[bamaboy]

The first generation GL-Class (chassis codename X164) was launched globally in 2006 as Mercedes-Benz’s flagship full-size SUV. Built on the W164 M-Class platform, it was stretched, widened, and reinforced to accommodate three genuinely usable rows, a full-fledged off-road drivetrain, and the kind of creature comforts expected from an S-Class on stilts. With its imposing presence and versatile capability, the GL-Class was Mercedes-Benz’s direct answer to the Land Cruiser 200, Range Rover, and Audi Q7.

While the facelifted GL-Class(like this one) was officially introduced in India in January 2010, a few pre-facelift models such as the GL500 and GL420 CDI had already made their way to Indian roads as CBU imports.

This particular GL350 CDI is also a CBU(Completely Built-Up) unit, manufactured at Mercedes-Benz’s Tuscaloosa plant in Alabama, USA, which was the global production hub for the GL-Class. When new, it carried a sticker price of around Rs.66 lakh (ex-showroom) about Rs. 10 lakh more than the Audi Q7 3.0TDI at the time. That premium brought a long list of equipment, imposing dimensions, and a level of off-road capability few luxury SUVs in India could match.

Reference Links for Context :

Pre-facelift GL420 CDI and GL500 discussion :

https://www.team-bhp.com/forum/super...-gl-class.html (Pics : Mercedes GL Class)

https://www.team-bhp.com/forum/test-...di-tested.html (Mercedes Benz GL420 CDI Tested)

Facelift was launched in January 2010 :

https://www.team-bhp.com/forum/india...0-l-india.html (Mercedes Benz launches the GL350 CDI and the new S500 L in India)

https://www.team-bhp.com/forum/india...e-edition.html (Mercedes-Benz launches two new variants of the GL-Class (luxury & Executive edition))

Reviews and Real-World Coverage :

https://www.autocarindia.com/car-rev...350-cdi-269212

https://www.team-bhp.com/forum/super...ml#post2555220 (Fascination Mercedes Leh, Ladakh with a Merc GL350 and an AMG G55)

Likes :

- Massive and commanding road presence. At over 5 meters long and nearly 2 meters wide, the GL-Class stands tall with true flagship SUV proportions. Built on a monocoque chassis derived from the W164 M-Class, it is stretched and reinforced to accommodate three usable rows, offering a balance of SUV capability and car-like refinement.

- Powered by the 2987cc OM642 V6 diesel engine paired with the 7G-TRONIC automatic gearbox. This combination is known for its long-term reliability, strong torque, and smooth performance when properly maintained. It delivers 224 BHP at 3600 rpm and 510 Nm between 1600 and 2400 rpm, enabling 0 to 100 km/h in approximately 10 seconds despite its 2.5-ton weight.

- AIRMATIC air suspension with Adaptive Damping System (ADS) delivers a plush, composed ride and superb comfort at highway speeds. It self-levels under load, adapts to road conditions in real time, and offers manual ride height adjustment from 180 mm to 307 mm for off-road use. Damping can be toggled between Comfort, Normal, and Sport modes. At speeds above 110 km/h, the suspension lowers by 15 mm for improved stability and reduced wind resistance.

- Very capable off-roader, equipped with the full Off-Road package: 4MATIC all-wheel drive, 4ETS traction control, ESP, low-range transfer case, locking differentials, and Downhill Speed Regulation (DSR). Off-road credentials are impressive - 307 mm of ground clearance, 600 mm water wading depth, 33° approach, 27° departure angles, and 35° tilt tolerance. Most of these capabilities have now been dropped from newer GLE/GLS models and are only found on the G-Class today. I’ve taken this GL through jungle trails and muddy tracks, and it has excelled across all terrains even with the highway tyres. With a set of AT or MT tyres, it becomes a seriously potent off-roader. You’ll even find several M-Class and X164 GL off-road builds featured on YouTube and Instagram.

- Rich cabin with full leather upholstery, Burr Walnut wood trim, wooden multifunction steering wheel, twin sunroofs, and tri-zone climate control. Features include COMAND APS with a 6-DVD changer and navigation, reversing camera, rear-seat entertainment with wireless headphones, powered butterfly windows, electrically folding third row, electric tailgate, bi-xenon headlamps, auto-folding ORVMs, and front and rear parking sensors. Many of these were flagship S-Class features in their time and still feel premium today, even on a 15 year old car. Nearly all features and equipment continue to work flawlessly, a true testament to the quality and durability of Mercedes-Benz engineering.

- Interior comfort is excellent across all three rows. The front seats are wide and supportive, the second row offers generous legroom and good thigh support, and even the third row is genuinely usable by tall adults, which is a rarity in this segment.

- Practical and versatile. The GL350 is ideal for long highway journeys, rough terrain or cross-country touring. Boot capacity ranges from 630 liters with all seats up to 2300 liters with both rear rows folded, offering impressive functionality without compromising on comfort.

- Since it shares the W164 M-Class platform, OM642 engine and 7G-TRONIC transmission, parts availability is not a challenge. Service parts are easily sourced from Delhi and Mumbai markets. Trim parts prone to breakage are available from Chinese vendors on eBay, while rarer bits can be found with scrap dealers across India or imported if needed.

Dislikes :

- The V6 diesel in a 2.5-ton SUV isn’t fuel-efficient. I average 7.5 km/l with 70% highway and 30% city driving. In pure city conditions, it drops to 4–5 km/l. Even idling with the AC on consumes a lot. With my 50–60 km daily usage, running costs are substantial. The best I’ve managed is 9.5 km/l on a 550 km highway run.

- Though the OM642 engine and 7G-TRONIC transmission are generally reliable, keeping them in mint condition requires effort and money. It’s not a money pit, but certainly not a Toyota either. Preventive maintenance is key. Annual servicing costs me around ₹25,000, with another ₹20,000–25,000 on smaller upkeep jobs through the year. More on that in future updates.

- Not fun to drive in terms of handling or maneuverability. This is a purpose-built SUV, not a corner-carver. The engine is torquey and offers smooth performance on highways, but in the city, it feels bulky and requires effort. The hydraulic steering isn't as heavy as in some Toyotas or Isuzu, but it still needs planning at low speeds. Its sheer length and width make parking and quick lane changes a task. This SUV is best enjoyed on wide, open roads.

- Like most older German cars, it doesn’t like being left idle. If not driven regularly, minor electrical or mechanical issues tend to crop up. The AIRMATIC suspension, in particular, can develop leaks in the air struts if the car sits unused for long periods. But if you drive it often and maintain it well, it remains dependable and surprisingly fuss-free.

- Despite being a high-mileage workhorse, the OM642 is prone to small electrical gremlins and sensor faults. Thankfully, these are usually easy to diagnose and fix if you have a competent, experienced mechanic or with some self-research online.

- The 7G-TRONIC gearbox, though generally reliable, can feel sometimes clunky at low speeds. While the higher gears (5th, 6th, and 7th) are well spaced for effortless highway cruising, the lower ratios tend to get confused during sudden throttle inputs. That said, this is more of a minor nitpick, especially considering the car is 15 years old and newer gearboxes have come a long way since then.

- The presence of a DPF can be annoying in city driving, as regeneration cycles sometimes trigger high revs and unusual behaviour. This isn’t an issue on highways. Given the era, Mercedes could’ve skipped the DPF on Indian models. The engine feels constrained in its stock tune and would benefit greatly from a Stage 1 remap and EGR delete to truly unlock its potential.

- The engine is sensitive to fuel quality. Low-grade diesel or adulteration can cause injector or sensor issues, especially over time.

- The chocolate and beige interior colour combination doesn’t feel very appealing. I especially dislike the hard plastics used on the door cards and lower dash. The contrast is odd. While part of the dashboard is wrapped in leather, the adjoining door panels use basic hard plastic, which feels inconsistent in an otherwise premium cabin.

Big, Bold, and Bought – The GL350 Journey Begins

Back in August 2022, I had just wrapped up the restoration of my beloved W124 E220. One random afternoon, I called up Viraat, just casually chatting about the idea of acquiring a project car in the likes of W221 S Class or an E38 7 Series. Without missing a beat, he mentioned that a 2010 GL350 belonging to his friend is for sale. He told me the car has done approximately 54000Kms and had undergone a major service at his garage in October 2021 and now the owner was looking to part with it to make way for a new Porsche Cayenne. The deal instantly caught my interest and I quickly made up my mind to go for it. The next day, I discussed it with the family and they gave their full support.

The car was registered in Faridabad(HR51) and had mostly seen life in Delhi before being moved to Lucknow due to NGT regulations. Viraat sent me some photos and I did a thorough research and sealed the deal. We agreed that the car needed to be brought back to Delhi for some freshening up—new battery, a front grille, and general TLC. Meanwhile, Viraat also offered me a 2013 BMW X5 30d which had done around 80000Kms but my heart was already set on the GL.

I wanted a second project car which is also practical and useable on a daily basis. As much as I love the idea of an S-Class, it wouldn’t suit my needs in a tier 2 city or for visiting mines and rough terrain. I needed something tough, with a touch of luxury and the GL fit the bill perfectly. The GL offers something unique: presence, practicality, off-road credentials, and that classic Merc luxury.

A week later, the car was with Viraat in Delhi. He shared a few pictures with me as it arrived from Lucknow:













That last photo stirred up some fond memories. It was taken at the same spot where my W124 E220 had been resting at Viraat’s for nearly a decade, before he entrusted me with his beloved Benz back in 2019.

I learned that a major service was carried out in October 2021 at Viraat's Garage, which included:

- Complete replacement of suspension bushings and linkages with genuine Lemförder components.
- New front and rear brake pads, fan belt replacement, AC gas top-up, turbo hose seal replacement, and fixing of the jammed sunroof.
- A comprehensive fluid service covering engine oil, automatic transmission oil, transfer case oil, front and rear differential oils, power steering fluid, brake fluid, along with replacement of all filters: Oil, Air, Diesel, AC, and Transmission.
- Interior restoration, including a new roof liner, steering wheel leather wrap, and seat leather repairs.
- Brand new Continental ContiSportContact5 tyres in 275/55 R19.
- Complete interior and exterior detailing.

While the GL350 was with him, I figured it was the perfect time to get some essential work and part replacements done:

- New Cooling Coil and AC Service
- New Radiator Grill
- New Battery (Dry type)
- New Auxiliary Battery
- Seat Back pockets remade
- New Regn Plates
- LED H7 Bulbs for Hi Beam



























All the work was carried out at Viraat’s Garage, upon my request. Much like with my W124, the entire process from purchase and payment to the mechanical and cosmetic work was managed remotely, without me ever seeing the car in person.

The Hunt for the Right Alloy

One of the things that constantly bugged me was the rather plain jane stock Ronal alloys. They did their job, but made the car feel a bit dated especially on such a large SUV that otherwise carries strong road presence. I was looking for something that would sharpen the overall stance, add a more planted look, yet remain understated and not shouty or aftermarket.

I got in touch with Mr. Saurabh Khaneja of Pahiya 4x4 (Gurugram) over a phone call and WhatsApp. He was extremely helpful in walking me through multiple options while keeping the original 19-inch size in mind. I briefly flirted with the idea of AMG-style replicas, but concerns over long-term durability(especially given the GL’s 2.5-ton heft) held me back. I wanted something stronger, cleaner, and reliable.

After some discussion, I finally zeroed in on the HRS Taiwan B40 in Hyper Silver. These were 19inches, 9.5J width(1 inch wider than stock), ET38(negative offset compared to ET56 of the stock rims). Compared to the stock setup, the new wheels sit nearly 30mm further outward (thanks to both the lower offset and wider width), giving the SUV a much more muscular and planted stance. The fitment is now flush with the fenders, very much in line with what you'd find on factory AMG GL/ML/GLE rims, many of which run similar specs.




Source: http://www.wheelcalc.com/?page=rim

The rims were shipped directly to Viraat’s Garage in Palika Bhawan, and installation was handled there itself. The multi-spoke design is just right for a large SUV and adds sharpness without looking too aftermarket. The Hyper Silver finish also strikes a great balance between premium and sporty. In fact, it could easily be mistaken for a high-end OEM wheel if someone didn’t know better.















I was really happy with how this upgrade turned out. The GL now has a much more purposeful stance, and the wheels complement the SUV’s proportions beautifully. A clean, well-balanced upgrade that stays true to the GL’s original character while bringing it up to date visually.

Once everything was ready, my friend and I travelled to Delhi on 8th September 2022 to take delivery of the car.

We reached Delhi on the next day, checked into a hotel in Greater Kailash, and then headed straight to Viraat’s house. There, I inspected the car, completed the paperwork, and we had a long, detailed conversation about the dos and don’ts of ownership, maintenance tips, and the car’s backstory. It was a relaxed and insightful gentlemen’s chat, covering everything from mechanical quirks to practical advice on living with older German cars. This was our second used car purchase, the first being the W124. Both were impulse buys and both project cars, courtesy of Viraat.







I also had the chance to meet Viraat’s father, and we spoke for a while about their beloved W124. I showed him some recent photos of the restoration— it was heartening to see both him and Viraat pleased that the car had found a good home and was being well cared for.

Later that afternoon, we made a quick trip to Gurgaon and returned in the evening to perform a pooja at the Sanatan Dharam Mandir in GK-2. With everything in place, we were all set for the long journey back home the next morning.

[bamaboy]

10th September 2022: We dropped the metaphorical checkered flag in Delhi and set off on our 1200 km homebound drive to Bilaspur:





Since we were driving a 12-year-old diesel vehicle, Viraat accompanied us in his Skoda Laura for the initial stretch, just as a precaution due to the NGT restrictions in Delhi. Leaving early helped avoid any potential hassles. He guided us from his place in Greater Kailash to Greater Noida, and within half an hour, we were on the Yamuna Expressway. We had also packed the four stock 19-inch wheels in the boot, and to my surprise, they fit easily without having to fold the middle row.







Our first major halt was Gwalior, where we visited the iconic Taj Mahal. From there, we continued to Datia to visit the revered Baglamukhi Mata Mandir. As it was a Saturday, we were also fortunate to have darshan of Dhumawati Mata. Around 10:30 PM, we reached Jhansi and checked in at Sarovar Portico for the night. The total distance covered that day was roughly 500 km, which marked the halfway point of our journey.





From behind the wheel, the driving experience was impressive. The driver’s seat is highly ergonomic, especially for someone with a large frame like mine. I was able to figure out the right seat angle and posture easily. Driving such a massive SUV takes a bit of getting used to, but the large windscreen and generous glass area help with visibility and ease of handling in city traffic. Overtaking requires caution and good judgment due to its size, but once out on the highway, the GL truly comes into its element. It drives with the calmness of a yacht, effortlessly gliding over undulations and road imperfections. At cruising speeds above 100 km/h, the suspension lowers to its minimum height to improve stability and reduce drag. The AIRMATIC setup is phenomenal, offering a supremely smooth and composed ride, especially on open highways. Despite being a 2.5-ton vehicle, it corners surprisingly well with minimal body roll, thanks to the monocoque chassis. The 7G-TRONIC gearbox feels well suited for highway use, with gears 4, 5, and 6 delivering quick progress. The engine is free-revving and torque delivery becomes sharp after 2000 rpm, making the car pull effortlessly when required. The character of the GL transforms on the highway. What feels a bit lethargic in city driving suddenly turns into a surprisingly swift and confident cruiser on the open road. Strong mid-range punch and relaxed cruising manners make it a true comfortable long distance mile-muncher. I thoroughly enjoyed the first 500 km of the journey and even managed to get a respectable fuel economy of around 9 kmpl.











The next day, we left Jhansi a bit late after a relaxed breakfast of poha and kachori. We started from Jhansi around 11:30 AM. About 100 km into the journey, the AC suddenly gave up. This was unexpected since it had just been serviced a week prior. We decided to push on without it. Luckily, the skies turned overcast, and the weather became surprisingly pleasant, making the drive manageable. The GL is equipped with the NTG 2.5 COMAND system. While it had Bluetooth for telephone calls, it lacked Bluetooth media streaming and didn’t even offer an AUX port. With CDs and DVDs being obsolete, the only practical option for music was an SD card. So, in Jhansi, we stepped into a small mobile shop, bought an SD card, and asked the guy to fill it with MP3s to keep us entertained during the long journey ahead. He happily obliged and, for good measure, added a generous selection of 90s Kumar Sanu tracks. We didn’t knew of it at the time, but when those tunes kicked in later, nostalgia hit hard. We reached Jabalpur by around 5:30 PM, took a short break to catch up with a friend, and were back on the road by 7:30PM. After having dinner in Mandla, we reached Chilpi Ghat, the Madhya Pradesh–Chhattisgarh border around midnight. Heavy rain had caused a traffic jam, and we were stuck there for an hour. Finally, we rolled into Bilaspur at around 2:30AM, covering approximately 750km that day. It was a long stretch, especially after the 500 km drive the previous day. But in a big, comfortable cruiser like this, the journey was surprisingly fatigue-free. Aside from the AC issue, the car ran flawlessly. I was even able to extract 10.5 kmpl without air conditioning, which is quite respectable for a 2.5-ton, 3.0L V6 SUV.

The second leg of our journey was filled with amazing views of the Satpura forest, rolling hills, and a mesmerizing landscape. We also crossed through the buffer zone of the Kanha Tiger Reserve between Mandla and Chilpi during the night, which added a sense of adventure to the drive. The road trip was truly memorable and brought back the same sense of excitement and satisfaction I felt when I travelled to Delhi to bring home my W124 to Nagpur back in March 2019.



The next morning, I dropped the car off at a local detailing shop for a thorough exterior wash and interior cleaning. Everything felt much fresher once it was cleaned up properly after the long journey.



I also got the AC diagnosed. Turns out the compressor clutch had given up, so I immediately ordered a new compressor from Viraat. The AC compressor is known to be a relatively weak link in OM642 engines, whether it is the X164 or the newer X166 platform. After replacing the compressor, we discovered there was still a leak in the system. Since the front cooling coil had already been replaced earlier, we inspected the rear coil next and, sure enough, found a leak there as well. That was promptly fixed, followed by a refill of fresh refrigerant, and the AC was back to blowing cold.







However, the roof-mounted rear blowers were not working. A scan revealed a rear AC refrigerant sensor open circuit. I suspected it to be a faulty sensor. Since the front AC was working well and the rear vents, apart from the roof blower, were cooling, we decided to call it a day. I planned to order the sensor and address it later.

I also got the Wheel balancing and alignment :







I began using the GL as a daily driver and even took it through some light off-roading to get a feel for its capabilities. The car already had light green factory-tinted glass. I got 70% visibility Garware Sunfilm installed all around, including the windshield. Nothing too fancy, just enough to cut glare and reduce heat. Here's how the car looks with the suspension raised to Offroad Level 2:







I ordered the following parts that needed immediate replacement:

- Key Fob Shell – The original was heavily scratched and worn. I replaced just the shell to retain the internal electronics.https://www.ebay.com/itm/124983299858?var=426055930338

Image Source :eBay

- Hood Air Vent Grille Covers – The factory chrome vents were brittle and broken. Replaced with matte black units for a cleaner look.https://www.ebay.com/itm/203791185226

Image Source :eBay

- AC Vent Adjustment Tabs – Two were broken, making airflow direction adjustment difficult.https://www.ebay.com/itm/224923615761

Image Source :eBay

- Mudflaps – The front set was missing. I ordered a complete set and kept the rear pair as spares.https://www.ebay.com/itm/263706902153

Image Source :eBay

- Bluetooth AUX-IN Adapter (NTG 2.5) – Adds Bluetooth media streaming by connecting to the rear AUX port on the head unit.https://www.ebay.com/itm/263706902153

Image Source :eBay

- Hood Emblem Badge – The old one had lost its paint and shine.link

Image Source :eBay

- Facelift ORVMs – The pre-facelift mirrors had limited visibility and looked dated. Facelift-style units offer better function and a refreshed appearance.https://www.ebay.com/itm/305575406172

Image Source :eBay

I ordered all these parts after doing plenty of research to ensure both quality and originality. Everything arrived on time, was installed without fuss, and turned out to be of good quality.

[bamaboy]

Unfortunately, the Bluetooth kit didn’t work. I tinkered with it and tried various fixes, but it remained a dud. I had hoped it would solve the media streaming limitation, especially since the car already came with a factory-fitted reverse camera. Interestingly, the X164 GL was the first Mercedes Benz model to offer one. Eventually, I decided to replace the entire head unit, and the hunt for a suitable Android system began.

Back in the day, I was deep into the ICE scene, building DIY 3 way active SQ setups and collecting high end amplifiers, speakers, head units, and DSPs. I still have some collectible car audio gear packed away in storage. With newer generation cars coming in our garage with integrated factory systems, the keeda has mellowed over time. Maybe someday I’ll revive that audio obsession I had a decade ago, but for now, the passion has shifted more toward project cars.

For the Headunit upgrade in the GL, I did thorough research and came across several examples of 10 inch units fitted using frames made for the W164 and X164 platforms. However, most of them were fairly common and limited to 600p or 720p resolution. Joying, at the time, had a solid reputation for making high-quality Android head units, so I went with their 11.6-inch 2K IPS display model which had 1920 x1200 resolution. It featured an 8-core UIS7862 processor, 8GB of RAM, and 128GB of internal storage. The slim-bezel, tablet-style rectangular design fit neatly into the GL’s dashboard. The dimensions perfectly aligned and made it look almost like OE. Since the screen was flat and the dash had a slightly curved layout, I also ordered a 10-inch dash trim kit to cover the visible side gaps.

I placed the order directly through Joying’s eBay store, and they were helpful in recommending a compatible CAN-bus based factory integration kit, which I purchased separately. This enabled steering controls and other CAN functions like door-ajar warnings to be retained and track info display on the instrument cluster. Thankfully, Indian-spec X164 GL came with a standard audio system and no factory amplifier, which simplified the installation. Had it been equipped with the Harman Kardon system, I would’ve needed a MOST optical converter and dealt with a much more complex wiring process. The Headunit install was DIY and took 2 hours to complete. I also routed a USB C cable from the back of the headunit to cupholder console for wired carplay/android auto connection.











The complete head unit setup, including all ancillary components and custom duties, cost me close to Rs.50,000. A standard 10-inch Android head unit available locally in India would have cost around Rs.28,000 at most, including installation accessories. But I willingly paid the premium for the 2K 1200p display since its crisp and sharp visuals made it worth the extra spend. This Joying unit has an improved DAC and an integrated DSP, which eliminated the need for an external amplifier. It allowed me to fine-tune the sound with multi-band EQ, time alignment, and channel-level adjustments. The factory speakers, which were decent to begin with, sounded even better with this setup. The output is clean, well-balanced, and surprisingly dynamic. The unit fits beautifully into the dashboard and completely modernizes the cabin. Wireless Android Auto and Apple CarPlay work flawlessly.



My GL also came with the rear entertainment package, which includes DVD and USB playback - both outdated now. However, the screens still have a 3.5mm analog input jack. The Joying head unit has an analog RCA video output, so I might try connecting it to mirror the head unit display to the rear screens. It’s worth a shot and could make those screens useful again may be with the help of an installer.

Here's the Hood Emblem Badge DIY replacement :



Before:



After :



Mechanically, the car was performing well but it needed some aesthetic attention. The front section had accumulated its fair share of scratches and dents over the years and required repainting. The plastic trims had faded with age and the entire exterior was due for a proper compounding and detailing session. I wanted the car to look clean and presentable again. It was time to begin the restoration so I decided to get the hood, front bumper and both fenders repainted.

I chose the same FNG where we had restored my W124 and opted for the full Sikkens system which included degreaser, base coat, autoclear, hardener and slow reducer. Everything was selected to match factory-quality paint. Since my car is a CBU, the original paint was excellent in quality and had impressively retained its lustre even after 15 years.

























Here’s the end result after getting just the front section repainted. While we were at it, we deleted the front number plate frame for a cleaner look. The compounding and detailing were postponed by a month to allow the clear coat to fully cure, as we had used an oil-based paint system :















I’m not much of an auto photographer, nor do I usually click detailed shots. I rarely get the chance to line up our cars together either. But here’s one photo I just couldn’t resist taking. The GL parked next to our Toyota Fortuner Σ4, which is my elder brother's daily driver :



Side by side with our office V Cross - a remapped workhorse that’s clocked over 2.5 lakh kilometres. It serves as a dependable support vehicle for truck fleet operations and continues to do its job without fuss :



I never imagined I’d get the opportunity to share an ownership and restoration thread for the GL. Had I known back then, I would’ve documented the entire journey more thoroughly, with proper step-by-step photos. Now, almost three years later, I’m just piecing together bits from my phone, WhatsApp chats, and whatever I can recall from memory. I’ve shared the journey so far, right up to December 2022. There’s still a lot left to tell. The real life drama of living with a fifteen year old German machine includes the small victories, the occasional headaches, and those quiet moments of joy when everything just works. It takes patience, a bit of obsession, and more late night research than I care to admit to keep a car like this running as it should. The journey to bring this car closer to perfection has been anything but linear.

In the next set of posts, I’ll dive into the fixes, the quirks, and the joys of daily driving. There will be stories of road trips, memories made, and plenty of hands-on learning. Stay tuned.

[bamaboy]

Achanakmar Tiger Reserve Jungle Trail and mild Offroad experience :































The trail was a narrow hilly route with plenty of ups and downs, definitely more challenging than it initially seemed. While the forest Gypsies are short and nimble, the GL felt fairly large and heavy in comparison. But to its credit, it tackled the entire 27 km trail beautifully. Thanks to its shorter overhangs and generous ground clearance, it never scraped or felt out of place. I kept the suspension raised to Offroad Level 2 throughout the drive which made a noticeable difference. It gave us a real opportunity to appreciate the 4MATIC system and the way the AIRMATIC suspension absorbed ruts, dips, and uneven terrain with absolute ease.

[Aditya]

Thread moved out from the Assembly Line. Thanks for sharing!

[123.rishabh]

Congratulations on acquiring the amazing beast and giving it a good TLC. Always loved this generation of the GL/GLS & feel this is the most butch looking generation.

[rosh_aveo1.4]

Oh that was very nice...first thought the alloys didn't match but after seeing the remaining pics it looked better than what I had in mind. I have a similar year C220 CDI and yes, you were right on most of the points. I am curious on the ebay purchases, they all arrive at the address without any major hassle at customs or so? I got my AC controls broken as yours and the replacements I got from this site (https://carcraftindia.com/) are just acceptable quality. How does it work for eBay? Loved the audio system as well...that's from eBay?

[sp4589]

Congrats. You have done a great job on restorations and the alloys suit the SUV perfectly. The head unit also looks OEM and suits the interior. Which brand did you get? Also did you upgrade the speakers ?

[Thyag]

Great wriiteup and Nice Pictures, so much time spent in attention to details is really impressive.

The GL350 CDi comes with a Strong V6 diesel engine, Luxurious & spacious and good towing capability also. The downside being Expensive repairs, Ageing electronics, Suspension and Diesel particulate filter issues.

As you mentioned earlier always use high quality diesel and also avoid running low for injectors longevity. Hope you are using low-SAPS oil from Merc - they will help in avoid DPF clogs & blocks.Monitor AIRMATIC system regularly for Air strut leaks, worn compressor or valve block.

My kuwaiti manager used to have this vehicle as rental, during smoke breaks used to lurk around this

[dsnaveen21]

Congrats, car looks awesome..

2 doubts..
a. Do you know any agent who does the registration in Mumbai, Maharashtra for Delhi cars..
b. One has to get the NOC before the expiry of RC, is this correct..

Thanks,

[MercedesFan]

Good build. It has long been a dream of mine to get a X164 and turn it into a mild overlander with addition of roof tent. I have had three W164 . I think the weakest link in X166 is the air suspension and the easiest way to make them relaible is to convert air suspension to coilovers from a some good brand from USA. Rest of the vehicle is mostly relaible to be taken to any offroad adventure.
I am on hunt for a grand edition X164 to start my project.
These vehicles needs enormous care and attention.

[Utopian]

Amazing ownership review. Brought back memories of the movie "The Jurassic Park" where a similar make was used to ferry people in and around the park. The cosmetic work has surely done wonders in the looks department. Wishing you loads of happy times with the humble beast. Pity we cant have beauties like this in NCR anymore.

[bamaboy]

Originally Posted by rosh_aveo1.4

Oh that was very nice...first thought the alloys didn't match but after seeing the remaining pics it looked better than what I had in mind. I have a similar year C220 CDI and yes, you were right on most of the points. I am curious on the ebay purchases, they all arrive at the address without any major hassle at customs or so? I got my AC controls broken as yours and the replacements I got from this site (https://carcraftindia.com/) are just acceptable quality. How does it work for eBay? Loved the audio system as well...that's from eBay?

Thanks. Ebay Purchases mostly from China are economy shipping so custom duty is collected by local Post Office while delivering the parcel. For premium shipping like Fedex, DHL etc. they inform you the duty amount and you have to pay in their website portal along with KYC. They also charge handling fees in the range of Rs.500-1000 depending upon the duty amount and size/content of the parcel. Android headunit was bought from ebay : https://www.ebay.com/str/joyforwaaudio

Originally Posted by 123.rishabh

Congratulations on acquiring the amazing beast and giving it a good TLC. Always loved this generation of the GL/GLS & feel this is the most butch looking generation.

Thanks. I couldn't agree more - this generation of the GL/ML are really well designed and look timeless.

Originally Posted by sp4589

Congrats. You have done a great job on restorations and the alloys suit the SUV perfectly. The head unit also looks OEM and suits the interior. Which brand did you get? Also did you upgrade the speakers ?

Thanks. The 19-inch multispoke alloys really complement the GL’s massive proportions. They fill out the wheel arches nicely and balance the overall stance. HU is from Joying like I mentioned earlier. Speakers are factory fitted and sound great.

Originally Posted by Thyag

Great wriiteup and Nice Pictures, so much time spent in attention to details is really impressive.

The GL350 CDi comes with a Strong V6 diesel engine, Luxurious & spacious and good towing capability also. The downside being Expensive repairs, Ageing electronics, Suspension and Diesel particulate filter issues.

As you mentioned earlier always use high quality diesel and also avoid running low for injectors longevity. Hope you are using low-SAPS oil from Merc - they will help in avoid DPF clogs & blocks.Monitor AIRMATIC system regularly for Air strut leaks, worn compressor or valve block.

My kuwaiti manager used to have this vehicle as rental, during smoke breaks used to lurk around this

Thanks. I've performed three oil service till now and have used MB229.51 approved oil. You are right about Airmatic. It is troublefree for most of the time, you do have to monitor the ride height regularly for any strut leak.

Originally Posted by dsnaveen21

Congrats, car looks awesome..

2 doubts..
a. Do you know any agent who does the registration in Mumbai, Maharashtra for Delhi cars..
b. One has to get the NOC before the expiry of RC, is this correct..

Thanks,

Thanks.
a. I know of an agent in Nagpur. Getting a car transferred from another state to the Maharashtra RTO is quite expensive. I got the GL re-registered in Chhattisgarh, where the road tax is typically around 10% of the depreciated value plus some additional charges and agent fees. The total cost came to Rs.1.15 lakhs.
b. Yes. You have to get the NOC before RC expiry.

Originally Posted by MercedesFan

Good build. It has long been a dream of mine to get a X164 and turn it into a mild overlander with addition of roof tent. I have had three W164 . I think the weakest link in X166 is the air suspension and the easiest way to make them relaible is to convert air suspension to coilovers from a some good brand from USA. Rest of the vehicle is mostly relaible to be taken to any offroad adventure.
I am on hunt for a grand edition X164 to start my project.
These vehicles needs enormous care and attention.

Thanks. The air suspension is not that much unreliable. Grand edition has more goodies. Look for sagged headliner and sunroof leaks. These are weak links.

Originally Posted by Utopian

Amazing ownership review. Brought back memories of the movie "The Jurassic Park" where a similar make was used to ferry people in and around the park. The cosmetic work has surely done wonders in the looks department. Wishing you loads of happy times with the humble beast. Pity we cant have beauties like this in NCR anymore.

Thanks. More updates on the way!

[bamaboy]

During February 2023, I took up detailing the GL myself. I’ve been doing basic DIY detailing since 2012 using tried and tested products like Klasse AIO, Klasse High Gloss Sealant Glaze and the ever-reliable Collinite 845, all applied by elbow grease. Collinite 845 in particular has been my go-to sealant wax for over 12 years. It always delivers outstanding results.

Before handing the car over to a professional detailer I wanted to try my hand at using a machine polisher. I reached out to an old friend and fellow BHPian SunnyBoi for advice. On his recommendation I picked up a North Wolf 5 inch DA Polisher which is a clone of the Rupes Bigfoot Random Orbital Polisher along with 5 inch yellow polishing pad and a black finishing pad. I also got Meguiar’s Ultimate Compound.

The GL had significant oxidation and plenty of swirl marks. I wanted to preserve the factory paint as much as possible so I chose a mild abrasive polish for my first machine detailing attempt.

After a thorough wash and surface prep we started polishing with the yellow pad and Meguiar’s Ultimate Compound then finished with Collinite 845 applied using the black finishing pad. The results were far better than expected. The paint came alive with a deep gloss and much improved clarity.







We also applied Ceriglass Pro, a cerium oxide-based windshield polishing compound, to remove hard water stains and restore factory like shine and visibilty. Additionally, we applied Turtle Wax Trim Restorer on the faded black plastic trims and the lower section of the bumper grille. These small touches made a noticeable difference in the overall appearance, bringing back the contrast and freshness to the aged surfaces. My driver assisted me through the detailing process and was just as thrilled with the outcome. The shine at the end of it all was deeply satisfying and made all the hard work feel worth it.









By March 2023, I had completed six months of ownership of the GL and had clocked nearly 6,000 km since the car left Lucknow. It was time for routine - B service. The previous major service, including the last oil change, had been carried out in September 2021 at the 53,500 km mark. How did I know? Well, the car came with an unexpected easter egg – a handwritten logbook maintained by the first owner's team. Every odometer reading for each major outing including service visits was recorded right from day one. It provided a rare and clear picture of the car’s complete service history. Although the car wasn’t used much after 2017 and spent most of its time parked in a garage, it was revived with a major service in September 2021. Here's a list of work done at Viraat's Automotive Garage :



https://www.instagram.com/p/CUeJRIGh...F4ZGV3MHNiZ2l3



For the service, I ordered the following:

Engine Oil – 9 litres of Mobil 1 ESP 5W30, which meets MB 229.51 Low SPAsh specification.
Oil Filter - Mahle
Air Filters - OEM
AC Cabin Filter - OEM
Coolant/Antifreeze – 2 litres of Mannol 4113 AG13, which meets MB 325.0 specification.

I sourced the engine oil and coolant from Amazon, while the filters were ordered through Viraat.



Once we opened the engine cover, my love-hate relationship with the OM642 truly began :



There was clear evidence of oil seepage around the turbo intake area. The sight of an oil-soaked intake wasn’t exactly reassuring. I did some research, checked in with Viraat and found that the Intake seals had worn out and were due for replacement. It’s a textbook issue with this engine. The culprit is the failed intake manifold seals, a well-documented weak point in the early OM642 design. Over time, the rubber gaskets harden and shrink due to repeated heat cycles, allowing oil mist from the crankcase ventilation system to escape and collect around the turbo inlet and intake runners.

This isn’t a unique problem to my car. It’s a known design flaw in the earlier generation of OM642 engines. Mercedes eventually addressed it in later versions like the W166 and X166 by revising the intake manifold and improving the sealing system. Unfortunately, the X164 GL still uses the older layout, which is prone to these leaks as components age.

YouTube also turned out to be a goldmine with plenty of videos and DIYs showing similar cases with the OM642.

Here’s a helpful video that walked me through the fix:

https://www.youtube.com/watch?v=D9AL...nnel=DrewFixIt

Viraat immediately dispatched the new intake seals, and while we waited for them to arrive, I decided to take things a step further. I planned to include EGR valve cleaning, throttle body cleaning, and intake manifold cleaning, since these areas hadn’t been addressed during the previous service.







The PCV valve also arrived about a month later, and I had it replaced.





With the service complete, here’s a breakdown of the costs incurred:
Air Filters (pair) – Rs.3200
Oil Filter – Rs.850
AC Cabin Filter (set of 2 elements) – Rs.2200
Intake Seals – Rs.2800
Engine Oil (9L) – Rs.10500
PCV Valve – Rs.3800
Coolant – Rs.4500
Miscellaneous – Rs.1000
Labour Charges – Rs.8000

Total: Rs.36850/-

What began as a routine Type B service with standard fluids and filters gradually turned into a more thorough preventive maintenance session. Given the OM642’s tendency to accumulate carbon deposits in the intake tract particularly around the EGR and swirl flap regions. It made sense to get everything cleaned and refreshed in one go. I also ordered another spare set of Intake Gasket set to kept as spare for future. With the intake manifold cleaned, a new PCV valve installed, and fresh engine oil and filters in place, throttle response noticeably improved. The engine felt more eager and responsive, offering better drivability and a slight uptick in acceleration. From that point on, the GL ran effortlessly smooth.



I got the GL in September 2022. The car was originally registered on 18 August 2010, with a manufacturing date of April 2010. Its RC was valid till 2025 under Haryana RTO. However, being a diesel vehicle over 10 years old, it was no longer permitted to run in Delhi and NCR due to NGT regulations. We began the NOC process in December 2022. Since the car had an older, certificate-style registration document, the first step was to issue a new smart card and update the records on the Vahan portal. Another hurdle came up due to the car bearing a VIP registration number. The number had to be surrendered, as such VIP numbers are retained by the RTO and later auctioned. Because of this, the car was re-assigned a new HR registration number from the HR70 series. This made the transfer process unusually tedious and time-consuming. Finally, in August 2023, the registration was updated and the NOC was issued, allowing us to transfer the vehicle to Chhattisgarh RTO. Registration plates were now changed bearing new number.





In January 2024, due to a moment of carelessness, my driver damaged the rear left tyre by scraping it against a boulder. The sidewall was torn, rendering the tyre completely unusable. Since the Continental tyres on the car were manufactured in 2021 and already three years old, I wasn’t eligible for an unconditional warranty replacement. I ordered the same Continental CSC5 SUV tyre in 275/55 R19 111W spec from Tyremarket and got it installed, balanced, and aligned. Total damage to the wallet - Rs.22,000.







In February 2024, we embarked on a family road trip to Khajuraho, Chhatarpur, and Maihar - a 1200 km round journey that turned out to be one of the most memorable. The GL performed flawlessly throughout. Touring in this car is supremely comfortable, and it shines on long-distance highway drives. Our route from Bilaspur to Katni took us through Shahdol and Anuppur. This stretch in Madhya Pradesh included a lot of single lane sections with rough patches, especially near Anuppur. The road conditions improved after Katni.















This journey gave me a deeper appreciation for the GL’s suspension system. For those unfamiliar, the AIRMATIC system uses pressurized air bellows in place of conventional steel springs. Each strut houses an air spring which is inflated or deflated in real time by an onboard air compressor connected to a reservoir tank. This setup allows the system to adjust ride height and damping characteristics on the fly based on driving conditions and terrain. Another clever feature of the AIRMATIC system is its automatic speed-sensitive lowering. Once the vehicle crosses around 80 kmph, the suspension gradually lowers itself to its minimum ride height. This helps reduce aerodynamic drag, improves high-speed stability, and lowers the center of gravity for a more planted feel on expressways.

The GL offers three suspension modes - Comfort, Normal, and Sport. The default is Normal mode, which strikes an ideal balance between ride quality and control. Comfort mode softens the suspension significantly, ideal for slow speeds and uneven terrain, but at times it can feel floaty and unsettled due to the softer damping. The system frequently adjusts air pressure in this setting to maintain ride comfort.

Sport mode, on the other hand, stiffens the suspension noticeably. This mode is better suited for high-speed expressway driving or tight handling conditions, but in a tall SUV like the GL, it may feel unnecessarily firm. I find Sport mode more appropriate for sedans like the S-Class or EQS, both of which come with the ADS+ active damping system. My EQS handles Sport mode beautifully, but in the GL, it feels out of place for most real world conditions.

In my experience, the Normal suspension mode is the sweet spot. It offers just the right amount of spring tension and damping to absorb bad roads gracefully while keeping the body stable. Over 60 kmph, the system really comes into its own. The ride remains flat and controlled even on rough surfaces. The GL seems to glide over road imperfections, making it a supremely comfortable long-distance cruiser. Paired with the torquey OM642 V6 Diesel and a gearbox engineered for relaxed highway cruising, the GL becomes an exceptional long-distance tourer. It effortlessly absorbs road imperfections and remains composed even on patchy stretches. The AIRMATIC system works silently in the background, delivering a flat and sublime ride. At cruising speeds over 60 kmph, the suspension really comes into its own and makes covering miles a genuine pleasure.

Except for the tyre damage, the GL ran fuss-free for a full year without any additional expenses. By March 2024, the odometer had touched the 66,000 km mark, which meant I had covered nearly 11,000 km since taking ownership. It has been immensely rewarding for the sheer comfort, commanding road presence and undeniable snob value it brings every time I take it out. The GL quickly became my go-to daily runner, thanks to its practicality and effortless drive. Naturally, the W205 and W124 E-Class saw much less use. The 2023 Tucson, on the other hand, was mostly reserved for outstation business trips, where its efficiency made it the sensible choice.

[bamaboy]

The honeymoon was short lived. In April 2024, the AIRMATIC compressor failed, bringing the GL quite literally down to earth.



I immediately took the car to my trusted FNG. A diagnostic scan revealed an open circuit fault in the AIRMATIC compressor. The culprit was a blown fuse caused by a short circuit, thanks to water ingress through the compressor’s breather valve. As it turns out, my overenthusiastic driver had pressure washed the front right wheel well, right where the breather is located. That sent water straight into the solenoid, shorting it out.







We sourced a used original compressor from the used parts market. It took about a week to arrive. It was an AMK unit, which is factory OEM and the same is used in later W166 and X166 models. It costed around Rs.23,000, which was far more affordable than the Rs.1 lakh plus price tag of a brand-new unit.

In the meantime, my mechanic disassembled the failed compressor, dried out the solenoid, and attempted a repair. While the compressor came back to life, he found a leak in the body itself, ruling it out for use.

Since I had the scanner at hand, I ran a full system scan to check for any hidden issues while we were waiting on parts. A few small niggles popped up:











- Rear Roof AC Blowers Not Working: The scan revealed a fault code for “Rear AC Temperature Sensor – Open Circuit.” This was the reason the rear blowers had stopped working. I ordered a replacement sensor (A1718300272) from eBay to resolve it.

- Parktronic Display Error: The Parktronic system had stopped functioning, and the scanner showed a “Display Wiring – Open Circuit” fault. Initially, I was unsure what exactly this meant. My mechanic checked the wiring and sensors thoroughly, suspecting a rat bite or short, but everything seemed intact. At that point, we couldn't pinpoint the issue, so this was kept pending.

- Rear Tailgate Non-Functional: The powered tailgate had stopped working, and the scanner flagged an open circuit in the anti-pinch contact strip. This part is no longer available(NLA), and the known workaround is to bridge the circuit using two 4.7K resistors to simulate a closed loop. However, while troubleshooting we fiddled the contact strip, which unexpectedly resolved the issue. The DTC cleared, and the tailgate started functioning normally again.

- The diesel hose (A6420783481) connecting to the fuel filter element had worn out over time and needed replacement. My mechanic replaced it with a new high-pressure diesel line.

- The blown fuse for the AIRMATIC pump was replaced with a new one, which interestingly happened to be the same type used in the Renault Duster.

Once the replacement compressor unit arrived, we installed it and began the task of re-pressurising and recalibrating the AIRMATIC system using a diagnostic scanner. This was unfamiliar territory for my mechanic, so I decided to take over the scanning and calibration work myself. Since it was also my first attempt, I did a thorough research - reading articles through Mercedes forums, studying Xentry DAS screenshots and of course, frequently pestering Viraat for his expert guidance.

Since the system had fully depressurised, the GL was sitting at its absolute lowest height. The first step was to refill the air reservoir tank, which serves as the pressure source for all four air struts. Using the diagnostic scanner, we initiated the compressor to begin filling the tank. Once enough pressure was built up, I manually began inflating each air strut in sequence : starting from the front left, then front right, followed by the rear left and rear right.













This process must be done with care. AIRMATIC compressors can easily overheat if you try to inflate the system too quickly. So, we used short pulses of air while closely monitoring the height values to ensure even and gradual inflation. It’s a delicate and time-consuming process that requires a lot of patience, as rushing can trip errors or damage the struts.





Reference Ride Height :
The AIRMATIC system expects a baseline ride height before it will accept calibration. This is measured from the center of the wheel hub to the bottom edge of the fender arch. For the X164 GL350, these are the approximate reference values:

Front: 485mm to 510mm
Rear: 500mm to 525mm

It’s important to manually inflate or deflate each strut so that it falls within this range before proceeding to the inclination-based calibration. In my case, I carefully inflated and deflated each strut until the values matched approximately -28mm in the front and -32mm at the rear. This took a bit of trial and error, as the scanner will reject calibration attempts if the input values fall too far outside the expected threshold.



Only after achieving stable baseline heights could I proceed with the actual calibration. Here were my final input values for Inclination Angle for final calibration:
Left Front Inclination Angle: 4.8
Right Front Inclination Angle: 4.8
Left Rear Inclination Angle: -1.4
Right Rear Inclination Angle: -1.4



With these values in place, the scanner accepted the inputs and initiated auto-calibration. After a few minutes of pressurising, depresurings and auto levelling on all four struts, the system completed the process successfully.
During this repair, we also encountered a fault code for the front-left suspension acceleration sensor.



This sensor is mounted just above the strut. Thankfully, it turned out to be a connectivity issue. Cleaning the contacts resolved the fault, and the system cleared without further trouble.

After this we also performed the engine service as the last service was performed a year ago in March 2023. This time we used :

- Gulf Formula Elite 5W30 which is BS6 compatible and also Low SPAsh spec and MB229.51 approval. Bought 9L for Rs. 4500 from Amazon.

- Mann Air Filters, AC Cabin Filters, Oil Filter and new Bosch Wiper Blades. All procured from Boodmo.com. I usually anticipate the service and pre order the parts a month or two ahead. I paid Rs.9500 for these parts.

After the service I felt Gulf Formula Elite performance more or less the same to Mobil 1 ESP and it is less than half the cost. With the AIRMATIC system restored, the GL was once again floating on air but we had a problem. The replacement AIRMATIC compressor worked flawlessly but was absurdly loud. It was more like an industrial pneumatic tool than something you’d expect in a Mercedes. After three days of enduring the racket, I returned to the workshop and asked my mechanic to get creative. He managed to swap the outer casing of the new compressor onto the internals of the original unit. The result was a perfectly functioning, whisper-quiet AIRMATIC system that felt just like factory spec. I kept the noisy one aside as a spare for future emergencies.



Post AIRMATIC service and recalibration, the ride height settled slightly higher than before. I feel this setup gives the GL a more balanced stance, with improved front-rear distribution and a noticeably better dynamic posture on the road.

Some more pics :







The RTO transfer process from Haryana to Chhattisgarh was finally completed in October 2024. The delay stretched over a year since we had initially obtained the NOC from Chandigarh RTO. During this period, the original NOC documents and forms went missing at home, causing further setbacks. Fortunately, the folder was found in September 2024. Inspection was conducted the following month, and after approval, a new Chhattisgarh registration number was allotted. The total cost came to around Rs.1.25 lakhs, which included agent charges for the Haryana NOC, 10% road tax based on the car’s depreciated value, penalty, interest, new RC smartcard fees, etc. and local agent service fees.