2011 06 002 004 en PDF

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 –
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© 2011 by Daimler AG
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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: P00.01-4194-00

Image no. of posters: 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 6
Overview
Models and major assemblies 7
Brief description 8
Equipment 9
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 3

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

Models and major assemblies
Overview
BR 166 Model Engine Automatic Market launch
7-speed transmission
ML 350 4MATIC 166.057 276.955 722.906 09/2011
ML 350 4MATIC 166.057 276.955 722.906 02/2012

Flexible Fuel1
ML 550 4MATIC1 166.073 278.928 722.909 02/2012
ML 250 CDI 166.004 651.960 722.908 11/2011

BLUETEC
4MATIC2
ML 350 CDI 166.024 642.826 722.903 09/2011

BLUETEC 4MATIC
1
USA only
2 ECE only
P00.00-4737-00
Model series 166

Brief description
Overview
Vehicle concept New features
As the successor to model series W 164, model series • New Telematics Generation 4.5 with USB interface
W 166 is the latest vehicle in the SUV (Sport Utility • Intelligent Light System (ILS)1
Vehicle) category. The interior and exterior styling set • Partially electric trailer hitch
new trends. The vehicle's dynamic styling coupled • New generation of gasoline engines M 276/M 278
with the newly developed and more advanced tech- • New diesel engine OM 651
nology make it an even more attractive option. • Uprated diesel engine OM 642 with reduced
consumption
• Radiator shutters
Dimensional concept • ECO start/stop
• Switchable engine mounts on diesel models
With a vehicle length of 4804 mm and a vehicle width • BLUETEC with external filling
of 1926 mm, model series W 166 exceeds the length • ON&OFFROAD package
of the predecessor model series by 23 mm and the • ACTIVE CURVE SYSTEM
width by 15 mm. The maximum height has been • Electric power steering
reduced by 19 mm in the interests of a more dynamic • Electric parking brake
vehicle design and better aerodynamics. • New digital reversing camera
• Active Park Assist
• DISTRONIC PLUS incl. Brake Assist System PLUS
Environmental compatibility (BAS) and PRE-SAFE® brake
• Attention assistance system (ATTENTION ASSIST)
A major focus of the development of the new M-Class • Speed Limit Assist
was, in addition to its key performance values and • PRE-SAFE®
driving characteristics, lower fuel consumption both • Blind Spot Assist and Active Blind Spot Assist
on-road and off-road. • Lane Keeping Assist and Active Lane Keeping
Assist
The consumption of the vehicle has been reduced
• Adaptive Highbeam Assist
compared to the predecessor model series, in parti-
• Night View Assist (Intelligent Night View)1
cular through engine developments and other
• Cooled/heated cup holders
consumption-reducing measures on the vehicle and
• Active engine hood (ECE only)
drivetrain.
• Further developed NAG2FE PLUS automatic
By selecting materials with excellent recycling proper- transmission
ties, a recycling rate of 85% has been achieved. In 1 Not for market launch
addition, a recoverability rate of 95% has been
achieved in accordance with the calculation model of
ISO 22628.
i Note
Further details on the electrical systems of model
series 166 (e.g. function descriptions) are avail-
able in the Workshop Information System (WIS)
under information type "Basic knowledge/func-
tions" (GF).

Equipment
Overview
ML 350 ML 550 ML 250 CDI ML 350 CDI
4MATIC 4MATIC1 BLUETEC BLUETEC
4MATIC 4MATIC
Equipment variants
AMG exterior sport package Code P31 Standard Code P31
Interior sport package 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 Standard — Standard

off-road button (ECE only)
ECO start/stop function Standard — Standard
Diesel particulate filter (DPF) — — Standard4
AIRMATIC package Code 489
ACTIVE CURVE SYSTEM Code 468 — Code 468
BLUETEC diesel emission control — — Standard5

system with SCR technology (Selec-
tive Catalytic Reduction) and
AdBlue® tank (except Japan)
ON&OFFROAD package6 (except Code 430

Japan)
Electric parking brake Standard
1 ML 550 only in USA und ROW (not ECE)

2
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

Equipment
Overview

4MATIC 4MATIC BLUETEC BLUETEC
4MATIC 4MATIC
Powerplant, engine, suspension, brakes
70l diesel tank (ECE only) — — Standard
78l gasoline tank (ECE only) Standard — — —
93l tank (standard in USA) Code 915 Standard Code 915
93l tank (Flexible Fuel) Standard1 — — —
Wheels, tires, light alloy wheels
43.2 cm (17") light alloy wheel — Standard

(except USA) weighted wheel Code 25R
235/65; 7.5 J x 17 ET 53
43.2 cm (17") light alloy wheel — Code R24

(except USA) Aero wheel
235/65; 7.5 J x 17 ET 56
45.7 cm (18") light alloy wheel Standard — Code R41

(except USA) 255/55;
8 J x 18 ET 56
45.7 cm (18") light alloy wheel Code 03R — Code 03R

255/55; 8 J x 18 ET 56.5
48.3 cm (19") light alloy wheel Code R552 — Code R55 Code R552
255/50; 8 J x 19 ET 56
48.3 cm (19") light alloy wheel Code R53 Code R533 Code R53
255/50; 8.5 J x 19 ET 59
1
With Code 929 Flexible Fuel (USA only)
2 Standard in USA
3
Except USA

Equipment
Overview
4MATIC 4MATIC
Wheels, tires, light alloy wheels
255/50; 8.5 J x 19 ET 59
48.3 cm (19") AMG light alloy wheel — Standard —

255/50; 8.5 J x 19 ET 59 Code 780
265/45; 9 J x 20 ET 57
50.8 cm (20") light alloy wheel Code 50R

265/45; 9 J x 20 ET 57
50.8 cm (20") AMG light alloy wheel Code 758 Standard in Code 758
265/45; 9 J x 20 ET 57 USA
53.3 cm (21") AMG light alloy wheel Code 7572

265/40; 9 J x 21 ET 53
Tire pressure monitor (TPM)3 Code 475 Standard Code 475

(except Japan)
MOE run-flat tires Code R66
Tire pressure loss warning (except Standard — Standard

USA)
TIREFIT tire sealant with electric air Standard

pump (ECE only)
Emergency spare tire in trunk floor Code 6904
1
Except USA
2 Except USA and Japan
3
Standard in USA
4
Standard in USA and Japan

Equipment
Overview

4MATIC 4MATIC
Light systems
Ambiance illumination Code 876
Light package: Code P351

Bi-xenon headlamps
Intelligent Light System
Position lamp (USA only)
Headlamp cleaning system
Adaptive Highbeam Assist
Roof systems
Sliding roof2 Code 414 Standard Code 414
Panoramic sliding sunroof Code 413
Driver assistance package Plus: Code 23P

DISTRONIC PLUS
Active Blind Spot Assist
Active Lane Keeping Assist
Automatic child seat recognition in
front passenger seat (not in USA)
Active Park Assist (except Japan) Code 235
Downhill Speed Regulation (DSR) Standard
Night View Assist Code 6101

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

Equipment
Overview
4MATIC 4MATIC
LANE PACKAGE: Code 22P

Blind Spot Assist
Lane Keeping Assist
Speed Limit Assist Code 513

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

(ATTENTION ASSIST)
Safety and theft protection
Sidebag for driver and front Standard

passenger
Sidebags in rear Code 2932
Windowbag for all seat rows Standard
Kneebag on driver side Standard
PRE-SAFE® system Standard
Automatic child seat recognition in Code U181

front passenger seat (except USA)
Front passenger seat with weight Code U10

detection (USA only)
Active engine hood (except USA and Standard

Japan)
1
Standard in Japan
2 Standard in USA and Japan

Equipment
Overview

4MATIC 4MATIC
Safety and theft protection
KEYLESS-GO Code 889
Anti-theft alarm system (ATA) (USA Standard

only)
Theft protection package (except Code P54

USA)
Climate control
2-zone automatic air conditioning Standard
3-zone comfort automatic air condi- Code 581

tioning (THERMOTRONIC)
WINTER PACKAGE: Code 228

Stationary heater
Remote control (feedback and timer
incl. antenna)
Heated windshield washer system
Front seat heaters (except USA and
Japan)
Temperature-controlled cup holder Code 311
Comfort systems
MEMORY PACKAGE Code P64
Seat heaters for 1st seat row1 Code 873 Standard Code 873 Code 873
Seat heaters for 2nd seat row Code 872
1
Standard in USA and Japan

Equipment
Overview
4MATIC 4MATIC
Comfort systems
Seat climate control Code 401
Multifunction steering wheel in Standard

Nappa
Multifunction steering wheel in Code 289
Nappa leather/wood finish
Heated multifunction steering wheel Code 443

in Nappa leather
Through-loading feature over Code 282

armrest in rear
Automatic rear-end door (standard Code 890

in USA)
Telephone, audio and communications
Audio 20 (ECE only) Standard
Audio 20 with CD changer (ECE Code 510

only)
Preinstallation for Becker MapPilot Code 508
(ECE only)
COMAND Online (except USA) Standard in Japan

Code 527
COMAND (USA only) Standard

Code 528
COMAND Online with DVD changer Code 512

(except Japan)1
1
COMAND APS in USA

Equipment
Overview

4MATIC 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) Code 537

radio operation (ECE only)
Comfort telephony (ECE only) Code 386
USB interface in center console Standard
Miscellaneous
115 V socket (USA only) Code U80
Trailer hitch with electric release Code 550

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

Exterior
Overall vehicle
Front view Rear view
The front is dominated by a powerful radiator grille The harmonious rear end with newly designed two-
with central star in the style typical of the M-Class. The piece LED/fiber-optic rear lamps and the lowered roof
design of the engine hood fits harmoniously into the with large roof spoiler emphasize the width of the
overall picture and meets the increased requirements vehicle and give it the appearance of sitting securely
resulting from legislation on pedestrian protection. on the road. The bumper with integrated chrome-style
loading sill protector and new "wing design" shapes
The headlamps have a high-quality, exclusive and
the appearance of the rear of the SUV.
innovative appearance. The higher, generously propor-
tioned underbody protector in chrome design extends
up below the radiator grille to support the impressive
appearance of the vehicle.
P00.00-4738-00
Rear view (model series 166)

Exterior
Overall vehicle
Side view
The stretched linear design of the side view empha- Running boards with sturdy stainless steel inserts are
sizes the on-road nature of the vehicle, whose available optionally to give the vehicle a more "SUV-
compact proportions are underlined by a large wheel- style" appearance.
base and short overhangs. The C-pillar, which is char-
The rear side windows transition into the rear window
acteristic of this model series, follows the example of
without a visible column and, together with the wrap-
earlier generations of the M-Class and clearly differen-
around rear lamps, create a well-integrated design.
tiates the vehicle's styling from that of its competitors.
The roof line, which drops towards the rear end, under-
lines the sportiness of the new M-Class.
The high beltline with high-quality stainless steel trim
strip and the dynamic, rising character line create a
harmonious and coherent overall picture.
P00.00-4739-00
Side view (model series 166)

Exterior
Overall vehicle
Sliding roof, panoramic sliding sunroof
As previously, an electrically powered sliding roof in The external skin of the full-glass roof with top sliding
glass is available as special equipment. An automatic roof consists of three separate glass panels made of
reversing function increases the operating safety safety glass:
during closing.
• A fixed glass panel at the front
In addition, a top sliding roof in glass (full-glass roof) is • A moving glass panel in the middle
also available. This provides a continuous glass • A fixed glass panel at the rear
surface extending from the windshield to the C-pillar
The movable glass panel can be tilted electrically (tilt
with a trim strip on each side that blends with the all-
position), raised and moved back towards the rear of
glass look.
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
Panoramic sliding sunroof

Exterior
Overall vehicle
Aerodynamics Aeroacoustics
Compared with the predecessor model, model series
Aerodynamics is a development discipline of
166 features a highly noise-insulating acoustic wind-
increasing significance. It has a decisive influence on
shield and additional seals in the upper and side rear-
fuel consumption and noise-related comfort. Through
end door joints to further reduce wind noises.
the use of the latest development and test proce-
dures, the coefficient of drag (Cd value) of the new The newly developed outside mirror meets both of
M-Class has been further reduced. In this market these requirements. It has very low aerodynamic drag
segment, it is the most drag-reducing SUV in the and excellent aeroacoustics. In addition, the housing
world. has been designed so that rainwater flows to the
outside and drips off through a narrow channel around
The already excellent value of the predecessor model
the outside.
of down to 0.34 has been further reduced.
P88.70-2644-00
Outside mirror

Dimensions
Overall vehicle
P00.10-5071-00
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)
1 Vehicle without license plate adapter (5 mm)

Dimensions
Overall vehicle
P00.10-5072-00
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 Loaded ready to drive (EC) with driver of 68 kg, 7 kg luggage, tank 90% full
2 At permissible gross vehicle weight
3 Incl. license plate adapter (5 mm)
4 With trailer hitch (special equipment)

Technical data
Overall vehicle
Comparison of model series 164 against model series 166
Unit W 164 W 1661 Difference
Dimensions
Vehicle length mm 4781 4804 +23
Vehicle width mm 1911 1926 +15
Vehicle width mm 2170 2141 -29

(with outside mirrors folded out)
Vehicle height with detachable parts mm 1815 17882 -27
Vehicle height of bodyshell mm 1767 1759 -8
Wheelbase mm 2915 2915 0
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 0
Ramp angle ° 17 17 0
Coefficient of drag Cd 0.34 0.322 -0.02
1
Based on example of ML 250 CDI BLUETEC 4MATIC with steel suspension
2 Values depend on model, suspension and country variant

Technical data
Overall vehicle
Unit ML 350 ML 550 ML 250 CDI ML 350 CDI

4MATIC 4MATIC
Dimensions and weights
Curb weight (EC) kg 2130 —1 2150 2175
Permissible gross vehicle kg 29002 —1 2950 2950

weight 28503
Maximum payload (EC) kg 770 —1 800 775
Open cargo area volume l 1210

behind driver seat
Open cargo area volume l 690

behind rear seat
Maximum luggage compart- l 2010

ment volume behind driver
seat
Maximum luggage compart- l 1025

ment volume behind rear seat
Turning circle m 11.80
Fuel tank4 l 78 93 70 70
Including reserve l 10 12 11 11
Fuel tank4 with increased l 93 — 93 93

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

2
ECE
3
USA
4 93 liters standard in USA

Interior
Overall vehicle
Interior design
The interior has an impressive, coherent design which The following features, in particular, contribute to the
makes use of very fine materials and it has been high perceived quality of the cockpit:
crafted with great attention to detail. The emphasis on
• The sprayed polyurethane skin with dual-gloss
the wide appearance of the vehicle is continued in the
grained surface for the upper and lower section of
cockpit. The large central display is flanked by two air
the instrument panel and glove box lid. Compared
outlets. The controls for the air conditioning are
to the predecessor model series, this has a more
located underneath the head unit whose frame, like all
pleasant feel and greater resistance to dirt.
other trim pieces, features the new Silver Shadow
• The integrated hood of the instrument cluster (no
surface design.
joints)
The modern instrument cluster impresses with its • The invisible airbag flap
excellent legibility and high-quality appearance. • 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.
P68.10-4444-00
Instrument panel

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

Shown on model 166.023
A1 Instrument cluster A1e51 Brake system warning lamp
A1e1 Left turn signal indicator lamp A1e54 Coolant temperature warning lamp
A1e2 Right turn signal indicator lamp A1e58 Engine diagnosis indicator lamp
A1e3 High beam indicator lamp A1e59 DISTRONIC warning lamp (with (code 233)
A1e4 Fuel reserve warning lamp Distronic Plus)
A1e9 Seat belt warning lamp A1e66 Tire pressure monitor warning lamp (with code
A1e10 Parking brake indicator lamp (475) Tire pressure monitor (Premium))
A1e11 Parking brake warning lamp A1e67 Low beam indicator lamp
A1e15 Supplemental restraint system indicator lamp A1e75 Brake force distribution warning lamp
A1e16 Preglow indicator lamp (with diesel engine) A1p1 Coolant temperature gauge
A1e17 Antilock brake system indicator lamp A1p2 Fuel level indicator
A1e18 Rear fog light indicator lamp A1p5 Tachometer
A1e20 Regenerative braking system indicator lamp A1p8 Speedometer
A1e32 ESP®/ASR OFF warning lamp A1p12 Gear indicator
A1e41 Electronic Stability Program warning lamp A1p13 Multifunction display
A1p16 Transmission mode display

Interior
Overall vehicle
Center console
The new center console can optionally be equipped Pressing the button twice starts the warming process.
with temperature-controlled cup holders. These are This is indicated by illumination of a red LED. As of a
located under a roller blind which, together with the temperature of approx. T = 40 °C, the residual heat
controls of the center console and the comfortable indicator lamp indicates the elevated temperature to
armrest with integrated palm rest, forms a unit in front the vehicle occupants. Pressing the cup holder button
of/above the large stowage compartment. again stops the warming process.
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 differ-
ence 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.
P68.00-6827-00
Temperature-controlled cup holder (special
equipment)
R5/1 Cupholder
R5/1e1 Residual heat indicator lamp
R5/1 s1 Cupholder button

Interior
Overall vehicle
Seats
There are a total of 4 different seat cover variants The required high strength of the backrest is achieved
available (fabric, Artico, leather, Edition One/designo) through a sheet steel frame with sturdy connections
in up to 6 different color combinations. to the side seat fittings.
The driver and front passenger seats are equipped Pullmaflex supporting springs are secured in the
with electric seat adjustment as standard. This allows frame. These support the foam padding. There is a
electric adjustment of the seat height, backrest incli- luggage net on the rear of the backrest. A sidebag is
nation and cushion angle as well as the fore/aft posi- also integrated in the backrest under a seam at the
tion. The head restraint is manually adjustable, both side.
vertically and longitudinally. A memory package is
The rear seat cushions are made of solid foam. The
available optionally as special equipment.
seat cushion and backrest are split in the ratio 60:40.
The seat cushion shell, which is made of sheet steel The narrow part of the seat is behind the front
with supporting springs (sine springs), is connected to passenger seat. The wide part contains a folding
the seat adjustment fittings. There is a molded foam armrest with compartment and cup holder. The three
part over the supporting springs. The mechanical seat rear seats are each equipped with L-shaped head
components are covered by panels in the interior restraints with manual vertical adjustment. Backrest
equipment color. angle adjustment (comfort position) of the rear back-
rests is a new feature.
P91.00-2296-00
Seats

Interior
Overall vehicle
Storage and stowage compartments
In addition to the glove compartment, there are There is also large stowage compartment under the
4 stowage compartments in the center console. Both armrest, providing for a wide range of stowage
in the front area below the A/C operating unit and in options.
the rear area in front of the second seat row there is
Additional beverage holders are located in the armrest
either a stowage compartment or, optionally, an
of the second seat row. There are nets on the rear of
ashtray.
both front seats.
Furthermore, there is a roller blind compartment in
Extra stowage compartments can be found in the load
front of the armrest next to the hand rest which
compartment, depending on the equipment of the
optionally serves as a temperature-controlled
vehicle. There is also stowage space under the remov-
beverage holder.
able load compartment floor.
P68.00-6826-00
Overview of stowage areas and compartments

1 Glove compartment 8 Net on rear panel
2 Front center console stowage compartment 9 Cup holder in second seat row
(SA: smoker package) 10 Net
3 Center console center stowage compartment 11 Stowage box (depending on equipment installed)
(SA: cup holder) 12 Load compartment
4 Center console stowage compartment (front armrest) 13 Spare wheel well (depending on equipment installed)
5 Rear center console stowage compartment 14 Lockable loading floor handle/laptop compartment
(SA: smoker package) (depending on equipment installed)
6 Net in front passenger footwell
7 Door pockets

Interior
Overall vehicle
Load compartment
The passenger compartment and load compartment A luggage compartment cover, twin roller blinds
are separated by a rear bench seat with a 60:40 split, behind the 2nd seat row and a cargo strap rail are
whose seat cushions can be raised vertically towards available as special equipment. Four anchoring lugs
the front and backrests can be folded down towards on the loading floor and a folding bag hook are
the front. This provides simple operation, a flat loading installed as standard. In contrast to other model
floor and a low loading height. series, the net of the twin roller blinds cannot be used
behind the first seat row. If necessary, this net can be
With a load compartment depth of 1046 mm, at least
retrofitted through Mercedes-Benz Accessories.
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.
P68.80-2098-00
Trunk, 2nd seat row folded down completely

Interior
Overall vehicle
Cargo area variants as per VDA DIN 70020
Open cargo area

Loaded up to top edge of rear backrest
Volume: 690 liters1
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
1
P00.00-4740-00 Upright backrest position
Cargo area variants

ASSYST PLUS
Maintenance
New technical features Use of NAT2 FE+
The M-Class is based on the tried-and-tested tech- Due to development of the NAT2 transmission and the
nology of the predecessor model. increased durability of the new fluid, the fluid and filter
change intervals have changed from a one-off change
Technical innovations include the maintenance-free
at 60,000 km (old) to every 125,000 km/5 years
electromechanical steering and external AdBlue®
(new).
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-and- P27.00-2345-00
tested extended maintenance strategy is also used for NAT2 Fuel Economy Plus
model series W 166. Both workshops and the
customer will benefit from the extended maintenance
scopes from the very first kilometer driven.
PLUS package
By making maintenance less complicated and intro-
ducing the basic service which covers the technically The service advisor must offer the PLUS package to
essential items, we are able to offer maintenance that the customer during a consultation because it is no
is more cost-efficient and competitive without longer included in the conventional maintenance
compromising the usual Mercedes-Benz service scopes.
quality.
The aim of this consultation is to offer the customer
As with the current model series, there is a basic the package best suited to him or her.
service and a supplementary PLUS package.

ASSYST PLUS
Maintenance
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.
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 equip-
ment.
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
Display on multifunction display (shown for ECE)
All service, body and major assembly operations are Workshop code
documented in a central database using the Digital
Service Booklet (DSB) aftersales system. The cus-
tomer receives a service report which he/she stores
in the service booklet as evidence of the service.
The Digital Service Booklet is available for Europe, the
Middle East, North Africa and Russia.
P00.01-4190-00
Display of Digital Service Booklet

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

Engine data for diesel engines
Drive
Unit ML 250 CDI BLUETEC ML 350 CDI BLUETEC
4MATIC 4MATIC
Engine data 651.960 642.826
Engine designation OM 651 DE22 LA OM 642 DE30 LS
Engine configuration/no. of cylinders Inline 4 V6
Displacement cm3 2143 2987
Bore mm 83.0 72.0
Stroke mm 92.0 92.0
Fuel Diesel
Performance
Acceleration 0 ... 100 km/h s 9.0 7.4
Maximum speed km/h 210 224
Fuel economy/CO2 emissions
Fuel economy, overall (NEDC) l/100 km 6.0-6.5 6.8-7.4
CO2 emissions g/km 158-170 179-194
Exhaust emission standard ECE/USA Standard EU 6/BIN 5 EU 6/BIN 5

Gasoline engines M 276 and M 278
Drive
In model series W 166, the newly developed V6/V8

engine family of M 276/M 278 engines is being used i Note
as of the market launch in 2011. This replaces the Introduction into Service Manual "Introduction of
previous V6/V8 engine family of M 272/M 273 the New 6 and 8-Cylinder V-Engine Generation
engines. M 276/M 278" is available for the new V-engines.
The 6-cylinder M 276 engine is used in the
ML 350 4MATIC. The 8-cylinder M 278 engine is Order No. 6516 1379 02
installed in the ML 550 4MATIC (USA and Russia only).
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%.
P01.10-3076-00
M 276 DE 35 and M 278 DE 46 LA

Gasoline engines M 276 and M 278
Drive
Unit ML 350 4MATIC ML 550 4MATIC
Engine data M 276 DE 35 M 278 DE 46 LA
Rated output kW 225 300

at engine speed rpm 6500 5000-5750
Rated torque Nm 370 600

at engine speed rpm 3500-5250 1600-4750
Compression ratio ε 12.2 10.5
P01.00-3307-00 P01.00-3308-00
Performance graph M 276.955 Performance graph M 278.928
M Torque
P Power output
n Rpm

Diesel engines OM 651 and OM 642
Drive
OM 651 OM 642
There are numerous new technical features and de- The most important new technical features of the
velopments in the OM 651 diesel engine installed in 6-cylinder OM 642 diesel engine offered in the ML 350
the ML 250 CDI BLUETEC 4MATIC, which improve, for CDI BLUETEC 4MATIC include:
example, the specific consumption as well as emission
• Increased power and torque
and noise-related characteristics.
• Further developed cylinder head
The most important technical features include: • Reduced compression ratio in combination with an
optimized, roller bearing-mounted turbocharger
• Common Rail technology of the 4th generation
• Friction-optimized crank assembly with TWAS
with an injection pressure of up to 1800 bar
(twin-wire-arc-sprayed) cylinder barrel coatings
• NVH optimization (Noise-Vibration-Harshness)
(ECE)
• Compact design through rear camshaft drive
• ECO start/stop function (ECE)
• Lanchester balancer
• Regulated oil pump
• Dual-stage turbocharger without variable turbine
• Friction-optimized vacuum pump
geometry
• Switchable water pump
• ECO start/stop function (ECE)
• Improved EGR cooling path with switchable bypass
• Compliance with EU 6 and BIN 5 emissions
• Ceramic glow system
standards
• Modified air ducting
• Compliance with EU 6 and BIN 5 emissions
standards
P01.10-3077-00
OM 651 DE22 LA and OM 642 DE30 LS

Diesel engines OM 651 and OM 642
Drive
Unit ML 250 CDI BLUETEC ML 350 CDI BLUETEC
4MATIC 4MATIC
Engine data OM 651 DE22 LA OM 642 DE30 LS
Rated output kW 150 1901/1792

at engine speed rpm 4200 3600
Rated torque Nm 500 6201/6172

at engine speed rpm 1600-1800 1600-2400
Compression ratio ε 16.2 15.5
1
ECE
2
USA
P01.00-3309-00 P01.00-3310-00
Performance graph M 651.960 Performance graph M 642.826 (ECE)
M Torque
P Power output
n Rpm

Engine mounts
Drive
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 P22.10-2378-00
Engine mount design
hydraulic system builds up the dampening effect.
1 Flange
The operating conditions are switched depending on 2 Seal bellows
the rpm, torque and vehicle speed. 3 Diaphragm
4 Check ball
5 Buffer stop
6 Protective cap
7 Hub
8 Retaining ring
9 Cover
10 Bore
11 Solenoid
P22.10-2377-00
Integral carrier from front

Y123 Left switchable engine mount A Integral carrier
Y123/1 Right switchable engine mount B Electrical connector

Engine cooling
Drive
General Adjustable radiator shutters
All gasoline and diesel engines of the new M-Class The models with engine variants M 276, OM 651 and
come with a cooling module with cross-flow radiator, OM 642 are equipped with adjustable radiator shut-
a transmission oil heat exchanger, a condenser with ters in combination with a 600 W radiator fan. This
attached refrigerant accumulator and drier and a allows the air flow through the cooling module of the
continuously variable fan motor. engine and through the engine compartment to be
regulated. On vehicles with diesel engine and with the
The cooling equipment on the CDI engines also
trailer hitch special equipment option, radiator shut-
includes a charge air cooler. This is located ahead of
ters are not installed.
the condenser above the crossmember and attached
to the front end module. Shutters consisting of a number of slats are arranged
in a circular shape between the radiator and fan.
On the V8 engine, charge air cooling is carried out via
These slats can be turned jointly by an actuator
a low-temperature circuit. As with the charge air
attached to the cooling module and they influence the
cooler on the CDI engines, the low-temperature cooler
flow path of the cooling air.
is attached to the front end module.
One of the most important advantages of adjustable
The cooling requirements are met by a varying number
radiator shutters currently is the positive effect they
of radiator fins and different fan motors with powers of
have on the aerodynamics of the vehicle at elevated
400 W and 850 W.
vehicle speeds, which in turn makes a reduction in fuel
The electric control unit for the fan motor is integrated consumption possible as well as emissions improve-
into the electric motor on all variants. ments.
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 inte- i Note
grated in the front end module. All components of the The radiator shutters are not installed on vehicles
cooling module are connected to each other with clips with diesel engine if they are fitted with a trailer
and quick couplings to allow for easy assembly and hitch.
service access.
P20.20-2414-00
Radiator shutters
Y84 Radiator shutters actuator

Exhaust system
Drive
Gasoline engines
The catalytic converter system of the ML 350 4MATIC On the M 276, the connecting points are located
(M 276) and ML 550 4MATIC (M 278) consists of a directly ahead of the center mufflers. The M 276 DES
firewall and a NOx storage catalytic converter also has a service connecting point between the fire-
(M 276 DES) for both the left and right cylinder banks. wall and NOx storage catalytic converters. In the event
of a repair, it is also possible to make connecting
The muffler system consists of two center mufflers
points ahead of the rear muffler so that the center and
each with 5.3 liter volume (M 276), or a center muffler
rear mufflers can be replaced separately.
of approx. 12 liter volume (M 278) and a transverse-
mounted rear muffler at the rear end of the vehicle The tailpipes are located behind the bumper in a non-
with a volume of approx. 33 liters. The center and rear visible area.
mufflers consist of a combination of absorption and
reflection chambers.
The connecting points of the exhaust system of the
M 278 are located directly ahead of the firewall cata-
lytic converters and the center muffler.
P49.00-2150-00
Gasoline engine exhaust system (M 276 DES)

Exhaust system
Drive
Diesel engines
The catalytic converter system of the 4 and 6-cylinder The connecting points of the exhaust system are
diesel engines (OM 651/OM 642) consists of an located directly ahead of the oxidation catalytic
oxidation catalytic converter, a diesel particulate filter converter in the area of the firewall and ahead of the
and an SCR catalytic converter. The muffler system SCR catalytic converter in the underfloor. In the event
consists of just one rear muffler of approx. 15 liters of repair, it is possible to subsequently make a
volume in the vehicle rear with two reflection cham- connecting point ahead of the rear muffler so that the
bers. SCR catalytic converter and rear muffler can be
replaced separately.
In order to meter the AdBlue® urea solution into the
SCR catalytic converter, an injection nozzle specially As of the connecting point ahead of the oxidation cata-
designed for the AdBlue® urea solution is attached to lytic converter, the exhaust system of the OM 651 and
the exhaust pipe directly after the DPF. 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 non-
visible area behind the bumper.
P49.10-2961-00
Diesel engine exhaust system (OM 651)

1 Pressure lines N37/7 NOx control unit sensor downstream of diesel
B16/15 Temperature sensor upstream of SCR catalytic particulate filter
converter N37/7b1 NOx sensor downstream of diesel particulate fil-
B19/7 Temperature sensor upstream of catalytic con- ter
verter N37/8 NOx control unit sensor downstream of SCR
B19/9 Temperature sensor upstream of diesel particu- catalytic converter
late filter N37/8b1 NOx sensor downstream of SCR catalytic con-
B28/8 Diesel particulate filter differential pressure verter
sensor Y129 AdBlue® metering valve
G3/2 Oxygen sensor upstream of catalytic converter

Fuel system
Drive
Gasoline engines
The electronically commutated gasoline fuel pump is Via the high-pressure pumps, the fuel pressure is
actuated via a fuel tank control unit. The fuel tank brought up to the pressure required for spray-guided
control unit regulates the fuel pump based on the fuel direct injection (up to 200 bar depending on the oper-
pressure specifications from the engine control unit. ating condition) and the fuel is fed into the rails via the
high-pressure line where it is stored.
Via the low-pressure circuit (4.0-6.7 bar), the fuel
moves from the tank and through the fuel filter to the The fuel pressure and temperature sensor registers
high-pressure pump (M 276) or to the two high-pres- the current fuel high pressure (rail pressure) and the
sure pumps (M 278). fuel temperature in the left rail (M 276) or in the right
rail (M 278). The rail pressure is regulated by the
In the high-pressure circuit, the high-pressure pumps
ME-SFI [ME] (motor electronics) control unit, which
are protected by pressure relief valves and each have
actuates the quantity control valves on the high-pres-
one quantity control valve. This regulates the quantity
sure pumps with a PWM signal until the specified pres-
of fuel fed to the pump element depending on the
sure is obtained in the rail.
specified fuel pressure.
The fuel injectors in each cylinder bank are supplied
with fuel directly from the corresponding rail.
P47.00-2205-00
Fuel system in ML 350 4MATIC

Fuel system
Drive
Diesel engines Fuel preheating
The diesel fuel pump is actuated by a fuel tank control In order to ensure the flowability of the fuel at low out-
unit. The fuel tank control unit regulates the fuel pump side temperatures, a condensation sensor with heat-
based on the fuel pressure specifications from the ing element is integrated in the fuel filter to monitor
engine control unit. the water level.
The fuel reaches the high-pressure pump from the The heating element is energized by the glow output
tank via the low-pressure circuit. When actuated, the stage and warms up the fuel in the fuel filter. The
fuel pump draws the fuel out of the fuel feed module current condensation level is transmitted to the CDI
and pumps it through the fuel filter to the high-pres- control unit via the condensation sensor in the fuel
sure pump. Depending on the fuel requirements, the filter. As of a condensation level of approx. 100 ml,
fuel pressure is regulated to approx. 3.0-5.0 bar. the CDI control unit transmits a message to the instru-
ment cluster, which displays this on the multifunction
In the high-pressure fuel circuit, the fuel is pumped
display as a warning message.
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 quan-
tity 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.
The fuel reaches the fuel injectors from the respective
rail via the high-pressure lines. Based on a perfor-
mance 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.

Fuel system
Drive
Fuel tank
i Note
The newly developed, blown fuel tank made of High- As soon as the AdBlue® supply drops to a mini-
Density Polyethylene (HDPE) with multi-layered walls mum level, a message is shown on the multifunc-
is located ahead of the rear axle under the rear bench tion display and the driver is prompted to visit a
seat. This means that the opening between the load workshop.
compartment and passenger compartment remains
as large as possible when the rear seat backrest is If the reservoir is empty, this is shown by an indi-
folded down. cator on the multifunction display. From this point
onwards, the engine can only be started a
The Flexible Fuel special equipment option offered in maximum of 16 times. After this, the engine can
the USA includes a separate fuel tank variant with no longer be started again.
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 i Note
the AdBlue® additive (urea) is located on the fuel tank.
More information about BLUETEC can be found in
the system description "BlueTEC exhaust after-
treatment with AdBlue®".
Order no.: 6516 1378 02
P47.10-2605-00
View of diesel engine fuel tank with AdBlue® reservoir

1 AdBlue® reservoir

Fuel system
Drive
Ventilation
On vehicles with gasoline engine, the fuel tank is venti- On USA vehicles, the vent opening of the container for
lated via three roll-over valves as well as a refueling, the activated charcoal filter is sealed by a solenoid
limiting and vent valve on the tank shell. This ventila- valve. This allows the tank system to be checked for
tion system is combined with an activated charcoal leaks by means of a pressure test.
filter located in the right rear wheel well. The stored
The diesel tank system is equipped with a simplified
hydrocarbons are fed from the activated charcoal filter
ventilation system.
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.
P47.10-2606-00
View of gasoline engine fuel tank (USA version)

45 Fuel filler neck 77 Activated charcoal filter
55 Fuel feed module B4/1 Fuel level indicator sensor, left
55/2a Fuel filter B4/2 Fuel level indicator sensor, right
55/2b Overflow valve B4/3 Fuel tank pressure sensor
75 Fuel tank B4/7 Fuel pressure sensor
75/1 Refueling, limiting and vent valve B4/31 Fuel quality sensor
75/2 Bidirectional vent valve M3 Fuel pump
Y58/4 Activated charcoal filter shutoff valve

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

Plus automatic transmission.
With the combustion engine running, the primary
The 7G-Tronic Plus has been optimized with modifica- pump delivers oil to the electrohydraulically actuated
tions to the torque converter and main transmission. automatic transmission. The oil pump is driven via the
This is why the transmission is called 7G-Tronic Plus. drive flange of the torque converter. It is installed in
the transmission bell housing behind the torque
It features a new generation of torque converter which
converter.
offers improved dynamic response characteristics
combined with reduced fuel consumption. Oil supply for automatic transmission with
stopped internal combustion engine (with ECO
The consumption-reducing measures include a reduc-
start/stop function)
tion in drag through a new bearing on the oil pump,
improved Torlon rings on the input and output shafts When the combustion engine is shut off in ECO start/
as well as a new automatic transmission fluid stop mode, oil is no longer supplied by the primary
(FE-ATF). pump as the combustion engine is stationary. With
this, all the control elements and actuators change to
The color of the new fluid has been changed from red
a basic state under no load and the automatic trans-
to blue because it may not be used in older transmis-
mission power flow stops.
sions. The notes in service information
SI00.40-P-0014A in WIS on usage of the new trans- The electric transmission oil pump is actuated via the
mission fluid must be observed. transmission oil auxiliary pump control unit when the
combustion engine is switched on and off. When the
The oil change intervals have been extended because
internal combustion engine is switched off, the elec-
the transmission fluid is subjected to less energy due
tric transmission oil pump takes over the oil supply of
to the minimization of drag. For more information, see
the control elements and actuators of the automatic
the corresponding documents in WIS.
transmission. In addition, it minimizes the time loss
between the start-off request and actual start-off time.

7G-Tronic Plus transmission
Transmission
Technical data Unit ML 350 ML 550 ML 250 CDI ML 350 CDI
4MATIC 4MATIC
Transmission model 722.906 722.909 722.908 722.903
Transmission version W7C700
Number of gears 7+R
Weight (including torque kg 111 118 119 120

converter, transmission fluid
and transfer case)
Overall length including mm 925-993

transfer case1
Max. input torque Nm 700
1
Depending on equipment without/with ON & OFFROAD package SA
P27.10-2391-00
Sectional view of 7-speed automatic transmission W7C700

Transfer case
Transmission
Transfer case, general information
The standard version consists of permanent all-wheel This activates a modified, flatter accelerator pedal
drive with three open differentials (transfer case, rear curve. In addition, the ABS, ETS and ESP control
and front axle). The torque split of 50:50 between the systems are adjusted for off-road driving and a modi-
front axle and rear axle is specified as a fixed value in fied shift characteristic of the transmission mode is
the transfer case. The gear ratio of the transfer case is selected.
1:1.
Downhill Speed Regulation is switched on and off via
The driver can activate the off-road function via the the Downhill Speed Regulation button. The Downhill
off-road program button (except USA and ML 250 CDI Speed Regulation button is located in the lower
BLUETEC) located in the lower control panel. control panel. On the ML 250 CDI BLUETEC, the auto-
matic transmission mode button replaces the off-road
program button.
Sectional view of transfer case

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

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

A1 Instrument cluster N49 Steering angle sensor
A1e41 Electronic Stability Program warning lamp N51/3 AIRMATIC control unit (with code (489)
A1e58 Engine diagnosis indicator lamp Airmatic (air suspension with level adjustment
A1p13 Multifunction display and adaptive damping system (ADS))
A7/3 Traction system hydraulic unit N72 Lower control panel control unit
A80 Intelligent servo module for DIRECT SELECT N72/3 Off-road control panel control unit (with code
B37 Accelerator pedal sensor (430) On&off-road package)
L6/1 Left front axle rpm sensor N73 Electronic ignition lock control unit
L6/2 Right front axle rpm sensor N80 Steering column tube module control unit
L6/3 Left rear axle rpm sensor S9/1 Brake light switch
L6/4 Right rear axle rpm sensor S16/13 DIRECT SELECT lever
N3/9 CDI control unit S40 Cruise control lever (with code (494) USA
N3/10 ME-SFI [ME] control unit version)
N10 SAM control unit S40/4 Cruise control lever (except code (494) USA
N15/7 Transfer case control unit (with code (430) version)
On&off-road package) S110 Left multifunction steering wheel button group
N28/1 Trailer recognition control unit (with code (550) S111 Right multifunction steering wheel button group
Trailer hitch) Y3/8n4 Fully integrated transmission control unit
N30/4 Electronic Stability Program control unit X11/4 Diagnostic connector

Axles
Chassis
Front axle
The principle of a double wishbone axle designed with The integral carrier is a welded structure consisting of
high-mounted upper wishbones (high position of the sheet steel parts and IHU (hydroformed) tubes and is
top wishbone control arm) has been selected as the specially designed to meet the high requirements in
front suspension. terms of crash resistance and operational durability.
In view of the special range of usage of the vehicle, The two transverse control arms and steering
this axle with high-mounted upper wishbones in knuckles are weight-optimized forged aluminum parts.
combination with the integral carrier provides the The wheel bearing unit is bolted to the steering
optimal set-up for good off-road capability, good knuckle. The tie rod is made of forged steel. The stabi-
driving comfort and good vehicle dynamics. lizer bar is attached to the steering knuckle via a
linkage. At the stabilizer bar end, the linkage is
The front axle transmission and engine are mounted
equipped with a rubber bushing for improved comfort.
on the integral carrier via special rubber bushings. The
steering gear is rigidly fixed to the integral carrier The electrically assisted rack-and-pinion steering gear
which, in turn, is decoupled from the body via four installed ahead of the wheel center provides self-
rubber bushings. This minimizes the transmission of steering behavior with an intentional understeering
vibrations via the front axle and drivetrain to the body. tendency when cornering forces act upon the vehicle.
P33.35-2013-00
Front axle (with air suspension) Offroad (special equipment)

Axles
Chassis
Rear axle
The rear axle is designed as a four-link axle. Its compo- Coil springs and shock absorbers are positioned one
nents include: behind the other in the direction of travel.
• Wishbone control arms made of cast aluminum The rear axle carrier is a welded sheet steel structure.
• Upper control arm plane with camber strut (formed It is connected to the body at the front via high-damp-
sheet steel component) and tension/compression ening hydro-mounts and at the rear via conventional
rod (forged steel) rubber bushings. The rear axle differential is
• Tie rod behind wheel center (welded tube supported flexibly on the rear axle carrier via 3 rubber
structure) bushings.
P35.00-2102-00
Rear axle (with air suspension) (special equipment)

Suspension
Chassis
Suspension systems Air suspension with adjustment damping

(AIRMATIC)
The basic equipment includes conventional steel
suspension which, compared to the predecessor On the two optional air suspension variants, there is a
model series, is tuned for more comfort and better difference in both the number and magnitude of the
vehicle dynamics. With the use of a selective damping height levels which can be set at the touch of a button
system as standard, the shock absorber hardness is or automatically. Another variable which influences
varied depending on the vehicle speed. Available as level control is the ADS switch position set by the
special equipment is an air suspension system with driver. The ADS switch positions "Sport" and
all-round level control and adaptive damping system "Comfort" (button designation "COMF") are available
(ADS) (AIRMATIC package). This is, in particular, and these set different switching thresholds between
intended to allow customers to increase the ground the four ADS operating stages/damper characteris-
clearance of the vehicle in particularly rough off-road tics.
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.
P32.00-2063-00
Suspension (with air suspension) (special equipment)

ON&OFFROAD package
Chassis
A permanent all-wheel drive system with one lockable It is possible to select 6 predefined transmission
differential (transfer case) and two open differentials modes with specific settings for the suspension (level
(front axle and rear axle) is used in the ON&OFFROAD and damping characteristics), drivetrain (transmission
package special equipment. Other components of the shifting program, accelerator pedal characteristics
package include a reinforced underride guard, a trans- and ESP function) and steering.
mission mode switch, a switch for a manual shift
The transmission modes provide the optimal settings
program, an engageable cross-country reduction
for the applicable driving situation:
setting (Low Range), air suspension with advanced
level control and an adaptive traction system (4ETS). • Automatic mode "AUTO" as the standard program
• "Offroad 1", for light-duty off-road situations: dirt
The torque split of 50:50 between the front axle and
roads, gravel, sand
rear axle is specified as a fixed value in the transfer
• "Offroad 2", for heavy-duty of-road situations:
case. Via the Low Range button, which is located in
steep inclines, rocks, axle articulation
the lower control panel, the driver can switch the gear
• "Sport", for handling-oriented roads, provides
ratio in the transfer case between the on-road ratio
optimal vehicle dynamics
"High" (gear ratio 1:1) and the cross-country reduction
• "Snow", for snowy roads, driving stability when
ratio "Low" (gear ratio 2.93:1).
cornering, traction-oriented for straight-ahead
The differential lock in the transfer case can be actu- travel (snow chain operation)
ated via the off-road package transmission mode • "Trailer", for downhill driving with a trailer, starting
controller. Selection of the programs is displayed in off and maneuvering with a heavy trailer
the off-road menu of the head unit.
Sectional view of transfer case

(ON&OFFROAD package)
1 Interaxle differential lock disk pack
2 Input shaft
3 Front differential side gear
4 Differential pinion
5 Rear axle output flange
6 Front axle output flange
7 Ring gear
8 Planetary gear
B57 Transfer case absolute sensor
M46/2 Transfer case actuator motor
P28.10-2280-00

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

1 Transfer case 6 Right rear axle shaft
2 Vibration damper 7 Front axle propeller shaft
3 Rear axle propeller shaft 8 Front axle transmission
4 Rear axle differential 9 Left front axle shaft
5 Left rear axle shaft 10 Right front axle shaft
ON&OFFROAD package controls in center console

N72 Lower control panel control unit
N72s30 Downhill Speed Regulation button
N72s31 Low Range button
N72s37 Transmission mode "M" button
N72s39 Vehicle level rotary switch
N72s42 On-road/off-road menu button
N72/3 Off-road control panel control unit
N72/3s1 Off-road package transmission mode controller
P54.21-3246-00

ON&OFFROAD package
Chassis
Vehicle levels with ON&OFFROAD package special equipment
Level designation Level [mm] v [km/h] Remarks
Fast driving level -45 v > 70 At v < 70 km/h and t = 20 s

v > 40 At v < 40 km/h and t = 0 s
raise to -30 mm
Basic/normal level -30 v < 120 At v > 120 km/h and t = 20 s

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

lower to -30 mm
Offroad 2 +30 v < 65 At v > 65 km/h and t = 20 s

v < 80 At v > 80 km/h and t = 0 s
lower to 0 mm
Offroad 3 +60 v < 20 At v > 20 km/h

lower to +30 mm
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 At v < 70 km/h and t = 20 s

v > 40 At v < 40 km/h and t = 0 s
raise to -30 mm
Basic/normal level -30 v < 120 At v > 120 km/h and t = 20 s

v < 140 At v > 140 km/h and t = 0 s
lower to -45 mm
Offroad 1 +30 v < 65 At v > 65 km/h and t = 20 s

v < 80 At v > 80 km/h and t = 0 s
lower to -30 mm

Steering
Chassis
Electric power steering Steering column
The M-Class is equipped with an electromechanically The M-Class is equipped with a manual longitudinally
assisted steering gear as standard. In addition to the and vertically adjustable steering column as standard.
speed-dependent steering force assistance as Optionally available as special equipment is an electric
provided on previous models, a further significant longitudinal and vertically adjustable version with Easy
improvement in steering comfort has been achieved Entry function, which is included in the memory
over the entire vehicle speed range. Other advantages package SA.
compared to hydraulic power steering are:
The adjustment travel distances for the manual and
• Fuel saving potential electric steering column versions are +/- 25 mm verti-
• Compact design cally and 25 mm forward and 35 mm back horizon-
• Assisted steering return tally, measured from the basic position of the steering
• Diagnosis capability wheel.
• No power steering fluid required
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.
P46.00-2170-00
Steering (with steering column tube and front axle)

ACTIVE CURVE SYSTEM
Chassis
ACTIVE CURVE SYSTEM
The ACTIVE CURVE SYSTEM is available as special The ACTIVE CURVE SYSTEM is deactivated with the
equipment and increases and improves ride comfort vehicle at a standstill and at a vehicle speed
and vehicle dynamics through the following system v < 5 km/h, all valves are deenergized. No active
features. torque interventions are applied.
• Improved suspension comfort when driving A vehicle on a lean (e.g. single-sided load, vehicle on
straight ahead with excitation on alternating sides curb) thus does not cause any roll pressure even
• Increased driving safety through forgiving lane- though the ACTIVE CURVE SYSTEM lateral accelera-
change behavior up to vehicle maximum speed tion sensor supplies a signal.
• Roll stabilization during cornering and active wheel
As of a vehicle speed v = 5 km/h, the ACTIVE CURVE
load distribution
SYSTEM is started and becomes fully active as of a
• Increased responsiveness with significantly
vehicle speed of 20 km/h.
reduced steering angle requirement
• Improved torsional flexibility off-road (axle articu- If a system fault is detected, an entry is made in the
lation) fault memory of the ACTIVE CURVE SYSTEM control
• Improved sensing of individual obstacles unit. A corresponding message appears on the multi-
function display of the instrument cluster at the same
On vehicles with the ACTIVE CURVE SYSTEM, the
time. The ACTIVE CURVE SYSTEM safety valve is no
passive torsion stabilizer bars (front and rear axle) are
longer energized and is closed. The hydraulic fluid in
replaced by two torsion stabilizer bars which allow
the front axle stabilizer bar hydraulic rotary actuator is
active intervention. Active intervention is made
confined here and locks up the actuator. The active
possible by the use of two hydraulic rotary actuators.
torsion bar on the front axle then acts as a passive
The ACTIVE CURVE SYSTEM control unit regulates the torsion bar. At the same time, the flow of the pump is
hydraulic pressure in the respective rotary actuator diverted directly and unpressurized towards the fluid
based on a characteristics map. reservoir. The rear axle stabilizer bar hydraulic rotary
actuator remains open. This produces safe vehicle
The most important input variable is the lateral accel-
handling characteristics tending towards understeer.
eration of the vehicle. This is measured, on the one
hand, by the ACTIVE CURVE SYSTEM lateral accelera-
tion sensor and, on the other hand, is computed by the
ACTIVE CURVE SYSTEM control unit.

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

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

Brake system
Chassis
Brakes
Model series W 166 uses a hydraulic dual-circuit Brake booster

brake system with a brake circuit each for the front
The brake booster consists of an aluminum 20.3 cm/
and rear axle and the ADAPTIVE BRAKE brake control
22.9 cm (8"/9") tandem vacuum-powered brake
function as standard.
booster which covers the entire model range. The
The system takes into account the vehicle-specific diameter of the master brake cylinder measures
circumstances such as 4x4 drive with on-road and off- 28.57 mm.
road operation, axle load distribution, weight and
Electric parking brake
driving performance.
As on model series 172 and 218, the parking brake is
Sports brakes are available as a component of the
electrically operated.
AMG exterior sport package special equipment
option. These include perforated brake disks on the It makes use of a combined floating brake caliper with
front and rear axle with brake caliper trim panels with electric parking brake function.
the label "Mercedes-Benz".
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 dimen-
sions). 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.
P42.00-2159-00
Front brake system

Brake system
Chassis
Technical data Unit ML 350 ML 550 ML 250 CDI ML 350 CDI

4MATIC 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 In contrast to the predecessor model series, it is
additional brake pads are installed for the electric no longer necessary to connect a diagnostic tester
parking brake. in order to change the pads.
See WIS for detailed information.

Wheels and tires
Chassis
Front light alloy Front tires Rear light alloy Rear tires
wheel wheel
Code 25R/R24 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 9J x 20 ET57 265/45 R 20 9J x 20 ET57 265/45 R 20

(AMG)
Code 757 9J x 21 ET53 265/40x R 21 9J x 21 ET53 265/40 R 21
P40.10-6081-00 P40.10-6082-00
Code 25R Code R24 (Aero wheel)
P40.10-6083-00 P40.10-6084-00
Code R41 Code 03R

Wheels and tires
Chassis
P40.10-6085-00 P40.10-6086-00
Code R55 Code R53
P40.10-6087-00 P40.10-6088-00
Code R39 Code 780
P40.10-6089-00 P40.10-6090-00
Code R33 Code 758
P40.10-6091-00 P40.10-6095-00
Code 757 Code 50R

Overall network in model series W 166
Interior CAN Drivetrain sensor CAN Diagnostic CAN

Chassis CAN Sensor CAN MOST
Drivetrain CAN Vehicle dynamics CAN Telematics CAN
Introduction of the New M-Class, Model Series 166 n
Overall network
P00.19-5095-00
65
Networking
Networking
66
Interior CAN Interior CAN Chassis CAN 1 Chassis CAN 2
1 Instrument cluster 12 Driver seat control unit 21 Electronic ignition lock control 1 Instrument cluster
2 Radio 13 Front passenger seat control unit 6 Reversing camera
3 Stationary heater control unit unit 23 Left front reversible emergency 21 Electronic ignition lock control
4 COMAND controller unit 14 Left front door control unit tensioning retractor unit
5 Panoramic sliding sunroof 15 Right front door control unit 24 Right front reversible emergency 34 Multifunction camera
control module 16 Left rear door control unit tensioning retractor 35 Parking system control unit
7 SAM control unit 17 Right rear door control unit 25 Left rear bumper intelligent 36 Electrical power steering control
8 Rear control unit 18 KEYLESS-GO control unit radar sensor unit
Overall network
9 Automatic air conditioning 19 Sliding roof control unit 26 Right rear bumper intelligent 38 Tire pressure monitor control
control and operating unit 20 Rear control panel control unit radar sensor unit
10 ATA/tow-away protection/ 21 Electronic ignition lock control 27 Supplemental restraint system 70 Headlamp control unit
interior protection control unit unit control unit 71 Night View Assist control unit
11 Trailer recognition control unit 22 Liftgate 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
n Introduction of the New M-Class, Model Series 166

Telematics CAN
control unit
33 Electric parking brake control 2 Radio
unit 4 COMAND controller unit
37 Steering column tube module 39 Cradle for navigation module
control unit 40 DVD player
68 ACTIVE CURVE SYSTEM control 41 Left rear display
unit 42 Right rear display
43 Audio/COMAND display
44 Audio/COMAND control panel
45 TV tuner
46 Digital TV tuner
69 Navigation module
Drivetrain CAN Drivetrain sensor CAN MOST i Note
28 CDI control unit (with diesel 28 CDI control unit (with diesel 2 Radio The overall network shows all the
engine) engine) 4 COMAND controller unit control units that can be installed
29 ME-SFI [ME] control unit (with 29 ME-SFI [ME] control unit (with 45 TV tuner
gasoline engine) gasoline engine) 46 Digital TV tuner
at the time of the market launch
47 Intelligent servo module for 52 Left NOx sensor control unit (M 60 Sound system amplifier control and their locations in the vehicle.
DIRECT SELECT 276.9, with stratified operation) unit The vehicle illustrated is fictional
48 Transfer case control unit 53 Right NOx sensor control unit (M 61 Digital Audio Broadcasting as it shows the control units of all
49 Transmission oil auxiliary pump 276.9, with stratified operation) control unit engine variants in the vehicle at
control unit 54 NOx sensor control unit 62 Satellite Digital Audio Radio the same time.
50 Fuel system control unit downstream of diesel particulate control unit
51 Fully integrated transmission filter 63 Media interface control unit
control unit 55 NOx sensor control unit
downstream of SCR catalytic
converter
56 AdBlue® control unit
Diagnostic CAN Vehicle dynamics CAN Sensor CAN

21 Electronic ignition lock control 30 Electronic Stability Program 32 Video and radar sensor system
unit control unit control unit
59 Emergency call system control 32 Video and radar sensor system 64 Left front bumper DISTRONIC
unit control unit sensor
57 DISTRONIC electric controller 65 Right front bumper DISTRONIC
unit sensor
58 Yaw rate, lateral and longitudinal 66 Left rear bumper radar sensor
acceleration sensor 67 Right rear bumper radar sensor
Introduction of the New M-Class, Model Series 166 n

Overall network
67
Networking
Overall network
Networking
Network architecture
The vehicle electronics are networked using the fol- Crimpable contact systems which are suitable for
lowing data bus systems: automated assembly are used as electrical connec-
tors. In wet areas, e.g. in the engine compartment,
• Controller Area Network (data bus/CAN bus)
vehicle underfloor and bumpers, additional single-wire
(CAN)
seals, mat seals or extrusion-coated lines are used.
• Media Oriented System Transport (MOST)
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 SAM control unit
data over two lines. In contrast to model series 164,
The familiar 2 SAM concept of model series 164 has
the chassis CAN has been divided into chassis CAN 1
been retained but the functions have been assigned
and chassis CAN 2.
specifically to the two central processing units.
The SAM control unit is installed on the right front
MOST A-pillar for the purpose of optimal electrical wiring. It
is the central unit for the lights, wipers, power supply
MOST refers to an optical data bus system. Here, data and on-board electrical system. The SAM-H is a unit
are transferred via fiber optic cable to the connected used specifically to control and operate the rear
information, navigation, and communication compo- consumers.
nents. The MOST operates with a transfer rate of
22 MBit/s.
Wiring harnesses Fuses
The wiring harnesses for the interior compartment, Maxi fuses and ATO fuses are used. These are located
cockpit and engine compartment are designed in fuses boxes at the front of the engine compartment
customer-specifically. The wiring harness variants and at the right rear of the vehicle under the rear
result from the basic standard equipment, the engine bench seat where they are accessible to the customer.
variant and the respective special equipment items.
The prefuse box on the battery contains a pyrofuse
The wiring harnesses in the interior are routed in an which, in the event of a crash, disconnects the starter
H-structure in the vehicle and are protected by cable and alternator line from the battery.
ducts. Paint-removing screws are used at the ground
points of the body.

Batteries and alternator
Networking
Batteries and alternator
The on-board electrical system battery (G1), which has On vehicles with ECO start/stop function, this backup
a capacity of 95 Ah, is located under the front battery is replaced by a larger additional battery
passenger seat on all models. For shift-by-wire, this is (G1/13) in order to prevent voltage dips during engine
supplemented by a backup battery (G1/7) with 1.2 Ah starting. This is installed at the right rear of the trunk.
so that energy is available to achieve the defined
standstill position if the main supply fails.
P54.10-3634-00
Overview of energy management system components

A1 Instrument cluster K114 ECO start/stop function additional battery relay
B95 Battery sensor N3/9 CDI control unit
F4 Rear fuse box N3/10 ME-SFI [ME] control unit
F32/3 Engine compartment prefuse box N10 SAM control unit
G1 On-board electrical system battery N24/3 DC/AC converter control unit
G1/7 Additional battery N73 Electronic ignition lock control unit
G1/13 Additional battery for ECO start/stop function V19 ECO start/stop function diode
G2 Alternator X58/34 115 V socket

Exterior lights
Lights
Front lights Intelligent Light System (ILS)
The new M-Class is equipped with twin-tube halogen Headlamps with Intelligent Light System are available
headlamps as standard. Halogen bulbs (H7) are used optionally as a component of the light package (not in
as the light source in the standard equipment. time for market launch).
All lighting variants feature horizontally aligned In contrast to the standard version, the projection
daytime running lamps in the bumper, each consisting system performs both the low beam function and the
of four LEDs. high beam function. Only one single bulb is used per
headlamp. With the high beams activated, the entire
There are service flaps in the front wheel arch to allow
light output of the xenon bulb is available. When the
the low beams to be replaced easily. The high beams
low beams are activated, a panel moves between the
and the standing/parking lights are accessed via the
bulb and lens optics which covers the part of the light
engine compartment.
output which points into the distance.
P82.10-6683-00
Front lights

Exterior lights
Lights
Rear lamps
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 tech-
nology and a red lens is located in the liftgate in the
roof spoiler.
P82.10-6684-00
Rear lamps

Interior lights
Lights
Interior lights Ambiance illumination
A basic light package is installed as standard and Ambiance illumination consisting of the following
ambiance illumination is available as special equip- components is available as special equipment:
ment.
• Illuminated double cup holder in the front center
The basic light package includes: console
• Footwell illumination in rear
• Left and right LED interior lights in the overhead
• Ambient, multi-colored illumination in the
control panel
instrument panel and door panels (as on model
• LED reading lamps for driver and front passenger in
series 212)
the inside rearview mirror
• Front illuminated door sill moldings
• Indirect illumination of the center console in the
• Rear warning and exit lamps
inside rearview mirror
• Illuminated adjustment wheels on the air vents of
• Front footwell illumination with automatic dimming
the instrument panel
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
P82.20-3861-00
Ambiance illumination

Active/passive safety
Safety
Further improved driving and stress-reducing safety The safety concept which acts preventively when the
are achieved on the new M-Class by the following system registers signs of danger includes:
features in particular:
• PRE-SAFE®
• ADAPTIVE BRAKE with the added functions: Hill • DISTRONIC PLUS incl. Brake Assist System PLUS
Start Assist, precharging, dry braking and Hold (BAS) and PRE-SAFE® brake (SA)
function, standard
Crash sensor system
• Attention assistance system, standard
• Brake Assist System (BAS), standard and BAS The crash sensor system and its associated software
PLUS (in combination with DISTRONIC PLUS, SA) for the detection of the type of accident and severity
• Adaptive brake lights, standard of impact have been further refined compared to the
• Tire pressure loss warning, standard or tire predecessor model series. New features of the
pressure monitor (TPM) (USA only, standard) M-Class include:
• Intelligent Light System with bi-xenon, SA • A new generation of Supplemental Restraint
• Adaptive Highbeam Assist System control unit
• Night View Assist • Pressure sensors in the rear doors as standard
• Speed Limit Assist, SA • The acceleration sensors for detecting a
• Lane Keeping Assist or Active Lane Keeping Assist, pedestrian impact
SA
• Blind Spot Assist or Active Blind Spot Assist, SA
• Active Park Assist, SA
• Reversing camera, SA
• DISTRONIC PLUS, SA
P91.60-4233-00
Pedestrian protection sensors

1 Front bumper B151/2 Center front bumper pedestrian protection
B151/1 Left front bumper pedestrian protection sensor sensor
B151/3 Right front bumper pedestrian protection
sensor

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

Restraint systems
Safety
Restraint systems
The restraint systems have also been developed In contrast to the predecessor model series 164, the
further compared to the predecessor model series. WSS control unit is not directly connected to the CAN
The driver and front passenger airbags are each bus. It is connected to the SRS control unit via the LIN
equipped with a two-stage gas generator. Depending bus, which is connected to the CAN bus.
on the crash situation, the airbag control unit activates
one or both generator stages. The side impact protec-
tion system has also been redesigned. Head protec-
tion 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.
P91.60-4235-00
Airbag system (full equipment)

Overview of systems
General Speed Limit Assist
The vehicle components which ensure a high level of The Speed Limit Assist system available as special
perceptual safety include the safety-relevant support equipment can use image recognition (camera inte-
systems described below. grated in center of windshield) and attributes of the
digital road map (COMAND) to detect the permissible
The systems which have already been successfully
speed limit for symbolic display on the instrument
introduced in other model series include e.g.:
cluster and on the map view of the head unit.
Attention assistance system

Active Park Assist
The attention assistance system which is available as
The Active Park Assist system can support the driver
standard equipment in the M-Class can detect the
during parallel parking.
typical signs of fatigue or deteriorating attentiveness
of the driver on long, monotonous journeys in a speed An ultrasonic measurement system is used to scan the
range of approx. 80 to approx. 180 km/h. vehicle's surroundings. This is also used by the PARK-
TRONIC system and certain aspects of it have been
developed further for Active Park Assist.
Adaptive Highbeam Assist On vehicles with the Active Park Assist SA, parallel
parking spaces on both sides of the vehicle are
Adaptive Highbeam Assist is offered as a component
scanned in the direction of travel while driving at
of the "Light package" special equipment option.
speeds of v < 36 km/h and displayed on the instru-
The Multi Purpose Camera (MPC) on the front of the ment cluster in the form of an arrow symbol. The
overhead control panel ensures that the headlamp vehicle can be parked semi-automatically at the
range and the light cone are controlled so as to request of the driver.
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.
i Note
For more information on the driver assistance sys-
tems 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

Overview of systems

Lane Keeping Assist/ Blind Spot Assist/
Active Lane Keeping Assist Active Blind Spot Assist
Active Lane Keeping Assist builds upon the function- The Blind Spot Assist system monitors the rear and
ality of the Lane Keeping Assist system. side areas of the vehicle using short range radar and,
if necessary, warns the driver if another vehicle is
The Active Lane Keeping Assist system, like the Lane
detected in the blind spot during an intentional lane
Keeping Assist system, can detect when the vehicle
change (turn signal set). A visual indicator in the
unintentionally crosses over lane markings via the
outside mirrors indicates that the system is active. As
multifunction camera.
of 30 km/h, the yellow visual indicator in the outside
In certain situations, the system issues a warning mirror disappears if no system faults are detected. As
through the steering wheel warning system when the soon as a vehicle is detected in the detection range of
vehicle leaves the recognized lane. the radar sensor system, the driver is warned by illu-
In a vehicle speed range of v = 60 to 200 km/h, the mination of the red readiness and warning indicator in
Active Lane Keeping Assist system additionally the outside mirror on the side of the vehicle where
initiates selective brake system interventions if the there is a vehicle in the blind spot. If the driver tries to
driver does not respond to the warning in order to initiate a lane change despite illumination of the indi-
move the vehicle back into the lane. cator, an acoustic warning is also output and the
warning indicator flashes.
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 less-
ened.
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 responsibil-
ity at all times for the safety of his/her vehicle and
its behavior.

Overview of systems
DISTRONIC PLUS incl. BAS PLUS and Night View Assist

PRE-SAFE® brake
The Night View Assist system allows the driving situa-
The DISTRONIC PLUS driver assistance system auto- tion to be displayed visually in the dark. The road
matically regulates the vehicle speed and distance to ahead of the vehicle is illuminated by two antiglare
the vehicle in front as specified by the driver in the infrared lamps. The camera mounted in the area of the
speed range of v = 0 to 200 km/h and v = 200 to rearview mirror – on the windshield – records the road
0 km/h. area and displays it on the central COMAND display
after image processing. This provides better orienta-
BAS PLUS
tion for the driver in situations without the visible high
The BAS PLUS function (Brake Assist System PLUS), beams and allows the driver to respond earlier to
assists the driver through situation-dependent, persons, animals or objects. When person detection is
targeted brake force calculation during emergency active (see symbol 2 in picture) each person detected
braking. by the system is also highlighted with "photo frame
PRE-SAFE® brake 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 P54.32-9581-00
Grayscale video image, person detection not active Grayscale video image, person detection active

Reversing camera

Reversing camera
For the ECE and USA, the new generation of reversing The reversing camera function enables the driver to
camera is available as special equipment. As on the select between the following parking modes:
predecessor model, the reversing camera is inte-
• Maneuvering mode
grated in the liftgate of the vehicle and displays the
• Trailer mode (with code (550) Trailer hitch)
area behind the vehicle on the COMAND screen during
reversing. The corresponding selection takes place at the oper-
ating level of the COMAND controller unit.
Thanks to a new lens with digital image transmission
and additional electronic zoom functions, an opti- Maneuvering mode:
mized image for the respective driving situation is The maneuvering mode assists the driver when
achieved with a widened angle of vision > 130°. To reversing while parking. In doing so, dynamic guide
enable an improved display of the driving area to the lines are also shown on the Audio/COMAND display in
rear, electronic distortion correction is also conducted addition to the pictures documented by the reversing
through the integrated reversing camera control unit camera.
in addition to optical distortion correction by the lens.
P54.65-4590-00
Display of dynamic guide lines (with wheels in straight-ahead position)

1 Virtual bumper
A Display
B Example situation

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 Virtual steering angle c Distance line, approx. 0.25 m
2 Virtual bumper d Distance line, approx. 1.0 m
A Display e Distance line, approx. 4.0 m
B Example situation

Reversing camera

Virtual steering angle (yellow guide lines): Parking procedure:
The yellow guide lines are shown as soon as the driver In order to park the driver must now adapt the steering
turns the steering wheel. They indicate to the driver angle until an outer line of the yellow guide lines in the
the path which the vehicle would follow with the Audio/COMAND display virtually touches the parking
currently applied steering angle. This curve is auto- space marking.
matically adapted to the situation as the steering
This parking space marking can, e.g. be another
angle changes. The distance between the yellow guide
vehicle or a line on the asphalt. The driver must then
lines is slightly more than the vehicle width.
continue backing up and adapting the steering angle
until the displayed parking space limits run parallel to
the current direction of travel.
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 During initial startup, if work is performed on the
the Audio/COMAND display is overlaid with a reversing camera or if work is performed on the
warning message and the guide lines are hidden. liftgate, the reversing camera has to be calibrated
again using the diagnosis tester.

Reversing camera
Trailer mode:
On vehicles with SA Trailer hitch, trailer mode Distance line around the ball head (red guide
supports the driver when reversing to a trailer by lines):
zooming into the ball head.
The red distance line is shown permanently on the
When reversing, special guide lines are also shown on Audio/COMAND display and informs the driver about
the Audio/COMAND display in addition to the pictures the distance over a radius of 0.25 m around the ball
documented by the reversing camera. 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 auto-
matically 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 A Display
4 Bumper B Example situation
h Distance line, approx. 0.25 m

Climate control
Comfort
The standard equipment of the new M-Class consists Energy savings through new technologies in air
of 2-zone automatic air conditioning. Available as conditioning equipment
special equipment is 3-zone comfort automatic air
The W 166 is equipped with a mirror fogging sensor
conditioning (THERMOTRONIC) with separate temper-
integrated in the mirror base of the inside rearview
ature control for the driver, front passenger and rear
mirror (in Europe as of 2-zone automatic air condi-
as well as additional adjustable air vent doors in the
tioning, otherwise as of 3-zone comfort automatic air
B-pillars.
conditioning). The signals of the sensors are evaluated
The design of both operating units has been modified in order to regulate the compressor according to
for simpler operation and standardized appearance. demand during air conditioning operation, which not
only increases comfort but also saves drive energy.
Both systems feature air recirculation switching and
are equipped with an interior air/combination filter The use of an internal heat exchanger into refrigerant
and a dust filter as standard. The filter performance circuit further improves efficiency. The heat
has been raised to almost 100% for particle sizes down exchanger is used to increase the energy content of
to 10 micrometers and improved to approx. the refrigerant in the operating ranges and to reduce
96-98% for particle sizes of between 5-10 microme- the mass airflow and thus the operating energy input
ters. of the refrigerant compressor, while supplying the
same cooling power.
P83.00-2350-00
Climate control and air ducting

Climate control
Comfort
3-zone comfort automatic air conditioning THERMOTRONIC
The THERMOTRONIC special equipment option is a By pressing the AIR FLOW button, the customer can
3-zone comfort automatic air conditioning system influence the climate control comfort and choose
which offers the following additional functions between predefined ventilation programs. In the
compared to the 2-zone automatic air conditioning "DIFFUSE" setting, the climate control system oper-
system: ates with lower air speeds and in the "FOCUS" setting,
the interior compartment is ventilated more vigor-
• Selection of three predefined ventilation programs
ously. The "MEDIUM" setting is the normal setting.
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
P83.40-4634-00
Controls of THERMOTRONIC automatic air conditioning

Telematics

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

Telematics
Rear entertainment
The rear entertainment system is a complete enter- The control signals are transmitted via the infrared (IR)
tainment system for the rear passengers. It is interfaces on the remote control to the respective
comprised mainly of the following components: display.
• DVD player A headphone jack is integrated into each display.
• Left rear display Headphones can be connected directly to this. In addi-
• Right rear display tion, the volume can also be adjusted via the volume
• Remote control control of the respective headphones.
• Radio frequency headphones (cordless) or wired
headphones (wired headphones are not included)
P82.60-8636-00
Rear entertainment

Sound system

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.
P82.62-3745-00
® ®
harman/kardon Logic 7 surround sound system
A2 Radio H4/35 Left rear door tweeter
A40/3 COMAND controller unit H4/36 Right rear door tweeter
H4/3 Left rear door speaker H4/38 Rear bass speaker
H4/4 Right rear door speaker H4/62 Left rear surround speaker
H4/5 Left front door speaker H4/63 Right rear surround speaker
H4/6 Right front door speaker H4/86 Left door midrange speaker
H4/27 Center instrument panel speaker H4/87 Right door midrange speaker
H4/33 Left front door tweeter N40/3 Sound system amplifier control unit
H4/34 Right front door tweeter

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

Bodyshell
Body
General Passenger cell
The most important features considered in the devel- The main floor consists of three assemblies, whereby
opment of the bodyshell of model series 166 include: the center part has greater sheet thickness and forms
the backbone of the floor system as a tunnel. Addi-
• The increase in the rigidity and strength of the
tional solid tunnel reinforcements are placed on top.
passenger cell and the deformation resistance of
The floor to the left and right of the tunnel is reinforced
the front end and rear structure in comparison to
from the inside as follows:
the predecessor model series 164. The results in
an improvement in active and passive safety, ride • With a rigid crossmember for mounting the seats
comfort (particularly on-road) and durability and and for lateral support on the tunnel in the event of
driving stability (particularly off-road). a side collision
• Creating a tolerance balance in the joining of the • With a diagonal member from the firewall to the
individual bodyshell parts (low-stress connections) side longitudinal member/B-pillar node
by means of suitable flange designs
The driver/front passenger seat crossmember has a
• Dispensing with MAG weld seams to improve
sturdy design resistant to side collisions with a single-
production quality
piece reinforcement made of hot-worked, high-
• Detachable front and rear end assemblies to make
strength steel. This forms the divider to the rear-end
repair easier
floor.
In addition, the torsional stiffness of the bodyshell has
Crossmember under instrument panel
been increased significantly despite the integration of
a large roof opening system. The load-bearing element of the cockpit module is a
tubular magnesium assembly carrier which is bolted
The bodyshell is made of sheet steel. Modern high-
onto the two A-pillars.
strength and ultra high-strength steels with optimized
mechanical properties have been used. The carrier acts as a guide for the components
attached to it. This eliminates the need for time-
consuming tolerance compensation during assembly
gives the structure a higher-quality appearance.

Bodyshell
Body
Front end The front axle major assemblies including the steering
gear are preassembled together with the engine and
The front end structure of model series W 166, transmission on an integral carrier, which in turn is
consisting of the firewall, two front longitudinal connected to the body via four rubber bushings. This
members and two wheel arches, has been taken over minimizes the transmission of vibrations from the
from the predecessor model series. The following front axle to the body. The remarkably rigid integral
features further improve the energy absorption carrier is a welded structure made of high-strength
capacity in the case of a head-on collision: sheet steel.
• The two front longitudinal members with additional In the event of a severe frontal impact, the integral
internal third shell carrier is able to deform while absorbing impact
• Additional longitudinal outboard members on the energy.
right and left with support at the A-pillars (second
Model series W 166 features a major assembly
longitudinal member plane)
compartment which is separated from the engine
• Two vertical supports between the first and second
compartment by a multipart, plastic partition wall
longitudinal member plane to increase torsional
extending from left to right. This guarantees good
stiffness.
noise and thermal insulation with the passenger
The front end consists of: compartment.
• A high-strength steel profile for the bumper
components
• Two high-strength steel crash boxes with flexural Side wall
member forming a detachable connection to the
On model series W 166, the outer paneling of the side
two front longitudinal members
wall including the rear fender is made of a single
• A bolted hybrid front end made of steel and plastic
section. This outer paneling is firstly stiffened using a
serves as a mount for the two lamp units
reinforcing frame. The internal side wall structure is
• A bolted steel radiator crossmember
composed of several parts and, together with the rein-
• A plastic carrier part with steel inserts as the base
forced outer side wall, forms the three-piece cross-
for the components of the upgraded front module
sections 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.

Bodyshell
Body
Rear end Engine hood and front fenders
The axle components of the rear axle are mounted on The engine hood and front fenders are made of
a rear axle carrier which is joined to the body via four aluminum. This reduces the bodyshell weight
rubber bushings. compared to the predecessor model series by approx.
11 kg. Furthermore, the components are geometri-
To increase their strength, enhance their energy
cally designed to provide the best possible pedestrian
absorption capacity and improve their deformation
protection.
behavior, the multipart rear longitudinal members
have a cross section which is closed along their entire The engine hood hinges have a four-link design but an
length with graduated sheet thicknesses. The additional link allows the engine hood to be actively
recessed compartment for the compact spare wheel is raised if necessary for pedestrian protection. The
part of the steel rear floor assembly. The hot-worked engine hood can be steplessly positioned/locked in
steel flexural members which carry the rear bumper place from 45° to 85° for service purposes using
cover are connected to the rear-end structure by two Interstop pneumatic springs.
steel crash boxes.
Radiator grille
Rocker panels
The radiator grille has a sturdy, SUV-style design and
The side longitudinal members are covered over their is attached to the bumper. It is characterized by a
entire area with plastic rocker panels in a contrasting chrome-plated central Mercedes-Benz star and three
color, which connect to the fenders and doors at the chrome slats. The slat carrier is painted glossy black.
bottom. The rocker panels protect the side longitu-
Underneath the headlamps and the radiator grille is an
dinal members, fenders, doors and side wall from
opening in the front bumper covered by a black
stone chips and also give shape to the side of the
diamond-pattern grille for the purpose of engine
vehicle.
cooling. Next to the grille are covers with the same
Wide running boards with aluminum inserts and diamond-pattern structure, into which the LED
profiled rubber naps are available as special equip- daytime running lamps are integrated. In order to
ment. These can be placed under load and facilitate increase the perceived quality of the LED daytime
side entry, particularly for shorter persons. running lamps, they are framed with a chrome-plated
cover.
The visible area of the underride guard is in chrome.

Bodyshell
Body
Doors Rear-end door
The four large side doors have a lightweight steel In addition to a manually opened rear-end door, an
construction. They ensure comfortable entry and exit. automatic rear-end door is available as special equip-
The door gap is sealed all the way around (triple seals ment (standard in the USA) for the M-Class. This can
above the beltline and dual seals below) in order to be opened and closed without manual support by an
significantly reduce wind noises and keep the electromechanical drive system. It is however still
entrance areas largely free of dirt. possible to manually open and close a rear-end door
fitted with this convenience function. Both versions
Each door shell comprises two joined steel sheets.
are equipped with a power closing function for closing
The required dent resistance of the outer paneling is
the door from the pre-locking position.
achieved through a reinforcement profile, which is
bonded to the outer shell. In addition to the inner shell, The technical design of both door variants is largely
which is cut out appropriately to hold an assembly identical in terms of bodyshell, trim parts, glazing and
module, the lock, hinge, side impact protector and some other assembly parts. The automatic door is
outer beltline reinforcements make up the door shell. equipped with an electromechanical drive system
The window frame is formed from the inner shell and (rotary pillar drive) with control unit instead of the
a single-piece frame section. standard gas-operated springs.
The door holder function is integrated in the door In order to ensure a high level of rigidity, the load-
hinges. These are forged steel parts. The hinge system bearing body of the door shell, including the rear
is maintenance-free. As on model series 204/212, the window frame, is made up of an inner shell and outer
hinges are bolted from the inside to the pillars. 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 semi-
automatic trailer hitch on the outside left.
Two pneumatic springs and conventional U-shaped
hinges are used to hold the door.

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

Corrosion protection
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.
P97.30-2041-00
Bodyshell views, doors/flaps with seam seals highlighted

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 The standard door concept is characterized by:
includes complete filling of the folds with adhesive.
• Wax all the way around from beltline to beltline
The fold is thus sealed all the way around. This
• Seam sealing after KTL
measure improves robustness in production to the
• Full-length fold bonding and complete adhesive
maximum possible level.
filling of flange
P97.20-2585-00
Schematic illustration of door fold

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

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)
P97.30-2042-00
Steel rear axle carrier and integral carrier

Suspension
Special tools
Calibration device
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

Suspension
Special tools
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

Engine
Special tools
124-pin adapter cable
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

Body repair systems
Workshop equipment
Manufacturer CELETTE CAR BENCH CAR-O-LINER
Article CELETTE straightening CAR BENCH straightening Straightening and

and portal tool set and measuring system measuring system
Order number Supplementary straight- NEW: Universal kit with "D" EVO 3.3
ening bracket set parts A353/EVO (Mercedes)
7166.509 A4244100
Portal straightening set Portal straightening set
7166.800 A7244100/T
Source in CELETTE HSK Car-O-Liner

Germany Vertriebs GmbH Karosseriegeräte Vogesenstrasse 3
Siemensstrasse 19 Vertriebs-GmbH D-63811 Stockstadt
D-77694 Kehl-Sundheim Am Fliegerhorst 3
D-63762 Großostheim-
Ringheim
www.celette.de www.carbench.de www.car-o-liner.de
Source outside CELETTE FRANCE S.A.S. CAR BENCH International Car-O-Liner

Germany 3. Avenue Marcelin S.p.A. Box 7
Berthelot Via Dorsale 22
F-38200 Vienne I-54100 Massa 73621 Kungsör

France Italy Sweden
i Note i Note
The basic straightening tool set 7164.300 is http://gotis.aftersales.mercedes-benz.com
essential for body repairs with the CELETTE
system.
If using the previous CAR BENCH system 353, the
universal kit must be updated with a supplemen-
tary 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.

Abbreviations
Annex
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 für Normung (German Standards Intelligent Light System
Institute)
IR
DPF
Infrared
Diesel Particulate Filter
ISO
DSB International Organization for Standardization
Digital Service Booklet

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

Stichwörter
Annex
Numerics E
7G-Tronic Plus transmission . . . . . . . . . . . . . 48 Electric parking brake . . . . . . . . . . . . 9, 61, 62
Electric power steering . . . . . . . . . . . . . . 8, 58
A Engine data . . . . . . . . . . . . . . . 34, 35, 37, 39
Active Blind Spot Assist . . . . . . . . .8, 12, 73, 77 Engine mount . . . . . . . . . . . . . . . . . . . . . 99
ACTIVE CURVE SYSTEM . . . . . . . 8, 9, 54, 59, 60 Engine mounts . . . . . . . . . . . . . . . . . . . . 40
Active engine hood . . . . . . . . . . . . . . . 13, 74
Active Lane Keeping Assist . . . . . . .8, 12, 73, 77 F
Active Park Assist . . . . . . . . . . . . .8, 12, 73, 76 Flexible Fuel . . . . . . . . . . . . . . . . 7, 10, 34, 36
Active roll stabilization . . . . . . . . . . . . . . . . 59 Force progression . . . . . . . . . . . . . . . . . . 93
ADAPTIVE BRAKE . . . . . . . . . . . . . . . . 61, 73 Front axle . . . . . . . . . . . . . . . . . . . . . . . 52
Adaptive Highbeam Assist . . . . . . . . . . . 12, 76 Front view . . . . . . . . . . . . . . . . . . . . . . . 17
AdBlue® . . . . . . . . . . . . . . . . . .9, 32, 43, 46 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 68
Aeroacoustics . . . . . . . . . . . . . . . . . . . . . 20
Aerodynamics . . . . . . . . . . . . . . . . . . . . . 20 I
AIRMATIC . . . . . . . . . . . . . . . . . . . . . 9, 54 Instrument cluster . . . . 25, 26, 33, 45, 59, 61, 76
Ambiance illumination . . . . . . . . . . . . . 12, 72 Integral carrier . . . . . . . . . . . . . 52, 90, 96, 99
Attention assistance system . . . . . . .8, 13, 73, 76 Intelligent Light System . . . . . . . . . 8, 12, 70, 73
Automatic air conditioning . . . . . . . . . . . 14, 83
K
B Kneebag . . . . . . . . . . . . . . . . . . . . . . 13, 75
Blind Spot Assist . . . . . . . . . . . . .8, 13, 73, 77
L
Bluetooth® . . . . . . . . . . . . . . . . . . . . . . . 86
Lane Keeping Assist . . . . . . . . . . . 8, 13, 73, 77
C LED technology . . . . . . . . . . . . . . . . . . . . 71
CO2 emissions . . . . . . . . . . . . . . . . . . 34, 35 Load compartment . . . . . . . . . . . . . . . . 30, 31
Coefficient of drag . . . . . . . . . . . . . . . . . . 23
M
Comfort automatic air conditioning . . . . 14, 83, 84
Maintenance strategy . . . . . . . . . . . . . . . . 32
Crash sensor system . . . . . . . . . . . . . . . . . 73
MOST . . . . . . . . . . . . . . . . . . . . .65, 67, 68
Cup holder . . . . . . . . . . . . . .14, 27, 28, 29, 72
N
D
Night View Assist . . . . . . . . . . . . . . . 8, 12, 78
Digital Service Booklet . . . . . . . . . . . . . . . . 33
NTG 4.5 . . . . . . . . . . . . . . . . . . . . . . . 8, 85
Dimensions . . . . . . . . . . . . . . . . . . . 21, 23
Dimensions and weights . . . . . . . . . . . . . . . 24 O
DISTRONIC PLUS . . . . . . . . . . . . . . 12, 73, 78 Oil supply . . . . . . . . . . . . . . . . . . . . . . . 48
Downhill Speed Regulation . . . . . . . . . . . 12, 50 ON&OFFROAD package . . . . . . . . . . . 9, 55, 56

Stichwörter
Annex
P Sidebag . . . . . . . . . . . . . . . . . 13, 28, 75, 99

Panoramic sliding sunroof . . . . . . . . . . . 12, 19 Sliding roof . . . . . . . . . . . . . . . . . . . . 12, 19
Performance graph . . . . . . . . . . . . . . . 37, 39 Speed Limit Assist . . . . . . . . . . . . . . 8, 13, 76
PRE-SAFE® . . . . . . . . . . . . . . . . 8, 13, 73, 78 Steering column . . . . . . . . . . . . . . . . . . . . 58
Stowage compartments . . . . . . . . . . . . . . . 29
R
Rear axle . . . . . . . . . . . . . . . . . . . . . . . .53 T
Rear entertainment . . . . . . . . . . . . . . . 16, 86 Telephony . . . . . . . . . . . . . . . . . . . . . . . 85
Rear view . . . . . . . . . . . . . . . . . . . . . . . .17 THERMOTRONIC . . . . . . . . . . . . . . 14, 83, 84
Reversing camera . . . . . . . . . . . . 8, 13, 73, 79 Transfer case . . . . . . . . . . . . . . . . 50, 51, 55
Transmission modes . . . . . . . . . . . . . . . . . 55
S
Seats . . . . . . . . . . . . . . . . . . . . . . . . . .28 W
Side view . . . . . . . . . . . . . . . . . . . . . . . .18 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

Questions and suggestions

Image no. of title image: P00.01-4194-00

Order no. of this publication: 6516 1383 02 – HLI 000 000 02 72

Models and major assemblies 7

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

Introduction of the New M-Class, Model Series 166 n 3

7G-Tronic Plus transmission 48

ACTIVE CURVE SYSTEM 59

Wheels and tires 63

Batteries and alternator 69

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

Driving assistance systems

Audio and communications

Body repair systems 100

Introduction of the New M-Class, Model Series 166 n 5

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

ML 350 4MATIC 166.057 276.955 722.906 09/2011

ML 350 4MATIC 166.057 276.955 722.906 02/2012

ML 550 4MATIC1 166.073 278.928 722.909 02/2012

ML 250 CDI 166.004 651.960 722.908 11/2011

ML 350 CDI 166.024 642.826 722.903 09/2011

Introduction of the New M-Class, Model Series 166 n 7

Vehicle concept New features

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

AMG exterior sport package Code P31 Standard Code P31

Interior sport package 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 Standard — Standard

ECO start/stop function Standard — Standard

Diesel particulate filter (DPF) — — Standard4

AIRMATIC package Code 489

ACTIVE CURVE SYSTEM Code 468 — Code 468

BLUETEC diesel emission control — — Standard5

ON&OFFROAD package6 (except Code 430

1 ML 550 only in USA und ROW (not ECE)

Introduction of the New M-Class, Model Series 166 n 9

ML 350 ML 550 ML 250 CDI ML 350 CDI

Powerplant, engine, suspension, brakes

70l diesel tank (ECE only) — — Standard

78l gasoline tank (ECE only) Standard — — —

93l tank (standard in USA) Code 915 Standard Code 915

93l tank (Flexible Fuel) Standard1 — — —

Wheels, tires, light alloy wheels

43.2 cm (17") light alloy wheel — Standard

43.2 cm (17") light alloy wheel — Code R24

45.7 cm (18") light alloy wheel Standard — Code R41

45.7 cm (18") light alloy wheel Code 03R — Code 03R

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

Wheels, tires, light alloy wheels

48.3 cm (19") AMG light alloy wheel — Standard —

50.8 cm (20") light alloy wheel Code 50R

53.3 cm (21") AMG light alloy wheel Code 7572

Tire pressure monitor (TPM)3 Code 475 Standard Code 475

MOE run-flat tires Code R66

Tire pressure loss warning (except Standard — Standard