sensor continuously records the alcohol content and
temperature of the fuel.
A new feature is external filling of AdBlue on
BLUETEC models with SCR technology via a filler
connection behind the fuel filler flap. The reservoir for
the AdBlue additive (urea) is located on the fuel tank.
As soon as the AdBlue supply drops to a minimum level, a message is shown on the multifunction display and the driver is prompted to visit a
workshop.
If the reservoir is empty, this is shown by an indicator on the multifunction display. From this point
onwards, the engine can only be started a
maximum of 16 times. After this, the engine can
no longer be started again.
i Note
More information about BLUETEC can be found in
the system description "BlueTEC exhaust aftertreatment with AdBlue".
Order no.: 6516 1378 02
P47.10-2605-00
View of diesel engine fuel tank with AdBlue reservoir

1 AdBlue reservoir
46

Drive
Fuel system
Ventilation
On vehicles with gasoline engine, the fuel tank is ventilated via three roll-over valves as well as a refueling,
limiting and vent valve on the tank shell. This ventilation system is combined with an activated charcoal
filter located in the right rear wheel well. The stored
hydrocarbons are fed from the activated charcoal filter
via an electrically actuated purge valve in the engine
compartment to the intake manifold of the engine. The
activated charcoal filter is thus flushed during defined
purge phases.
On USA vehicles, the vent opening of the container for

the activated charcoal filter is sealed by a solenoid
valve. This allows the tank system to be checked for
leaks by means of a pressure test.
The diesel tank system is equipped with a simplified
ventilation system.
P47.10-2606-00
View of gasoline engine fuel tank (USA version)

45
55
55/2a
55/2b
75
75/1
75/2
Fuel filler neck

Fuel feed module
Fuel filter
Overflow valve
Fuel tank
Refueling, limiting and vent valve
Bidirectional vent valve
77
B4/1
B4/2
B4/3
B4/7
B4/31
M3
Y58/4
Activated charcoal filter

Fuel level indicator sensor, left
Fuel level indicator sensor, right
Fuel tank pressure sensor
Fuel pressure sensor
Fuel quality sensor
Fuel pump
Activated charcoal filter shutoff valve

47
Transmission

Automatic transmission oil supply
All models are equipped with the familiar 7G-Tronic

Plus automatic transmission.
General
The 7G-Tronic Plus has been optimized with modifications to the torque converter and main transmission.
This is why the transmission is called 7G-Tronic Plus.
It features a new generation of torque converter which
offers improved dynamic response characteristics
combined with reduced fuel consumption.
The consumption-reducing measures include a reduction in drag through a new bearing on the oil pump,
improved Torlon rings on the input and output shafts
as well as a new automatic transmission fluid
(FE-ATF).
The color of the new fluid has been changed from red
to blue because it may not be used in older transmissions. The notes in service information
SI00.40-P-0014A in WIS on usage of the new transmission fluid must be observed.
The oil change intervals have been extended because
the transmission fluid is subjected to less energy due
to the minimization of drag. For more information, see
the corresponding documents in WIS.
48
With the combustion engine running, the primary

pump delivers oil to the electrohydraulically actuated
automatic transmission. The oil pump is driven via the
drive flange of the torque converter. It is installed in
the transmission bell housing behind the torque
converter.
Oil supply for automatic transmission with
stopped internal combustion engine (with ECO
start/stop function)
When the combustion engine is shut off in ECO start/
stop mode, oil is no longer supplied by the primary
pump as the combustion engine is stationary. With
this, all the control elements and actuators change to
a basic state under no load and the automatic transmission power flow stops.
The electric transmission oil pump is actuated via the
transmission oil auxiliary pump control unit when the
combustion engine is switched on and off. When the
internal combustion engine is switched off, the electric transmission oil pump takes over the oil supply of
the control elements and actuators of the automatic
transmission. In addition, it minimizes the time loss
between the start-off request and actual start-off time.

Technical data
Unit
Transmission model
ML 350
4MATIC
ML 550
4MATIC
ML 250 CDI
BLUETEC
4MATIC
ML 350 CDI
BLUETEC
4MATIC
722.906
722.909
722.908
722.903
Transmission version
W7C700
Number of gears
7+R
Weight (including torque

converter, transmission fluid
and transfer case)
kg
Overall length including

transfer case1
mm
925-993
Max. input torque
Nm
700
Transmission
111
118
119
120
Depending on equipment without/with ON & OFFROAD package SA
Sectional view of 7-speed automatic transmission W7C700
P27.10-2391-00

49
Transmission
Transfer case
Transfer case, general information
The standard version consists of permanent all-wheel
drive with three open differentials (transfer case, rear
and front axle). The torque split of 50:50 between the
front axle and rear axle is specified as a fixed value in
the transfer case. The gear ratio of the transfer case is
1:1.
The driver can activate the off-road function via the
off-road program button (except USA and ML 250 CDI
BLUETEC) located in the lower control panel.
This activates a modified, flatter accelerator pedal

curve. In addition, the ABS, ETS and ESP control
systems are adjusted for off-road driving and a modified shift characteristic of the transmission mode is
selected.
Downhill Speed Regulation is switched on and off via
the Downhill Speed Regulation button. The Downhill
Speed Regulation button is located in the lower
control panel. On the ML 250 CDI BLUETEC, the automatic transmission mode button replaces the off-road
program button.
Sectional view of transfer case

1
2
3
4
5
6
Chain
Input shaft
Differential side gears
Differential pinions
Rear axle output flange
Front axle output flange
P28.00-2058-00
50

Transmission
Transfer case
P28.19-2062-00
Overview of transfer case system components

A1
A1e41
A1e58
A1p13
A7/3
A80
B37
L6/1
L6/2
L6/3
L6/4
N3/9
N3/10
N10
N15/7
N28/1
N30/4
Instrument cluster
Electronic Stability Program warning lamp
Engine diagnosis indicator lamp
Multifunction display
Traction system hydraulic unit
Intelligent servo module for DIRECT SELECT
Accelerator pedal sensor
Left front axle rpm sensor
Right front axle rpm sensor
Left rear axle rpm sensor
Right rear axle rpm sensor
CDI control unit
ME-SFI [ME] control unit
SAM control unit
Transfer case control unit (with code (430)
On&off-road package)
Trailer recognition control unit (with code (550)
Trailer hitch)
Electronic Stability Program control unit
N49
N51/3
N72
N72/3
N73
N80
S9/1
S16/13
S40
S40/4
S110
S111
Y3/8n4
X11/4
Steering angle sensor

AIRMATIC control unit (with code (489)
Airmatic (air suspension with level adjustment
and adaptive damping system (ADS))
Lower control panel control unit
Off-road control panel control unit (with code
(430) On&off-road package)
Electronic ignition lock control unit
Steering column tube module control unit
Brake light switch
DIRECT SELECT lever
Cruise control lever (with code (494) USA
version)
Cruise control lever (except code (494) USA
version)
Left multifunction steering wheel button group
Right multifunction steering wheel button group
Fully integrated transmission control unit
Diagnostic connector

51
Chassis
Axles
Front axle
The principle of a double wishbone axle designed with
high-mounted upper wishbones (high position of the
top wishbone control arm) has been selected as the
front suspension.
The integral carrier is a welded structure consisting of

sheet steel parts and IHU (hydroformed) tubes and is
specially designed to meet the high requirements in
terms of crash resistance and operational durability.
In view of the special range of usage of the vehicle,

this axle with high-mounted upper wishbones in
combination with the integral carrier provides the
optimal set-up for good off-road capability, good
driving comfort and good vehicle dynamics.
The two transverse control arms and steering

knuckles are weight-optimized forged aluminum parts.
The wheel bearing unit is bolted to the steering
knuckle. The tie rod is made of forged steel. The stabilizer bar is attached to the steering knuckle via a
linkage. At the stabilizer bar end, the linkage is
equipped with a rubber bushing for improved comfort.
The front axle transmission and engine are mounted

on the integral carrier via special rubber bushings. The
steering gear is rigidly fixed to the integral carrier
which, in turn, is decoupled from the body via four
rubber bushings. This minimizes the transmission of
vibrations via the front axle and drivetrain to the body.
The electrically assisted rack-and-pinion steering gear

installed ahead of the wheel center provides selfsteering behavior with an intentional understeering
tendency when cornering forces act upon the vehicle.
Front axle (with air suspension) Offroad (special equipment)
52

P33.35-2013-00
Rear axle
The rear axle is designed as a four-link axle. Its components include:
Coil springs and shock absorbers are positioned one

behind the other in the direction of travel.
Wishbone control arms made of cast aluminum

Upper control arm plane with camber strut (formed
sheet steel component) and tension/compression
rod (forged steel)
Tie rod behind wheel center (welded tube
structure)
The rear axle carrier is a welded sheet steel structure.

It is connected to the body at the front via high-dampening hydro-mounts and at the rear via conventional
rubber bushings. The rear axle differential is
supported flexibly on the rear axle carrier via 3 rubber
bushings.
Rear axle (with air suspension) (special equipment)
P35.00-2102-00

Chassis
Axles
53
Chassis
Suspension
Suspension systems
The basic equipment includes conventional steel
suspension which, compared to the predecessor
model series, is tuned for more comfort and better
vehicle dynamics. With the use of a selective damping
system as standard, the shock absorber hardness is
varied depending on the vehicle speed. Available as
special equipment is an air suspension system with
all-round level control and adaptive damping system
(ADS) (AIRMATIC package). This is, in particular,
intended to allow customers to increase the ground
clearance of the vehicle in particularly rough off-road
conditions. A modified form of the air suspension also
forms part of the ON&OFFROAD package special
equipment option. Air suspension can be combined
with the ACTIVE CURVE SYSTEM special equipment
option.
Air suspension with adjustment damping

(AIRMATIC)
On the two optional air suspension variants, there is a
difference in both the number and magnitude of the
height levels which can be set at the touch of a button
or automatically. Another variable which influences
level control is the ADS switch position set by the
driver. The ADS switch positions "Sport" and
"Comfort" (button designation "COMF") are available
and these set different switching thresholds between
the four ADS operating stages/damper characteristics.
Suspension (with air suspension) (special equipment)
54

P32.00-2063-00
A permanent all-wheel drive system with one lockable

differential (transfer case) and two open differentials
(front axle and rear axle) is used in the ON&OFFROAD
package special equipment. Other components of the
package include a reinforced underride guard, a transmission mode switch, a switch for a manual shift
program, an engageable cross-country reduction
setting (Low Range), air suspension with advanced
level control and an adaptive traction system (4ETS).
The torque split of 50:50 between the front axle and
rear axle is specified as a fixed value in the transfer
case. Via the Low Range button, which is located in
the lower control panel, the driver can switch the gear
ratio in the transfer case between the on-road ratio
"High" (gear ratio 1:1) and the cross-country reduction
ratio "Low" (gear ratio 2.93:1).
The differential lock in the transfer case can be actuated via the off-road package transmission mode
controller. Selection of the programs is displayed in
the off-road menu of the head unit.
It is possible to select 6 predefined transmission

modes with specific settings for the suspension (level
and damping characteristics), drivetrain (transmission
shifting program, accelerator pedal characteristics
and ESP function) and steering.
Chassis
ON&OFFROAD package
The transmission modes provide the optimal settings

for the applicable driving situation:
Automatic mode "AUTO" as the standard program
"Offroad 1", for light-duty off-road situations: dirt
roads, gravel, sand
"Offroad 2", for heavy-duty of-road situations:
steep inclines, rocks, axle articulation
"Sport", for handling-oriented roads, provides
optimal vehicle dynamics
"Snow", for snowy roads, driving stability when
cornering, traction-oriented for straight-ahead
travel (snow chain operation)
"Trailer", for downhill driving with a trailer, starting
off and maneuvering with a heavy trailer
Sectional view of transfer case

(ON&OFFROAD package)
1
2
3
4
5
6
7
8
B57
M46/2
Interaxle differential lock disk pack

Input shaft
Front differential side gear
Differential pinion
Rear axle output flange
Front axle output flange
Ring gear
Planetary gear
Transfer case absolute sensor
Transfer case actuator motor
P28.10-2280-00

55
Chassis
ON&OFFROAD package
P28.00-2059-00
Drivetrain with air suspension

1
2
3
4
5
Transfer case
Vibration damper
Rear axle propeller shaft
Rear axle differential
Left rear axle shaft
6
7
8
9
10
Right rear axle shaft

Front axle propeller shaft
Front axle transmission
Left front axle shaft
Right front axle shaft
ON&OFFROAD package controls in center console

N72
N72s30
N72s31
N72s37
N72s39
N72s42
N72/3
N72/3s1
Lower control panel control unit

Downhill Speed Regulation button
Low Range button
Transmission mode "M" button
Vehicle level rotary switch
On-road/off-road menu button
Off-road control panel control unit
Off-road package transmission mode controller
P54.21-3246-00
56

Vehicle levels with ON&OFFROAD package special equipment

Level designation
Level [mm]
v [km/h]
Remarks
Fast driving level
-45
v > 70
v > 40
At v < 70 km/h and t = 20 s

raise to -30 mm
Basic/normal level
-30
v < 120
v < 140
At v > 120 km/h and t = 20 s

At v > 140 km/h and t = 0 s
lower to -45 mm
Offroad 1
v < 100
At v > 100 km/h

lower to -30 mm
Offroad 2
+30
v < 65
v < 80

lower to 0 mm
Offroad 3
+60
v < 20
At v > 20 km/h
lower to +30 mm
Chassis
ON&OFFROAD package
Vehicle levels without ON&OFFROAD package special equipment with air suspension
Level designation
Level [mm]
v [km/h]
Remarks
Fast driving level
-45
v > 70
v > 40

raise to -30 mm
Basic/normal level
-30
v < 120
v < 140
At v > 120 km/h and t = 20 s

lower to -45 mm
Offroad 1
+30
v < 65
v < 80

lower to -30 mm

57
Chassis
Steering
Steering column
The M-Class is equipped with an electromechanically

assisted steering gear as standard. In addition to the
speed-dependent steering force assistance as
provided on previous models, a further significant
improvement in steering comfort has been achieved
over the entire vehicle speed range. Other advantages
compared to hydraulic power steering are:
The M-Class is equipped with a manual longitudinally

and vertically adjustable steering column as standard.
Optionally available as special equipment is an electric
longitudinal and vertically adjustable version with Easy
Entry function, which is included in the memory
package SA.
Fuel saving potential

Compact design
Assisted steering return
Diagnosis capability
No power steering fluid required
The adjustment travel distances for the manual and

electric steering column versions are +/- 25 mm vertically and 25 mm forward and 35 mm back horizontally, measured from the basic position of the steering
wheel.
In the event of a crash, the steering column moves
forward by up to 100 mm if a defined level of force is
reached in order to reduce the stresses placed on the
occupant.
Steering (with steering column tube and front axle)
58

P46.00-2170-00
ACTIVE CURVE SYSTEM

The ACTIVE CURVE SYSTEM is available as special
equipment and increases and improves ride comfort
and vehicle dynamics through the following system
features.
The ACTIVE CURVE SYSTEM is deactivated with the

vehicle at a standstill and at a vehicle speed
v < 5 km/h, all valves are deenergized. No active
torque interventions are applied.
Improved suspension comfort when driving

straight ahead with excitation on alternating sides
Increased driving safety through forgiving lanechange behavior up to vehicle maximum speed
Roll stabilization during cornering and active wheel
load distribution
Increased responsiveness with significantly
reduced steering angle requirement
Improved torsional flexibility off-road (axle articulation)
Improved sensing of individual obstacles
A vehicle on a lean (e.g. single-sided load, vehicle on

curb) thus does not cause any roll pressure even
though the ACTIVE CURVE SYSTEM lateral acceleration sensor supplies a signal.
On vehicles with the ACTIVE CURVE SYSTEM, the

passive torsion stabilizer bars (front and rear axle) are
replaced by two torsion stabilizer bars which allow
active intervention. Active intervention is made
possible by the use of two hydraulic rotary actuators.
The ACTIVE CURVE SYSTEM control unit regulates the
hydraulic pressure in the respective rotary actuator
based on a characteristics map.
The most important input variable is the lateral acceleration of the vehicle. This is measured, on the one
hand, by the ACTIVE CURVE SYSTEM lateral acceleration sensor and, on the other hand, is computed by the
ACTIVE CURVE SYSTEM control unit.
Chassis
ACTIVE CURVE SYSTEM
As of a vehicle speed v = 5 km/h, the ACTIVE CURVE

SYSTEM is started and becomes fully active as of a
vehicle speed of 20 km/h.
If a system fault is detected, an entry is made in the
fault memory of the ACTIVE CURVE SYSTEM control
unit. A corresponding message appears on the multifunction display of the instrument cluster at the same
time. The ACTIVE CURVE SYSTEM safety valve is no
longer energized and is closed. The hydraulic fluid in
the front axle stabilizer bar hydraulic rotary actuator is
confined here and locks up the actuator. The active
torsion bar on the front axle then acts as a passive
torsion bar. At the same time, the flow of the pump is
diverted directly and unpressurized towards the fluid
reservoir. The rear axle stabilizer bar hydraulic rotary
actuator remains open. This produces safe vehicle
handling characteristics tending towards understeer.

59
Chassis
ACTIVE CURVE SYSTEM
ACTIVE CURVE SYSTEM in W 166 (front axle)
P32.34-2026-00
P32.34-2027-00
ACTIVE CURVE SYSTEM in W 166 (rear axle)

1 Hydraulic rotary actuator
2 Right torsion bar
3 Left torsion bar
60

Brakes
Model series W 166 uses a hydraulic dual-circuit
brake system with a brake circuit each for the front
and rear axle and the ADAPTIVE BRAKE brake control
function as standard.
The system takes into account the vehicle-specific
circumstances such as 4x4 drive with on-road and offroad operation, axle load distribution, weight and
driving performance.
Sports brakes are available as a component of the
AMG exterior sport package special equipment
option. These include perforated brake disks on the
front and rear axle with brake caliper trim panels with
the label "Mercedes-Benz".
Chassis
Brake system
Brake booster
The brake booster consists of an aluminum 20.3 cm/
22.9 cm (8"/9") tandem vacuum-powered brake
booster which covers the entire model range. The
diameter of the master brake cylinder measures
28.57 mm.
As on model series 172 and 218, the parking brake is
electrically operated.
It makes use of a combined floating brake caliper with
electric parking brake function.
Mechanical design
The floating calipers of the front disk brakes are
located behind the center of the front axle and those
of the rear disk brakes are located in front of the
center of the rear axle. Brake wear is monitored by a
wear sensor on the outer brake pad of the front and
rear right wheel respectively. If the brake pads reach
their wear limits, this is indicated by an indicator lamp
on the instrument cluster.
On all variants, internally ventilated brake disks are
used on the front axle (see table for brake dimensions). The rear brake disks on the 6 and 8-cylinder
gasoline engine models are also internally ventilated.
All other models have solid brake disks at the rear.
Front brake system
P42.00-2159-00

61
Chassis
Brake system
Technical data
Unit
ML 350
4MATIC
ML 550
4MATIC
ML 250 CDI
BLUETEC
4MATIC
ML 350 CDI
BLUETEC
4MATIC
Front brake system

Brake type
2-piston floating caliper
Brake disk design
Internally ventilated
Brake disk diameter
mm
350
375
330
Brake disk thickness
mm
32
36
32
Lining area
cm2
2 x 74
2 x 86
2 x 74
Brake system, rear

Brake type
1-piston floating caliper
Brake disk design
Internally ventilated
Solid
Brake disk diameter
mm
330
345
325
Brake disk thickness
mm
22
22
14
Lining area
cm2
2 x 39
i Note
i Note
Due to the brake caliper which is installed, no

additional brake pads are installed for the electric
parking brake.
In contrast to the predecessor model series, it is

no longer necessary to connect a diagnostic tester
in order to change the pads.
See WIS for detailed information.
62

Front light alloy

wheel
Front tires
Rear light alloy

wheel
Rear tires
7.5J x 17 ET53
235/65 R 17
7.5J x 17 ET53
235/65 R 17
Code R41
8J x 18 ET56
255/55 R 18
8J x 18 ET56
255/55 R 18
Code 03R
8J x 18 ET56.5
255/55 R 18
8J x 18 ET56.5
255/55 R 18
Code R55
8J x 19 ET56
255/50 R 19
8J x 19 ET56
255/50 R 19
Code R53
8.5J x 19 ET59
255/50 R 19
8.5J x 19 ET59
255/50 R 19
Code R39/780 (AMG)
8.5J x 19 ET59
255/50 R 19
8.5J x 19 ET56
255/50 R 19
Code R33/50R/758
(AMG)
9J x 20 ET57
265/45 R 20
9J x 20 ET57
265/45 R 20
Code 757
9J x 21 ET53
265/40x R 21
9J x 21 ET53
265/40 R 21
Code 25R/R24
Code 25R
Code R41
P40.10-6081-00
P40.10-6083-00
Code R24 (Aero wheel)
Code 03R
P40.10-6082-00
P40.10-6084-00

Chassis
Wheels and tires
63
Chassis
Wheels and tires
Code R55
Code R39
Code R33
Code 757
64
P40.10-6085-00
P40.10-6087-00
P40.10-6089-00
P40.10-6091-00
Code R53
Code 780
Code 758
Code 50R

P40.10-6086-00
P40.10-6088-00
P40.10-6090-00
P40.10-6095-00
Drivetrain sensor CAN

Sensor CAN
Vehicle dynamics CAN
Interior CAN
Chassis CAN
Drivetrain CAN
Overall network in model series W 166
Telematics CAN
MOST
Diagnostic CAN
Networking
P00.19-5095-00
Overall network
65
66
11
10
7
8
9
1
2
3
4
5
Instrument cluster
Radio
Stationary heater control unit
COMAND controller unit
control module
SAM control unit
Rear control unit
Automatic air conditioning
control and operating unit
ATA/tow-away protection/
interior protection control unit
Trailer recognition control unit
Interior CAN
12 Driver seat control unit
13 Front passenger seat control
unit
14 Left front door control unit
15 Right front door control unit
16 Left rear door control unit
17 Right rear door control unit
18 KEYLESS-GO control unit
19 Sliding roof control unit
20 Rear control panel control unit
21 Electronic ignition lock control
unit
22 Liftgate control unit
Interior CAN
unit
23 Left front reversible emergency
tensioning retractor
24 Right front reversible emergency
tensioning retractor
25 Left rear bumper intelligent
radar sensor
26 Right rear bumper intelligent
radar sensor
27 Supplemental restraint system
control unit
28 CDI control unit (with diesel
engine)
29 ME-SFI [ME] control unit (with
gasoline engine)
30 Electronic Stability Program
control unit
31 AIRMATIC control unit
32 Video and radar sensor system
control unit
33 Electric parking brake control
unit
37 Steering column tube module
control unit
68 ACTIVE CURVE SYSTEM control
unit
Chassis CAN 1
2
4
39
40
41
42
43
44
45
46
69
Radio
Cradle for navigation module
DVD player
Left rear display
Right rear display
Audio/COMAND display
Audio/COMAND control panel
TV tuner
Digital TV tuner
Navigation module
Telematics CAN
1 Instrument cluster
6 Reversing camera
unit
34 Multifunction camera
35 Parking system control unit
36 Electrical power steering control
unit
38 Tire pressure monitor control
unit
70 Headlamp control unit
71 Night View Assist control unit
Chassis CAN 2
Networking
Overall network
Vehicle dynamics CAN

30 Electronic Stability Program
control unit
control unit
57 DISTRONIC electric controller
unit
58 Yaw rate, lateral and longitudinal
acceleration sensor

unit
59 Emergency call system control
unit

engine)
gasoline engine)
52 Left NOx sensor control unit (M
276.9, with stratified operation)
53 Right NOx sensor control unit (M
276.9, with stratified operation)
54 NOx sensor control unit
downstream of diesel particulate
filter
55 NOx sensor control unit
downstream of SCR catalytic
converter
56 AdBlue control unit

engine)
gasoline engine)
47 Intelligent servo module for
DIRECT SELECT
48 Transfer case control unit
49 Transmission oil auxiliary pump
control unit
50 Fuel system control unit
51 Fully integrated transmission
control unit
Diagnostic CAN
Drivetrain sensor CAN
Drivetrain CAN

control unit
64 Left front bumper DISTRONIC
sensor
65 Right front bumper DISTRONIC
sensor
66 Left rear bumper radar sensor
67 Right rear bumper radar sensor
Sensor CAN
Radio
TV tuner
Digital TV tuner
Sound system amplifier control
unit
61 Digital Audio Broadcasting
control unit
62 Satellite Digital Audio Radio
control unit
63 Media interface control unit
2
4
45
46
60
MOST
Networking
The overall network shows all the

control units that can be installed
at the time of the market launch
and their locations in the vehicle.
The vehicle illustrated is fictional
as it shows the control units of all
engine variants in the vehicle at
the same time.
i Note
Overall network
67
Networking
Overall network
Network architecture
The vehicle electronics are networked using the following data bus systems:
Controller Area Network (data bus/CAN bus)
(CAN)
Media Oriented System Transport (MOST)
Crimpable contact systems which are suitable for

automated assembly are used as electrical connectors. In wet areas, e.g. in the engine compartment,
vehicle underfloor and bumpers, additional single-wire
seals, mat seals or extrusion-coated lines are used.
The contact housings have a form-closed design with
the corresponding mechanical and color codings.
CAN
The CAN is an electrical bus system that transmits
data over two lines. In contrast to model series 164,
the chassis CAN has been divided into chassis CAN 1
and chassis CAN 2.
MOST
MOST refers to an optical data bus system. Here, data
are transferred via fiber optic cable to the connected
information, navigation, and communication components. The MOST operates with a transfer rate of
22 MBit/s.
The familiar 2 SAM concept of model series 164 has

been retained but the functions have been assigned
specifically to the two central processing units.
The SAM control unit is installed on the right front
A-pillar for the purpose of optimal electrical wiring. It
is the central unit for the lights, wipers, power supply
and on-board electrical system. The SAM-H is a unit
used specifically to control and operate the rear
consumers.
Wiring harnesses
Fuses
The wiring harnesses for the interior compartment,

cockpit and engine compartment are designed
customer-specifically. The wiring harness variants
result from the basic standard equipment, the engine
variant and the respective special equipment items.
Maxi fuses and ATO fuses are used. These are located
in fuses boxes at the front of the engine compartment
and at the right rear of the vehicle under the rear
bench seat where they are accessible to the customer.
The wiring harnesses in the interior are routed in an

H-structure in the vehicle and are protected by cable
ducts. Paint-removing screws are used at the ground
points of the body.
68
SAM control unit
The prefuse box on the battery contains a pyrofuse

which, in the event of a crash, disconnects the starter
and alternator line from the battery.


The on-board electrical system battery (G1), which has
a capacity of 95 Ah, is located under the front
passenger seat on all models. For shift-by-wire, this is
supplemented by a backup battery (G1/7) with 1.2 Ah
so that energy is available to achieve the defined
standstill position if the main supply fails.
On vehicles with ECO start/stop function, this backup

battery is replaced by a larger additional battery
(G1/13) in order to prevent voltage dips during engine
starting. This is installed at the right rear of the trunk.
Networking
P54.10-3634-00
Overview of energy management system components

A1
B95
F4
F32/3
G1
G1/7
G1/13
G2
Instrument cluster
Battery sensor
Rear fuse box
Engine compartment prefuse box
On-board electrical system battery
Additional battery
Additional battery for ECO start/stop function
Alternator
K114
N3/9
N3/10
N10
N24/3
N73
V19
X58/34
ECO start/stop function additional battery relay

CDI control unit
ME-SFI [ME] control unit
SAM control unit
DC/AC converter control unit
Electronic ignition lock control unit
ECO start/stop function diode
115 V socket

69
Lights
Exterior lights
Front lights
Intelligent Light System (ILS)
The new M-Class is equipped with twin-tube halogen

headlamps as standard. Halogen bulbs (H7) are used
as the light source in the standard equipment.
Headlamps with Intelligent Light System are available

optionally as a component of the light package (not in
time for market launch).
All lighting variants feature horizontally aligned

daytime running lamps in the bumper, each consisting
of four LEDs.
In contrast to the standard version, the projection

system performs both the low beam function and the
high beam function. Only one single bulb is used per
headlamp. With the high beams activated, the entire
light output of the xenon bulb is available. When the
low beams are activated, a panel moves between the
bulb and lens optics which covers the part of the light
output which points into the distance.
There are service flaps in the front wheel arch to allow

the low beams to be replaced easily. The high beams
and the standing/parking lights are accessed via the
engine compartment.
P82.10-6683-00
Front lights
70

Rear lamps
Lights
Exterior lights
The rear lamps of the new M-Class have been modified

in terms of their design and technology. The new rear
lamps feature two colors (red/clear white) and are
each divided into two parts, consisting of the side wall
and rear-end door lamp sections. The taillight and the
side marker lamp feature optical fiber technology, the
turn signal and rear fog lamp use LED technology and
all other functions are achieved using conventional
bulbs.
A center high-mounted brake light with LED technology and a red lens is located in the liftgate in the
roof spoiler.
P82.10-6684-00
Rear lamps

71
Lights
Interior lights
Interior lights
A basic light package is installed as standard and

ambiance illumination is available as special equipment.
Ambiance illumination consisting of the following

components is available as special equipment:
The basic light package includes:

Left and right LED interior lights in the overhead
control panel
LED reading lamps for driver and front passenger in
the inside rearview mirror
Indirect illumination of the center console in the
inside rearview mirror
Front footwell illumination with automatic dimming
after the door is closed
Make-up lamps in the headliner
Glove compartment illumination
Ashtray illumination or illumination of stowage
compartment
Lamp in stowage compartment of center console
Interior lights/reading lights for the rear
passengers
Interior light which also acts as load compartment
illumination in the headliner over the rear
Illuminated door handle recesses
Front warning/exit lamps (red/white) and rear
reflectors (standard), rear warning/exit lamps (SA)
Warning and ambient lamp in rear-end door
Illuminated double cup holder in the front center

console
Footwell illumination in rear
Ambient, multi-colored illumination in the
instrument panel and door panels (as on model
series 212)
Front illuminated door sill moldings
Rear warning and exit lamps
Illuminated adjustment wheels on the air vents of
the instrument panel
72

P82.20-3861-00
Further improved driving and stress-reducing safety

are achieved on the new M-Class by the following
features in particular:
ADAPTIVE BRAKE with the added functions: Hill
Start Assist, precharging, dry braking and Hold
function, standard
Attention assistance system, standard
Brake Assist System (BAS), standard and BAS
PLUS (in combination with DISTRONIC PLUS, SA)
Adaptive brake lights, standard
Tire pressure loss warning, standard or tire
pressure monitor (TPM) (USA only, standard)
Intelligent Light System with bi-xenon, SA
Night View Assist
Speed Limit Assist, SA
Lane Keeping Assist or Active Lane Keeping Assist,
SA
Blind Spot Assist or Active Blind Spot Assist, SA
Active Park Assist, SA
Reversing camera, SA
DISTRONIC PLUS, SA
The safety concept which acts preventively when the

system registers signs of danger includes:
Safety
PRE-SAFE
DISTRONIC PLUS incl. Brake Assist System PLUS
(BAS) and PRE-SAFE brake (SA)
Crash sensor system
The crash sensor system and its associated software
for the detection of the type of accident and severity
of impact have been further refined compared to the
predecessor model series. New features of the
M-Class include:
A new generation of Supplemental Restraint
System control unit
Pressure sensors in the rear doors as standard
The acceleration sensors for detecting a
pedestrian impact
P91.60-4233-00
Pedestrian protection sensors

1
Front bumper
B151/1 Left front bumper pedestrian protection sensor
B151/2 Center front bumper pedestrian protection

sensor
B151/3 Right front bumper pedestrian protection
sensor

73
Safety
Protective measures for pedestrians
In addition to the active measures (e.g. Brake Assist as
standard), the "passive" pedestrian protection
measures have also been further improved on the new
M-Class. In order to reduce the load that is applied to
the body during an impact on the hood of the vehicle,
the deformation clearances between the engine hood
and the components underneath have been optimized. This is partly achieved through appropriate
placing of components e.g. control units or fluid reservoirs in the engine compartment.
The deformation properties of the hood were developed specifically to meet these requirements. The use
of aluminum and homogeneous reinforcement on the
inside of the engine hood further reduce the loads
during an impact. In combination with the reduced
foam hardness in the front bumper, this reduces the
stress applied if the vehicle collides with the legs of a
pedestrian.
An active engine hood is also used on the M-Class on

a country-specific basis. In the event of a collision with
a pedestrian, three sensors in the bumper transmit
signals to a control unit. This actuates pyrotechnical
actuators in the area of the engine hood hinges. This
raises the engine hood by approx. 90 mm. The additional space freed up between the engine hood and
components in the engine compartment can significantly reduce the risk of injury to a pedestrian in an
impact.
P91.60-4234-00
Engine hood lifter

1
Engine hood lifter unit
R12/49 Left rear active engine hood squib

R12/50 Right rear active engine hood squib
74

Restraint systems
The restraint systems have also been developed
further compared to the predecessor model series.
The driver and front passenger airbags are each
equipped with a two-stage gas generator. Depending
on the crash situation, the airbag control unit activates
one or both generator stages. The side impact protection system has also been redesigned. Head protection is provided by a newly developed windowbag,
which is installed in the roof area and covers a wide
area of the head impact range. The rear seats feature
sidebags in the seat, either as an option or as standard
depending on the market. A kneebag is installed for
the driver as standard.
Safety
Restraint systems
In contrast to the predecessor model series 164, the

WSS control unit is not directly connected to the CAN
bus. It is connected to the SRS control unit via the LIN
bus, which is connected to the CAN bus.
P91.60-4235-00
Airbag system (full equipment)

75
Overview of systems
General
Speed Limit Assist
The vehicle components which ensure a high level of

perceptual safety include the safety-relevant support
systems described below.
The Speed Limit Assist system available as special

equipment can use image recognition (camera integrated in center of windshield) and attributes of the
digital road map (COMAND) to detect the permissible
speed limit for symbolic display on the instrument
cluster and on the map view of the head unit.
The systems which have already been successfully

introduced in other model series include e.g.:

The attention assistance system which is available as
standard equipment in the M-Class can detect the
typical signs of fatigue or deteriorating attentiveness
of the driver on long, monotonous journeys in a speed
range of approx. 80 to approx. 180 km/h.

Adaptive Highbeam Assist is offered as a component
of the "Light package" special equipment option.
The Multi Purpose Camera (MPC) on the front of the
overhead control panel ensures that the headlamp
range and the light cone are controlled so as to
provide the best possible illumination of the road
according to the traffic situation. A headlamp range of
up to 300 m is available to the driver. In the normal low
beam setting, the headlamp range is only approx.
65 m.
Active Park Assist

The Active Park Assist system can support the driver
during parallel parking.
An ultrasonic measurement system is used to scan the
vehicle's surroundings. This is also used by the PARKTRONIC system and certain aspects of it have been
developed further for Active Park Assist.
On vehicles with the Active Park Assist SA, parallel
parking spaces on both sides of the vehicle are
scanned in the direction of travel while driving at
speeds of v < 36 km/h and displayed on the instrument cluster in the form of an arrow symbol. The
vehicle can be parked semi-automatically at the
request of the driver.
i Note
For more information on the driver assistance systems listed here, see Introduction into Service
Manual "Introduction of the New CLS-Class
Introduction into Service Manual for Model
Series 218"
Order no.: 6516 1381 02
76

Lane Keeping Assist/

Blind Spot Assist/

Active Blind Spot Assist
Active Lane Keeping Assist builds upon the functionality of the Lane Keeping Assist system.
The Blind Spot Assist system monitors the rear and

side areas of the vehicle using short range radar and,
if necessary, warns the driver if another vehicle is
detected in the blind spot during an intentional lane
change (turn signal set). A visual indicator in the
outside mirrors indicates that the system is active. As
of 30 km/h, the yellow visual indicator in the outside
mirror disappears if no system faults are detected. As
soon as a vehicle is detected in the detection range of
the radar sensor system, the driver is warned by illumination of the red readiness and warning indicator in
the outside mirror on the side of the vehicle where
there is a vehicle in the blind spot. If the driver tries to
initiate a lane change despite illumination of the indicator, an acoustic warning is also output and the
warning indicator flashes.
The Active Lane Keeping Assist system, like the Lane

Keeping Assist system, can detect when the vehicle
unintentionally crosses over lane markings via the
multifunction camera.
In certain situations, the system issues a warning
through the steering wheel warning system when the
vehicle leaves the recognized lane.
In a vehicle speed range of v = 60 to 200 km/h, the
Active Lane Keeping Assist system additionally
initiates selective brake system interventions if the
driver does not respond to the warning in order to
move the vehicle back into the lane.
Overview of systems
Active Blind Spot Assist builds upon the functionality

of Blind Spot Assist. The Active Blind Spot Assist
system can additionally initiate course-correcting
brake interventions in a speed range of v = 30 up to
200 km/h, taking the surroundings of the systems
vehicle into account.
Active interventions by the brake system are
conducted on a wheel-specific basis and exert a
course-correcting influence on the vehicle with the
system. If a risk of collision is detected with vehicles
that are in the blind spot, then an accident can be
avoided or the consequences of the accident lessened.
i Note
All the driving assistance systems are merely aids
for the driver in controlling the vehicle in certain
difficult situations.
They can never replace a properly relaxed and
attentive driver. The driver bears sole responsibility at all times for the safety of his/her vehicle and
its behavior.

77
Overview of systems
DISTRONIC PLUS incl. BAS PLUS and
PRE-SAFE brake
Night View Assist
The DISTRONIC PLUS driver assistance system automatically regulates the vehicle speed and distance to
the vehicle in front as specified by the driver in the
speed range of v = 0 to 200 km/h and v = 200 to
0 km/h.
BAS PLUS
The BAS PLUS function (Brake Assist System PLUS),
assists the driver through situation-dependent,
targeted brake force calculation during emergency
braking.
PRE-SAFE brake
The Night View Assist system allows the driving situation to be displayed visually in the dark. The road
ahead of the vehicle is illuminated by two antiglare
infrared lamps. The camera mounted in the area of the
rearview mirror on the windshield records the road
area and displays it on the central COMAND display
after image processing. This provides better orientation for the driver in situations without the visible high
beams and allows the driver to respond earlier to
persons, animals or objects. When person detection is
active (see symbol 2 in picture) each person detected
by the system is also highlighted with "photo frame
corners" (see symbol 1 in picture).
The PRE-SAFE brake is an additional function of

DISTRONIC. It is designed as a three-stage warning
and braking system and continuously detects the
potential for a rear-end collision. As soon as the
system detects signs of danger, a visual and acoustic
warning is issued. If the driver does not respond,
autonomous partial braking can be initiated. If the
driver still does not respond, autonomous emergency
braking can be initiated. The accident cannot be
prevented at this stage, but the severity of impact can
be significantly reduced.
P54.32-9580-00
Grayscale video image, person detection not active
78
P54.32-9581-00
Grayscale video image, person detection active

Reversing camera
For the ECE and USA, the new generation of reversing
camera is available as special equipment. As on the
predecessor model, the reversing camera is integrated in the liftgate of the vehicle and displays the
area behind the vehicle on the COMAND screen during
reversing.
Thanks to a new lens with digital image transmission
and additional electronic zoom functions, an optimized image for the respective driving situation is
achieved with a widened angle of vision > 130. To
enable an improved display of the driving area to the
rear, electronic distortion correction is also conducted
through the integrated reversing camera control unit
in addition to optical distortion correction by the lens.
The reversing camera function enables the driver to

select between the following parking modes:
Maneuvering mode
Trailer mode (with code (550) Trailer hitch)
The corresponding selection takes place at the operating level of the COMAND controller unit.
Maneuvering mode:
The maneuvering mode assists the driver when
reversing while parking. In doing so, dynamic guide
lines are also shown on the Audio/COMAND display in
addition to the pictures documented by the reversing
camera.
Reversing camera
P54.65-4590-00
Display of dynamic guide lines (with wheels in straight-ahead position)

1 Virtual bumper
A Display
B Example situation

79
Reversing camera
P54.65-4591-00
Display of dynamic guide lines (with wheels turned to right)
P54.65-4592-00
Display of distance lines in maneuvering mode

1
2
A
B
80
Virtual steering angle

Virtual bumper
Display
Example situation
c Distance line, approx. 0.25 m

d Distance line, approx. 1.0 m
e Distance line, approx. 4.0 m

Virtual steering angle (yellow guide lines):
Parking procedure:
The yellow guide lines are shown as soon as the driver

turns the steering wheel. They indicate to the driver
the path which the vehicle would follow with the
currently applied steering angle. This curve is automatically adapted to the situation as the steering
angle changes. The distance between the yellow guide
lines is slightly more than the vehicle width.
In order to park the driver must now adapt the steering

angle until an outer line of the yellow guide lines in the
Audio/COMAND display virtually touches the parking
space marking.
This parking space marking can, e.g. be another
vehicle or a line on the asphalt. The driver must then
continue backing up and adapting the steering angle
until the displayed parking space limits run parallel to
the current direction of travel.
Reversing camera
Next the driver must turn the steering wheel back into
the straight-ahead position in order to drive in a
straight line up to the final parking position in the
parking lot.
The distance lines inform the driver about the
distances between the bumper and the obstacles.
i Note
i Note
If the liftgate is not closed, the picture shown on

the Audio/COMAND display is overlaid with a
warning message and the guide lines are hidden.
During initial startup, if work is performed on the

reversing camera or if work is performed on the
liftgate, the reversing camera has to be calibrated
again using the diagnosis tester.

81
Reversing camera
Trailer mode:
On vehicles with SA Trailer hitch, trailer mode
supports the driver when reversing to a trailer by
zooming into the ball head.
When reversing, special guide lines are also shown on
the Audio/COMAND display in addition to the pictures
documented by the reversing camera.
Distance line around the ball head (red guide

lines):
The red distance line is shown permanently on the
Audio/COMAND display and informs the driver about
the distance over a radius of 0.25 m around the ball
head.
Virtual steering angle (yellow guide lines):

As soon as the driver turns the steering wheel, this
yellow guide line is displayed. It shows the driver the
course which the vehicle would follow with the
steering angle currently applied. This curve is automatically adapted to the situation as the steering
angle changes. The displayed length of the yellow
guide line shows a distance of 1.0 m to the coupling.
P54.65-4593-00
Display of distance lines in trailer mode

2 Virtual steering angle
4 Bumper
82
A Display
B Example situation
h Distance line, approx. 0.25 m

The standard equipment of the new M-Class consists

of 2-zone automatic air conditioning. Available as
special equipment is 3-zone comfort automatic air
conditioning (THERMOTRONIC) with separate temperature control for the driver, front passenger and rear
as well as additional adjustable air vent doors in the
B-pillars.
The design of both operating units has been modified
for simpler operation and standardized appearance.
Both systems feature air recirculation switching and
are equipped with an interior air/combination filter
and a dust filter as standard. The filter performance
has been raised to almost 100% for particle sizes down
to 10 micrometers and improved to approx.
96-98% for particle sizes of between 5-10 micrometers.
Energy savings through new technologies in air

conditioning equipment
Comfort
Climate control
The W 166 is equipped with a mirror fogging sensor

integrated in the mirror base of the inside rearview
mirror (in Europe as of 2-zone automatic air conditioning, otherwise as of 3-zone comfort automatic air
conditioning). The signals of the sensors are evaluated
in order to regulate the compressor according to
demand during air conditioning operation, which not
only increases comfort but also saves drive energy.
The use of an internal heat exchanger into refrigerant
circuit further improves efficiency. The heat
exchanger is used to increase the energy content of
the refrigerant in the operating ranges and to reduce
the mass airflow and thus the operating energy input
of the refrigerant compressor, while supplying the
same cooling power.
P83.00-2350-00
Climate control and air ducting

83
Comfort
Climate control
3-zone comfort automatic air conditioning THERMOTRONIC
The THERMOTRONIC special equipment option is a
3-zone comfort automatic air conditioning system
which offers the following additional functions
compared to the 2-zone automatic air conditioning
system:
Selection of three predefined ventilation programs
for air flow via the AIR FLOW button on the
operating unit
Separately controlled specified temperature value,
air distribution and air flow for the rear area via an
additional operating unit in the center console in
the rear
Inclusion of additional sensor signals in the control
process (fogging sensor and pollutant sensor to
prevent the entry of pollutants such as carbon and
nitrogen)
Additional air outlets in the B-pillar trim
By pressing the AIR FLOW button, the customer can

influence the climate control comfort and choose
between predefined ventilation programs. In the
"DIFFUSE" setting, the climate control system operates with lower air speeds and in the "FOCUS" setting,
the interior compartment is ventilated more vigorously. The "MEDIUM" setting is the normal setting.
Controls of THERMOTRONIC automatic air conditioning
84

P83.40-4634-00
For the market launch, the new M-Class is equipped

with the New Telematics Generation 4.5 previously
used in model series 172.
The following head units are installed depending on
the equipment version and national version:
Variants for ECE:
Audio 20 (standard)
Audio 20 with Becker MapPilot (SA)
COMAND Online (SA)
Variants for USA:
COMAND without navigation function (standard)
COMAND APS (SA)
Variant for Japan:
COMAND Online (standard)
Variant for China:
Audio 20 (standard)
COMAND APS (SA)
The new customer-relevant features of the head units
of NTG 4.5 include:
Internet access (for COMAND Online only)
Becker MapPilot can also be retrofitted (requires
code 508, Preinstallation for Becker MapPilot)
(only for Audio 20 in ECE)
SIRIUS Weather Forecast (USA only)
Copy protection for HDD navigation data (for
COMAND Online/APS only)
USB interface in stowage compartment of center
console
SD card instead of PCMCIA adapter (for COMAND
Online/APS only)
Optimization of map display, 3D landmarks etc.
(for COMAND Online/APS only)
Theft protection through electronic assignment to
vehicle
Telephony
The telephone application offers three principle operating modes:
In the "Telephony via Bluetooth interface" mode, the
telephone is directly connected to the head unit via
Bluetooth. For connection to the external antenna and
in order to charge the mobile phone, this mode can be
combined with the comfort telephony preinstallation
(special equipment) and "passive cradles".
Telematics
In the "Comfort telephony" mode (ECE only), the telephone is connected to the cradle in the stowage
compartment of the center console. Depending on the
cradle, this takes place by inserting the mobile phone
or through a Bluetooth connection to the cradle. In
this configuration, the mobile phone is directly
connected to the external vehicle antenna and is
charged via the vehicle.
In the "MB SAP module" mode (ECE only), the optionally available MB SAP module is plugged into the
comfort telephony preinstallation in the armrest. The
MB SAP module can, on the one hand, be used as a
fixed installation telephone with a SIM card inserted.
On the other hand, it can be connected to a compatible mobile phone via the Bluetooth profile SAP (SIM
Access Profile).
The phone book and SMS messages (Short Message
Service) are available in all modes if the mobile phone
supports the required Bluetooth Phone Book Access
Profile (PBAP) and Message Access Profile (MAP). If
this is not the case, these functions are not available
in the "Telephony via Bluetooth interface" mode.
The telephone application can be operated via the
multifunction steering wheel and the head unit
buttons in all versions.

85
Telematics
Rear entertainment
The rear entertainment system is a complete entertainment system for the rear passengers. It is
comprised mainly of the following components:
The control signals are transmitted via the infrared (IR)

interfaces on the remote control to the respective
display.
A headphone jack is integrated into each display.

Headphones can be connected directly to this. In addition, the volume can also be adjusted via the volume
control of the respective headphones.
DVD player
Left rear display
Right rear display
Remote control
Radio frequency headphones (cordless) or wired
headphones (wired headphones are not included)
P82.60-8636-00
Rear entertainment
86

Surround sound system

Available as special equipment is a newly developed
surround sound system from harman/kardon
Logic 7 with an 11-channel DSP amplifier (Digital
Sound Processing), 830 watts and 14 speakers (power
output 7x50 Watt + 4x120 Watt). The surround system
is available for the Audio 20 with CD changer and the
COMAND Online/APS.
Sound system
P82.62-3745-00
harman/kardon Logic 7 surround sound system

A2
A40/3
H4/3
H4/4
H4/5
H4/6
H4/27
H4/33
H4/34
Radio
Left rear door speaker
Right rear door speaker
Left front door speaker
Right front door speaker
Center instrument panel speaker
Left front door tweeter
Right front door tweeter
H4/35
H4/36
H4/38
H4/62
H4/63
H4/86
H4/87
N40/3
Left rear door tweeter

Right rear door tweeter
Rear bass speaker
Left rear surround speaker
Right rear surround speaker
Left door midrange speaker
Right door midrange speaker
Sound system amplifier control unit

87
Bodyshell of W 166
P60.00-2925-00
Body
Bodyshell
88

General
Passenger cell
The most important features considered in the development of the bodyshell of model series 166 include:
The main floor consists of three assemblies, whereby

the center part has greater sheet thickness and forms
the backbone of the floor system as a tunnel. Additional solid tunnel reinforcements are placed on top.
The floor to the left and right of the tunnel is reinforced
from the inside as follows:
The increase in the rigidity and strength of the

passenger cell and the deformation resistance of
the front end and rear structure in comparison to
the predecessor model series 164. The results in
an improvement in active and passive safety, ride
comfort (particularly on-road) and durability and
driving stability (particularly off-road).
Creating a tolerance balance in the joining of the
individual bodyshell parts (low-stress connections)
by means of suitable flange designs
Dispensing with MAG weld seams to improve
production quality
Detachable front and rear end assemblies to make
repair easier
In addition, the torsional stiffness of the bodyshell has
been increased significantly despite the integration of
a large roof opening system.
The bodyshell is made of sheet steel. Modern highstrength and ultra high-strength steels with optimized
mechanical properties have been used.
Body
Bodyshell
With a rigid crossmember for mounting the seats

and for lateral support on the tunnel in the event of
a side collision
With a diagonal member from the firewall to the
side longitudinal member/B-pillar node
The driver/front passenger seat crossmember has a
sturdy design resistant to side collisions with a singlepiece reinforcement made of hot-worked, highstrength steel. This forms the divider to the rear-end
floor.
Crossmember under instrument panel
The load-bearing element of the cockpit module is a
tubular magnesium assembly carrier which is bolted
onto the two A-pillars.
The carrier acts as a guide for the components
attached to it. This eliminates the need for timeconsuming tolerance compensation during assembly
gives the structure a higher-quality appearance.

89
Body
Bodyshell
Front end
The front end structure of model series W 166,
consisting of the firewall, two front longitudinal
members and two wheel arches, has been taken over
from the predecessor model series. The following
features further improve the energy absorption
capacity in the case of a head-on collision:
The two front longitudinal members with additional
internal third shell
Additional longitudinal outboard members on the
right and left with support at the A-pillars (second
longitudinal member plane)
Two vertical supports between the first and second
longitudinal member plane to increase torsional
stiffness.
The front end consists of:
A high-strength steel profile for the bumper
components
Two high-strength steel crash boxes with flexural
member forming a detachable connection to the
two front longitudinal members
A bolted hybrid front end made of steel and plastic
serves as a mount for the two lamp units
A bolted steel radiator crossmember
A plastic carrier part with steel inserts as the base
for the components of the upgraded front module
90
The front axle major assemblies including the steering

gear are preassembled together with the engine and
transmission on an integral carrier, which in turn is
connected to the body via four rubber bushings. This
minimizes the transmission of vibrations from the
front axle to the body. The remarkably rigid integral
carrier is a welded structure made of high-strength
sheet steel.
In the event of a severe frontal impact, the integral
carrier is able to deform while absorbing impact
energy.
Model series W 166 features a major assembly
compartment which is separated from the engine
compartment by a multipart, plastic partition wall
extending from left to right. This guarantees good
noise and thermal insulation with the passenger
compartment.
Side wall
On model series W 166, the outer paneling of the side
wall including the rear fender is made of a single
section. This outer paneling is firstly stiffened using a
reinforcing frame. The internal side wall structure is
composed of several parts and, together with the reinforced outer side wall, forms the three-piece crosssections that lend strength and rigidity to the A, B, C
and D-pillars, to the side longitudinal member and the
roof frame. On vehicles with full steel roof, a sturdy
central bow positioned under the roof paneling joins
the two top ends of the B-pillars. The front and rear
roof frames each have a two-shell structure.

Rear end
Engine hood and front fenders
The axle components of the rear axle are mounted on

a rear axle carrier which is joined to the body via four
rubber bushings.
The engine hood and front fenders are made of

aluminum. This reduces the bodyshell weight
compared to the predecessor model series by approx.
11 kg. Furthermore, the components are geometrically designed to provide the best possible pedestrian
protection.
To increase their strength, enhance their energy

absorption capacity and improve their deformation
behavior, the multipart rear longitudinal members
have a cross section which is closed along their entire
length with graduated sheet thicknesses. The
recessed compartment for the compact spare wheel is
part of the steel rear floor assembly. The hot-worked
steel flexural members which carry the rear bumper
cover are connected to the rear-end structure by two
steel crash boxes.
Body
Bodyshell
The engine hood hinges have a four-link design but an

additional link allows the engine hood to be actively
raised if necessary for pedestrian protection. The
engine hood can be steplessly positioned/locked in
place from 45 to 85 for service purposes using
Interstop pneumatic springs.
Radiator grille
Rocker panels
The side longitudinal members are covered over their
entire area with plastic rocker panels in a contrasting
color, which connect to the fenders and doors at the
bottom. The rocker panels protect the side longitudinal members, fenders, doors and side wall from
stone chips and also give shape to the side of the
vehicle.
Wide running boards with aluminum inserts and
profiled rubber naps are available as special equipment. These can be placed under load and facilitate
side entry, particularly for shorter persons.
The radiator grille has a sturdy, SUV-style design and

is attached to the bumper. It is characterized by a
chrome-plated central Mercedes-Benz star and three
chrome slats. The slat carrier is painted glossy black.
Underneath the headlamps and the radiator grille is an
opening in the front bumper covered by a black
diamond-pattern grille for the purpose of engine
cooling. Next to the grille are covers with the same
diamond-pattern structure, into which the LED
daytime running lamps are integrated. In order to
increase the perceived quality of the LED daytime
running lamps, they are framed with a chrome-plated
cover.
The visible area of the underride guard is in chrome.

91
Body
Bodyshell
Doors
Rear-end door
The four large side doors have a lightweight steel

construction. They ensure comfortable entry and exit.
The door gap is sealed all the way around (triple seals
above the beltline and dual seals below) in order to
significantly reduce wind noises and keep the
entrance areas largely free of dirt.
In addition to a manually opened rear-end door, an

automatic rear-end door is available as special equipment (standard in the USA) for the M-Class. This can
be opened and closed without manual support by an
electromechanical drive system. It is however still
possible to manually open and close a rear-end door
fitted with this convenience function. Both versions
are equipped with a power closing function for closing
the door from the pre-locking position.
Each door shell comprises two joined steel sheets.

The required dent resistance of the outer paneling is
achieved through a reinforcement profile, which is
bonded to the outer shell. In addition to the inner shell,
which is cut out appropriately to hold an assembly
module, the lock, hinge, side impact protector and
outer beltline reinforcements make up the door shell.
The window frame is formed from the inner shell and
a single-piece frame section.
The door holder function is integrated in the door
hinges. These are forged steel parts. The hinge system
is maintenance-free. As on model series 204/212, the
hinges are bolted from the inside to the pillars.
The technical design of both door variants is largely

identical in terms of bodyshell, trim parts, glazing and
some other assembly parts. The automatic door is
equipped with an electromechanical drive system
(rotary pillar drive) with control unit instead of the
standard gas-operated springs.
In order to ensure a high level of rigidity, the loadbearing body of the door shell, including the rear
window frame, is made up of an inner shell and outer
shell made of sheet steel with reinforcements. The
shells are joined to each other with spot welds and
adhesive.
On the underside of the rear-end door there are, in
addition to the lock, two assist handles as on model
series 204/212, the switch for the automatic rear-end
door on the outside right and the switch for the semiautomatic trailer hitch on the outside left.
Two pneumatic springs and conventional U-shaped
hinges are used to hold the door.
92

Body
Bodyshell
P60.00-2926-00
Force progression in a head-on collision
P60.00-2927-00
Force progression in a side-on impact

93
Body
The MB corrosion protection concept is used widely
on model series W 166.
Seam sealant on body
All folds, flanges or edges susceptible to corrosion are
surface protected against corrosion with a seam seal
on the cathodic dip paint (KTL). The overall length of
seam seals on the body totals 138 m.
Bodyshell views, doors/flaps with seam seals highlighted
94

P97.30-2041-00
Body
Cavity preservation on body
The following structural areas which are highly
susceptible to corrosion are effectively protected
against corrosion by wax:
Front longitudinal member

Upper longitudinal member plane
Side longitudinal member
Rear longitudinal member
Door folds
P97.20-2584-00
Bodyshell views with cavity preservation highlighted
Bonded folds and adhesive filling on doors

The new Mercedes-Benz standard door concept
includes complete filling of the folds with adhesive.
The fold is thus sealed all the way around. This
measure improves robustness in production to the
maximum possible level.
The standard door concept is characterized by:

Wax all the way around from beltline to beltline
Seam sealing after KTL
Full-length fold bonding and complete adhesive
filling of flange
P97.20-2585-00
Schematic illustration of door fold

1 Full-length sealed fold
2 Cavity preservation
3 Seam seal
4 Schematic illustration of door fold

95
Body
Processing of carriers as per
new paint concept
Steel rear axle carrier and integral carrier
Abrasive blasting of weld seams

KTL coating
Partial waxing of carrier from below
Cavities of transverse bridges waxed (integral
carrier only)
Steel rear axle carrier and integral carrier
96

P97.30-2042-00
Calibration device
Special tools
Suspension
Use For calibrating the reversing camera
MB number W000 589 01 21 00
P58.20-2312-00
FG 54
Set B
Category Mercedes-Benz Passenger Car Special
Operations
Extraction and insertion tool
Use For removing and installing the rubber

bushings on the FA transverse control arm
MB number W166 589 00 43 00

FG 33
P58.20-2313-00
Set B
Category Mercedes-Benz Passenger Car Basic
Operations Recommended
Note Only in combination with:
Hydraulic press/W001 589 51 33 00
Hand pump/W652 589 00 33 21
Hydraulic hose/W652 589 00 33 23
for rubber bushings and comfort bearings.
For rubber bushings, additionally in
combination with: Extraction and insertion
tool/W164 589 04 43 00

97
Special tools
Suspension
Adapter
Use Adapter for filling the ACS system
MB number W166 589 00 91 00

FG 32
P58.20-2314-00
Set B
Operations
Pressure pump/W124 589 24 21 00
Sleeve
Use Sleeve for pulling rubber bushings of

suspension strut into lower RA transverse
control arm
MB number W166 589 01 14 00

FG 35
P58.20-2315-00
Set B
Operations Recommended
Extraction and insertion tool/
W164 589 00 43 00
Hand pump/W652 589 00 33 21
Hollow cylinder/W652 589 00 33 22
Hydraulic hose/W 652 589 00 33 23
Lead screw/W652 589 00 33 11
98

124-pin adapter cable
Special tools
Engine
Use Adapter cable (124-pin) for diagnosing

airbags (driver, front passenger, sidebag
and windowbag) and emergency tensioning
retractor control unit
MB number W166 589 04 63 00
P58.20-2316-00
FG 91
Set B
Operations Mandatory/Approved for
Cooperation
Test box/W000 589 00 21 00
Adapter set
Use Adapter sleeves for fixture for mounting

engine hoist on spring tower for replacement
operations e.g.: engine mount, oil pan,
integral carrier
MB number W240 589 01 31 00
P58.20-2317-00
FG 01, 22, 27, 33, 60

Set B
Operations
Note Set consists of 6 units each, l=125 mm
Only in combination with:
Engine hoist/W240 589 00 61 00
Engine hoist/W240 589 01 32 00

99
Workshop equipment
Body repair systems

Manufacturer
CELETTE
CAR BENCH
CAR-O-LINER
Article
CELETTE straightening
and portal tool set
CAR BENCH straightening

and measuring system
Straightening and
measuring system
Order number
Supplementary straightening bracket set

7166.509
Portal straightening set
7166.800
NEW: Universal kit with "D"

parts A353/EVO
A4244100
Portal straightening set
A7244100/T
EVO 3.3
(Mercedes)
Source in
Germany
CELETTE
Vertriebs GmbH
Siemensstrasse 19
D-77694 Kehl-Sundheim
HSK
Karosseriegerte
Vertriebs-GmbH
Am Fliegerhorst 3
D-63762 GroostheimRingheim
Car-O-Liner
Vogesenstrasse 3
D-63811 Stockstadt
www.celette.de
www.carbench.de
www.car-o-liner.de
CELETTE FRANCE S.A.S.

3. Avenue Marcelin
Berthelot
CAR BENCH International

S.p.A.
Via Dorsale 22
Car-O-Liner
Box 7
F-38200 Vienne
France
I-54100 Massa
Italy
73621 Kungsr
Sweden
Source outside
Germany
i Note
i Note
The basic straightening tool set 7164.300 is

essential for body repairs with the CELETTE
system.
http://gotis.aftersales.mercedes-benz.com
If using the previous CAR BENCH system 353, the

universal kit must be updated with a supplementary kit A353/KITEVO for the A353/EVO. The
vehicle-specific kit is no longer needed.
For further information on body repair tools and
special tools, see the Introduction into Service
Manual for model series 164.
100

ABS
DSR
Antilock Brake System
Downhill Speed Regulation
ADS
ECO
Adaptive Damping System
Economy
AGR
EDW
Exhaust gas recirculation (EGR)
Antitheft alarm system (ATA)
ASR
ESP
Acceleration skid control
Electronic Stability Program
BAS
ETS
Brake Assist System
Electronic Traction System
CAN
EU5
Controller Area Network
Euro 5 standard (exhaust emission regulation)
CDI
EU6
Common rail Direct Injection
Euro 6 standard (exhaust emission regulation)
CO2
FE-ATF
Carbon dioxide
Fuel Economy Automatic Transmission Fluid
COMAND
HDD
Cockpit Management and Data System
Hard Disk Drive (permanent/mass storage device)
Cd
HDPE
Coefficient of drag
High-Density Polyethylene
DAB
IHU
Digital Audio Broadcasting
Hydroforming
DIN
ILS
Deutsches Institut fr Normung (German Standards

Institute)
Intelligent Light System
Annex
Abbreviations
IR
DPF
Infrared
Diesel Particulate Filter

ISO
DSB
International Organization for Standardization
Digital Service Booklet

101
Annex
Abbreviations
KTL
SA
Cataphoretic immersion primer bath
Special equipment
LDS
SAM
Twin-wire-arc-sprayed coating (TWAS)
Signal aquisition and actuation module
LED
SCR
Light-Emitting Diode
Selective Catalytic Reduction
MAG
SD
Metal Active Gas welding
Secure Digital
MAP
SMS
Message Access Profile
Short Message Service
MOST
SUV
Media Oriented System Transport
Sport Utility Vehicle
MPC
UCI
Multi Purpose Camera
Universal Consumer Interface
NOx
ULEV II
Nitrogen Oxides
Ultra Low Emission Vehicle (US exhaust emission

regulation)
NTG
New Telematics Generation
USB
Universal Serial Bus
NVH
Noise Vibration Harshness
VDA
German Association of the Automotive Industry
PBAP
Phone Book Access Profile
WIS
Workshop Information System
PCMCIA
Personal Computer Memory Card International
Association
WSS
Weight Sensing System
PWM
Pulse Width Modulation
RDK
Tire pressure monitor (TPM)
102

Numerics
7G-Tronic Plus transmission . . . . . . . . . . . . . 48
Electric parking brake .

Engine data . . . . . . .
Engine mount . . . . . .
Engine mounts . . . . .
A
Active Blind Spot Assist . .
ACTIVE CURVE SYSTEM . .
Active engine hood . . . . .
Active Park Assist . . . . . .
Active roll stabilization . . .
ADAPTIVE BRAKE . . . . . .
Adaptive Highbeam Assist .
AdBlue . . . . . . . . . . .
Aeroacoustics . . . . . . . .
Aerodynamics . . . . . . . .
AIRMATIC . . . . . . . . . .
Ambiance illumination . . .
Automatic air conditioning .
. . . . . . .8, 12, 73, 77

. . . . . 8, 9, 54, 59, 60
. . . . . . . . . . 13, 74
. . . . . . .8, 12, 73, 77
. . . . . . .8, 12, 73, 76
Flexible Fuel . . . .
Force progression
Front axle . . . . .
Front view . . . . .
Fuses . . . . . . .
. . . . . . . . . . . . . 59
. . . . . . . . . . 61, 73
. . . . . . . . . . 12, 76
. . . . . . .9, 32, 43, 46
. . . . . . . . . . . . . 20
. . . . . . . . . . . . . 20
. . . . . . . . . . . 9, 54
. . . . . . . . . . 12, 72
. . . . . . .8, 13, 73, 76
. . . . . . . . . . 14, 83
. . . . . . . . . . . 9, 61, 62
. . . . . . . . . . . . . . 8, 58
. . . . . . . . 34, 35, 37, 39
. . . . . . . . . . . . . . . 99
. . . . . . . . . . . . . . . 40
. . . . . . . . . . . . 7, 10, 34, 36
. . . . . . . . . . . . . . . . . . 93
. . . . . . . . . . . . . . . . . . 52
. . . . . . . . . . . . . . . . . . 17
. . . . . . . . . . . . . . . . . . 68
I
Instrument cluster . . . . 25, 26, 33, 45, 59, 61, 76
Integral carrier . . . . . . . . . . . . . 52, 90, 96, 99
Intelligent Light System . . . . . . . . . 8, 12, 70, 73
Kneebag . . . . . . . . . . . . . . . . . . . . . . 13, 75
Blind Spot Assist . . . . . . . . . . . . .8, 13, 73, 77

Bluetooth . . . . . . . . . . . . . . . . . . . . . . . 86
C
CO2 emissions . . . . . . . . . . . . . . . . . . 34, 35
Coefficient of drag . . . . . . . . . . . . . . . . . . 23
Comfort automatic air conditioning . . . . 14, 83, 84
Crash sensor system . . . . . . . . . . . . . . . . . 73
Cup holder . . . . . . . . . . . . . .14, 27, 28, 29, 72
Annex
Stichwrter
Lane Keeping Assist . . . . . . . . . . . 8, 13, 73, 77

LED technology . . . . . . . . . . . . . . . . . . . . 71
Load compartment . . . . . . . . . . . . . . . . 30, 31
M
Maintenance strategy . . . . . . . . . . . . . . . . 32
MOST . . . . . . . . . . . . . . . . . . . . .65, 67, 68
D
Digital Service Booklet . .
Dimensions . . . . . . . .
Dimensions and weights .
DISTRONIC PLUS . . . . .
Downhill Speed Regulation
. . . . . . . . . . . . . . 33
. . . . . . . . . . . 21, 23
. . . . . . . . . . . . . . 24
. . . . . . . . . 12, 73, 78
. . . . . . . . . . . 12, 50
Night View Assist . . . . . . . . . . . . . . . 8, 12, 78

NTG 4.5 . . . . . . . . . . . . . . . . . . . . . . . 8, 85
O
Oil supply . . . . . . . . . . . . . . . . . . . . . . . 48
ON&OFFROAD package . . . . . . . . . . . 9, 55, 56

103
Annex
Stichwrter
P
Panoramic sliding sunroof . . . . . . . . . . . 12, 19
Performance graph . . . . . . . . . . . . . . . 37, 39
PRE-SAFE . . . . . . . . . . . . . . . . 8, 13, 73, 78
R
Rear axle . . . . . .
Rear entertainment
Rear view . . . . . .
Reversing camera .
. . . . . . . . . . . . . . . . . .53
. . . . . . . . . . . . . . . 16, 86
Telephony . . . . . .
THERMOTRONIC . .
Transfer case . . . .
Transmission modes
. . . . . . . . . . . . . . . . . .17
. . . . . . . . . . . 8, 13, 73, 79
S
Seats . . . . . . . . . . . . . . . . . . . . . . . . . .28
Side view . . . . . . . . . . . . . . . . . . . . . . . .18
104
Sidebag . . . . . . . . .
Sliding roof . . . . . . .
Speed Limit Assist . . .
Steering column . . . . .
Stowage compartments
. . . . . . . . 13, 28, 75, 99

. . . . . . . . . . . . . 12, 19
. . . . . . . . . . . 8, 13, 76
. . . . . . . . . . . . . . . 58
. . . . . . . . . . . . . . . 29
. . . . . . . . . . . . . . . . . 85
. . . . . . . . . . . . 14, 83, 84
. . . . . . . . . . . . 50, 51, 55
. . . . . . . . . . . . . . . . . 55
W
Windowbag . . . . . . . . . . . . . . . . . 13, 75, 99


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Mercedes-Benz Service

Introduction of the New M-Class

Daimler AG Technical Information and Workshop Equipment (GSP/OI) D-70546 Stuttgart

Information and copyright

Order no. of this publication:

6516 1383 02 HLI 000 000 02 72

Engine data for diesel engines

Gasoline engines M 276 and M 278

Diesel engines OM 651 and OM 642

Introduction of the New M-Class, Model Series 166 n

ACTIVE CURVE SYSTEM

Wheels and tires

Batteries and alternator

n Introduction of the New M-Class, Model Series 166

Audio and communications

Introduction of the New M-Class, Model Series 166 n

n Introduction of the New M-Class, Model Series 166

Models and major assemblies

Model series 166

Introduction of the New M-Class, Model Series 166 n

As the successor to model series W 164, model series

New Telematics Generation 4.5 with USB interface

n Introduction of the New M-Class, Model Series 166

designo Exclusive package2

Code X27, X11, X06

Edition 1 (ECE only)3

Powerplant, engine, suspension, brakes

ACTIVE CURVE SYSTEM

ON&OFFROAD package6 (except

Electric parking brake

ML 550 only in USA und ROW (not ECE)

Introduction of the New M-Class, Model Series 166 n

Powerplant, engine, suspension, brakes

78l gasoline tank (ECE only)

93l tank (standard in USA)

93l tank (Flexible Fuel)

Wheels, tires, light alloy wheels

43.2 cm (17") light alloy wheel

45.7 cm (18") light alloy wheel

45.7 cm (18") light alloy wheel

48.3 cm (19") light alloy wheel

48.3 cm (19") light alloy wheel

With Code 929 Flexible Fuel (USA only)

n Introduction of the New M-Class, Model Series 166

Wheels, tires, light alloy wheels

53.3 cm (21") AMG light alloy wheel

MOE run-flat tires

Tire pressure loss warning (except

TIREFIT tire sealant with electric air

Emergency spare tire in trunk floor

Introduction of the New M-Class, Model Series 166 n

Panoramic sliding sunroof

Driving assistance systems

Active Park Assist (except Japan)

Downhill Speed Regulation (DSR)

Night View Assist

n Introduction of the New M-Class, Model Series 166

Driving assistance systems

Speed Limit Assist

Reversing camera with guide lines1

Attention assistance system

Safety and theft protection

Kneebag on driver side