Mercedes-Benz E320 CDI Repair Manual 2007-2009 PDF | Wiring Diagrams

2007-2009 Index

Specifications & Maintenance Standards

• Comprehensive vehicle specifications, alignment data, tightening torques, tightening sequences, and fluid capacities (engine oil, manual/automatic transmission fluid, differential fluid, power steering fluid, and coolant).
• Brake system specifications, brake bleeding procedures, brake line/hose data, master cylinder specs, rotor/disc thickness limits, and parking brake adjustment values.
• Suspension and steering specifications including Airmatic, steel suspension, axle carriers, wheel hubs, torque struts, tie rods, and yaw rate sensor data.

Engine Mechanical & Overhaul Systems (CDI Diesel)

• Complete engine service, removal, and installation procedures, including engine wiring harness disconnection and crankshaft ring gear retaining locks.
• Cylinder inspection (light probe and leak testing), compression checks, and cylinder pressure loss determination.
• Camshaft service, end cover removal/installation, camshaft removal, lifters, and lash adjusters.
• Cylinder block assembly, main bearings, crankshaft measurement and mounting, expansion/freeze plugs, harmonic balancers, pistons, and piston rings.
• Cylinder head assembly, front covers, slide rails, valve covers, valve seats, valve springs, inspection, and machining.
• Drive belts, poly-V-belt wear inspection, belt tensioners, engine mounts, and engine lubrication.
• Oil pumps, oil pump chains, oil coolers, oil level/temperature sensors, oil pans, intake manifolds, timing components, timing chains, timing chain guides, tensioners, timing covers, and water pumps.

Engine Control, Fuel & Air Induction Systems

• Engine control module removal, installation, and programming.
• Fuel delivery and air induction safety precautions, accelerator pedals, air cleaner housings, and air filter element procedures.
• Diesel fuel metering valves, diesel MFI pumps, high-pressure fuel pumps and intermediate gears, fuel filters, fuel full-flow filters, fuel injectors, injector lines, pressure sensors/switches, and fuel rails.
• Fuel tanks, filler necks, fuel/water separators, intake air ducts, throttle bodies, turbochargers, intercoolers, charge air ducts, and variable induction control actuators.

Ignition, Exhaust & Emission Control Systems

• Firing order specifications, camshaft position sensors, crankshaft position sensors, and ignition switches.
• Complete exhaust system removal and installation, exhaust manifold replacement, rivet nut repairs, and AMG muffler retrofitting.
• Catalytic converters, diesel particulate filter (DPF) units, exhaust temperature sensors, exhaust back pressure sensors, differential pressure sensors, heat shields, and mufflers.

Cooling Systems & Climate Control

• Cooling system testing, coolant draining, flushing, and filling procedures.
• Auxiliary water pumps, radiator cooling fans, fan shrouds, coolant temperature sensors/switches, heater control valves, heater cores, radiators, and thermostats.
• Technical service bulletins covering A/C odor issues, blower motor inoperative fixes, control module diagnostics, and fluorescent dye leak testing.

Body Control Modules & Electrical Architecture

• SAM control unit descriptions, tasks, locations, and removal/installation procedures for driver-side front SAM, passenger-side front SAM, and rear SAM modules with integrated fuse and relay boxes.
• Data bus systems overview including CAN data bus specifications, fault recognition, data telegrams, block diagrams, and advantages.
• Fiber optical cable maintenance and removal/installation for the Media Oriented System Transport (MOST) bus.
• Prefuse boxes, interior fuse boxes, front backup fuse boxes, ground wiring schematics, and connector separation points.

Technical Service Bulletins (TSBs) & Diagnostics

• Diagnostic trouble code (DTC) reading and clearing, component tests, Mode 6 data, drive cycles, and readiness codes.
• Comprehensive factory TSB coverage addressing automatic transmission issues (722.6/722.9 fluid leaks, shift harshness, limp home mode), Sensotronic Brake Control (SBC) diagnostics, bleeding, and recall modifications.
• Electrical troubleshooting bulletins addressing battery control module programming, consumer shutoff messages, horn malfunctions, audio/COMAND interference, navigation updates, sunroof water leaks/rattles, seat adjustment faults, and steering/suspension creaks or noises.

Electrical Components Locator Guide

• Alphabetical physical component location index covering hundreds of vehicle sensors, actuators, control modules, connectors, ground points, fuses, and relays across the engine compartment, interior footwells, doors, trunk, and underbody (including AAC, AIRmatic, ATA, Audio Gateway, DCM, DTR, ESP, ETC, Keyless Go, PTS, SAM units, VGS, WSS, and Xenon headlamp modules).

Electrical Wiring Diagrams (EWD) & Circuit Schematics

• Factory electrical schematics covering Cockpit Management and Data System (COMAND), Electronic Stability Program (ESP), Anti-Theft Alarm (ATA), Drive Authorization System (DAS), and Panic Alarm System (PAS).
• Power distribution schematics for Driver-Side SAM, Passenger-Side SAM, Rear SAM, Overhead Control Panel (OCP), Upper Control Panel (UCP), and Lower Control Panel (LCP).
• System-specific wiring diagrams for Common Rail Diesel Injection (CDI), automatic transmissions (ETC/VGS), electronic ignition switch (EIS), steering column modules, air conditioning (AAC), instrument cluster (IC), exterior/interior lighting, central locking, power windows, power seats, dynamic seats, seat heating/ventilation, sunroofs, sound amplifiers, telephone (CTEL), emergency call (Tele Aid/E-Call), Parktronic (PTS), Distronic (DTR), and supplemental restraint systems (SRS / airbags).

Owner's Manual

• Factory owner's handbook covering introduction, at-a-glance guides, getting started, safety and security, detailed controls, operation, practical hints, technical data, and technical terms.

Engineering Breakdown: The CDI Architecture

The W211 E320 CDI is a marvel of integration where mechanical health and electronic monitoring are inseparable. At the heart of this vehicle is the 3.2L inline-six turbo diesel (648.961), a system that relies on micro-precise fuel delivery and vacuum-controlled boost regulation.

In this vehicle, a mechanical issue such as a slight vacuum leak at the turbo actuator often manifests as an electrical "limp mode" fault. Without the factory diagnostic socket pinouts and the CDI functional diagrams, you might find yourself replacing the expensive variable-geometry turbocharger when the issue is merely a $10 cracked vacuum line or a faulty Level Control Solenoid Valve. This workshop reference clarifies these system-level interactions, showing how the engine wiring harness connects to the injection system control unit (SAM modules).

Practical Repair Scenarios & Workshop Insights

In many real-world repair cases, technicians struggle with the W211’s electrical architecture, particularly the Signal Acquisition and Actuation Modules (SAM). A common issue technicians encounter is a "no-start" condition that looks like a failed starter or battery. However, a frequent diagnostic mistake is overlooking grounding issues affecting system performance—specifically the ground wiring separation points hidden behind the wheel housings.

Overlooking a corroded ground at the front axle carrier can cause the ESP and ABS modules to lose CAN-bus communication, even if the modules themselves are perfectly healthy. Using the included ground wiring schematics (Sheets 1–5), you can pinpoint these physical locations before committing to expensive module replacements.

Technical System Coverage

Spanning 6,107 pages, this resource is a massive deep-dive into the executive-class chassis. It includes:

• Mechanical Assemblies: Complete engine removal/installation, crankshaft measuring, camshaft timing, and harmonic balancer service.
• Chassis & Drivetrain: Detailed AIRmatic specifications, propeller shaft intermediate bearing replacement, and rear axle center assembly housing repair.
• Intricate Electrical: Full factory wiring schematics for the COMAND system, Keyless GO control modules, and the MOST fiber optic bus.
• Fuel & Air: Precise procedures for the high-pressure pump intermediate gear, intercooler ducts, and diesel particulate filter (DPF) units.

Why Accurate Data Matters

Modern executive cars like the E-Class suffer when precision is ignored. For example, incorrect torque affecting sensor readings is a major pitfall when replacing the Front Axle RPM Sensors or the Yaw Rate Sensor. If these components aren't seated to the exact tightening specifications found in this manual, the ESP system will interpret the mechanical vibration as an actual skid, leading to unwanted brake intervention.

This resource provides the "Test Values For Distance/Comparison" measurements necessary for wheel location and hub alignment that generic manuals simply skip. It ensures that when you work on the SBC (Sensotronic Brake Control) or the AIRmatic solenoid valves, you have the actual OEM test values for pressure and resistance.

Technical Features

• Searchable PDF Format: Quickly find any DTC or AR-procedure code.
• Zoomable Schematics: High-detail functional diagrams for the CAN Data Bus and interior lighting.
• Multi-Device Compatibility: Access the 347 MB file on your shop laptop, tablet, or smartphone.
• Factory-Level Detail: Includes everything from piston ring service to fiber optic cable routing for the Media Oriented System Transport (MOST).

Shop Floor Guarantee: Instant Access

We know that a car on the lift is a liability until it's fixed. That is why we provide immediate digital fulfillment. Once you complete your purchase via Credit Card, PayPal, Google Pay, or Apple Pay, the system triggers an automatic download link to your email and your customer account. Your access is valid for 10 days or 10 downloads. If you face any issues with the large 347 MB file, we offer a secondary backup via Dropbox to ensure you get your data.

Stop the guesswork at the fender. View our download guide here: https://servicemanuals.info/How-to-Download.mp4

Frequently Asked Questions

Does this manual cover the specific SBC (Sensotronic Brake Control) bleeding procedures?
Yes, the manual includes detailed sections on the Electronic Brake Control Module, brake bleeding specs, and the hydraulic control assembly to ensure the high-pressure system is handled safely.

Can I use this to find a parasitic draw on the battery?
Absolutely. By using the W211 parasitic draw diagnosis strategy combined with the provided Ground Distribution and SAM Fuse/Relay Module sheets (Sheets 1-4), you can isolate which circuit is failing to "sleep" on the CAN bus.

Is the OM648 engine teardown guide included?
Yes. It features full "AR" procedures for removing/installing camshafts, measuring cylinder bores, and even replacing the oil pump chain, complete with all necessary tightening sequences.