2004 Mercedes E-Class (W211) Service and Repair Manual
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🏷️ Basic Information Identification Make: Mercedes-Benz Model: E-Class Model Code: W211 Model Year: 2004 👋 Introduction Market Position Segment: Executive Sedan/Wagon Brand Perception: Luxury, comfort, engineering, safety Competitive Analysis Primary Competitors: BMW 5 Series (E60), Audi A6 (C6), Lexus GS Key Features Design Philosophy: Aerodynamic lines, elegant styling, focus on occupant comfort and advanced technology Innovation: Introduction of Sensotronic Brake Control (SBC) on many models, advanced electronic chassis controls 📋 Manual Details Coverage Areas Coverage Scope: All models and all repairs A-Z Page Count Estimated Page Count: Extensive (typically 2000+ pages for a complete W211 service manual) Manual Type Type: Service and Repair Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete teardown, inspection, and reassembly of all engine variants (e.g., M271, M112, M272, OM646, OM647, OM648) Engine Electrical: Engine control modules (ECM), ignition systems, fuel injection systems, sensors, actuators, wiring diagrams Transmission Mechanical: Service and repair of automatic transmissions (e.g., 722.6, 722.9) and manual transmissions (where applicable) Transmission Electrical: Transmission control modules (TCM), shift solenoids, sensors, wiring diagrams Braking System: Hydraulic and electronic braking systems, ABS, ESP, SBC (Sensotronic Brake Control) for applicable models, brake pad and rotor replacement, caliper service Suspension Steering: Front and rear suspension components, shock absorbers, springs, control arms, power steering systems, alignment specifications Electrical Systems: 12V electrical system, battery, alternator, starter, lighting systems, fuses, relays, body control modules (BCM), comfort systems HVAC System: Climate control systems, A/C compressor, refrigerant, heater core, blower motor, diagnostic procedures Body And Interior: Body panel removal and installation, door mechanisms, interior trim, seating systems, airbags, body integrity Chassis And Frame: Structural components, chassis rigidity, mounting points Diagnostic Systems: OBD-II diagnostics, trouble codes (DTCs), Mercedes-specific diagnostic tools (e.g., STAR Diagnosis) procedures Procedures Included Maintenance Procedures: Routine inspections, oil and filter changes, spark plug replacement, air filter replacement, fluid checks and top-offs Repair Procedures: Engine component replacement (e.g., water pump, thermostat, fuel injectors), transmission service, brake caliper rebuild, suspension component replacement, starter/alternator replacement Troubleshooting Guides: Systematic diagnostic trees for common malfunctions, symptom-based troubleshooting Technical Specifications: Torque specifications for all fasteners, clearance specifications, timing specifications Wiring Diagrams: Comprehensive electrical wiring schematics for all vehicle systems Special Tool Requirements: Identification and use of specialized Mercedes-Benz tools for specific repair procedures Recalibration Procedures: Procedures for recalibrating sensors and modules after component replacement (e.g., throttle body, steering angle sensor) Technical Depth Depth: Factory-level diagnostic and repair procedures Detail Level: Step-by-step instructions with detailed diagrams and illustrations 📊 Manual Specifications File Format Digital Format: PDF (Searchable Text Optimized) Print Quality Image Resolution: High-resolution for clear diagrams and text Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Options 2004: E320 (3.2L Diesel V6), E350 (3.7L V6), E500 (5.0L V8), E55 AMG (5.4L Supercharged V8), E200 Kompressor (2.0L Supercharged I4), E240 (2.6L V6), E270 CDI (2.7L Turbo Diesel I5), E320 CDI (3.2L Turbo Diesel I6) Performance E55 Amg Horsepower: 469 hp @ 6100 rpm E55 Amg Torque: 516 lb-ft @ 2650 rpm Fuel System Fuel Injection Type: Sequential Multi-Point Fuel Injection (MPI) or Common Rail Direct Injection (CDI) for diesel Engine Codes Common Gasoline Engines: M112 (V6), M272 (V6), M113 (V8), M113 ML (Supercharged V8) Common Diesel Engines: OM646 (I4), OM647 (I5), OM648 (I6) 🔧 Transmission Standard Standard Transmission Type: 5-speed Automatic (722.6) or 7-speed Automatic (722.9 '7G-TRONIC') Optional Optional Transmission Type: Manual transmission available in some markets/specific models (less common) Features Automatic Modes: Comfort (C), Sport (S), Manual (M) shifting modes 📐 Dimensions Exterior Wheelbase Sedan: 115.7 inches (2937 mm) Length Sedan: 190.9 inches (4850 mm) Width Sedan: 71.5 inches (1816 mm) Height Sedan: 57.3 inches (1455 mm) Weights Curb Weight Range: Approx. 3500 - 4000+ lbs (depending on engine and equipment) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 5 Stars NHTSA Front Impact Passenger: 5 Stars IIHS Front Offset Crash Rating: Good Active Features Traction Control: ASR (Acceleration Slip Regulation) / ESP (Electronic Stability Program) Braking Assistance: BAS (Brake Assist System), SBC (Sensotronic Brake Control) on applicable models Passive Features Airbag Systems: Front airbags, side airbags, window airbags, optional thorax airbags Seat Belt Pretensioners: Standard on front seats 💡 Technology Features Infotainment Infotainment System: COMAND (Cockpit Management and Data) system, with options for navigation, CD changer, and premium audio. Driver Assistance Adaptive Cruise Control: DISTRONIC (optional feature) Parking Assistance: PARKTRONIC parking sensors (front and rear) Headlights: Bi-Xenon headlights with adaptive front-lighting system (optional) Connectivity Cellular Integration: Integrated hands-free communication system (optional) 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10,000 miles or 1 year, whichever comes first (depending on driving conditions and oil type, often dictated by 'Assyst' service reminder system). Major Service Interval: Service B (around 20,000 miles or 2 years) and Service C (around 30,000 miles or 3 years), alternating and dependent...
Service and repair of automatic transmissions (e.g., 722.6, 722.9) and manual transmissions (where applicable)
Transmission Electrical:
Transmission control modules (TCM), shift solenoids, sensors, wiring diagrams
Braking System:
Hydraulic and electronic braking systems, ABS, ESP, SBC (Sensotronic Brake Control) for applicable models, brake pad and rotor replacement, caliper service
Suspension Steering:
Front and rear suspension components, shock absorbers, springs, control arms, power steering systems, alignment specifications
Electrical Systems:
12V electrical system, battery, alternator, starter, lighting systems, fuses, relays, body control modules (BCM), comfort systems
Sequential Multi-Point Fuel Injection (MPI) or Common Rail Direct Injection (CDI) for diesel
Engine Codes
Common Gasoline Engines:
M112 (V6), M272 (V6), M113 (V8), M113 ML (Supercharged V8)
Common Diesel Engines:
OM646 (I4), OM647 (I5), OM648 (I6)
🔧 Transmission
Standard
Standard Transmission Type:
5-speed Automatic (722.6) or 7-speed Automatic (722.9 '7G-TRONIC')
Optional
Optional Transmission Type:
Manual transmission available in some markets/specific models (less common)
Features
Automatic Modes:
Comfort (C), Sport (S), Manual (M) shifting modes
📐 Dimensions
Exterior
Wheelbase Sedan:
115.7 inches (2937 mm)
Length Sedan:
190.9 inches (4850 mm)
Width Sedan:
71.5 inches (1816 mm)
Height Sedan:
57.3 inches (1455 mm)
Weights
Curb Weight Range:
Approx. 3500 - 4000+ lbs (depending on engine and equipment)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5 Stars
NHTSA Front Impact Passenger:
5 Stars
IIHS Front Offset Crash Rating:
Good
Active Features
Traction Control:
ASR (Acceleration Slip Regulation) / ESP (Electronic Stability Program)
Braking Assistance:
BAS (Brake Assist System), SBC (Sensotronic Brake Control) on applicable models
Passive Features
Airbag Systems:
Front airbags, side airbags, window airbags, optional thorax airbags
Seat Belt Pretensioners:
Standard on front seats
💡 Technology Features
Infotainment
Infotainment System:
COMAND (Cockpit Management and Data) system, with options for navigation, CD changer, and premium audio.
Driver Assistance
Adaptive Cruise Control:
DISTRONIC (optional feature)
Parking Assistance:
PARKTRONIC parking sensors (front and rear)
Headlights:
Bi-Xenon headlights with adaptive front-lighting system (optional)
Connectivity
Cellular Integration:
Integrated hands-free communication system (optional)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 miles or 1 year, whichever comes first (depending on driving conditions and oil type, often dictated by 'Assyst' service reminder system).
Major Service Interval:
Service B (around 20,000 miles or 2 years) and Service C (around 30,000 miles or 3 years), alternating and dependent on vehicle usage, includes more extensive checks and fluid changes.
Fluid Specifications
Engine Oil Specification:
MB 229.5 (for gasoline engines) or MB 229.51/228.51 (for diesel engines with DPF), typically 0W-40 or 5W-40 synthetic.
MB 325.0 or MB 326.0 (Antifreeze/Coolant, blue color) - typically a 50/50 mix with distilled water.
Brake Fluid Specification:
DOT 4 Plus (MB 331.0)
Known Issues
Common Issue Sbc Failure:
Sensotronic Brake Control (SBC) hydraulic unit can fail, leading to 'Visit Workshop' messages and loss of braking function. Requires specialized diagnostics and replacement.
Common Issue Oil Cooler Leaks:
Oil cooler seals and lines can develop leaks, particularly on the M112 and M113 V6/V8 engines.
Common Issue Ecosystem Failures:
Various sensors (e.g., crankshaft position, camshaft position) and electronic modules can fail, often requiring diagnostic scanning to pinpoint.
Common Issue Suspension Components:
Worn control arm bushings, ball joints, and strut mounts can lead to noise and handling issues, especially on higher mileage vehicles.
📚 Vehicle History
Brand Heritage
Brand Legacy:
Mercedes-Benz has a long-standing reputation for automotive engineering excellence, safety, and luxury since its inception.
Model Evolution
W211 Introduction:
The W211 generation of the E-Class was introduced in 2002 for the 2003 model year, replacing the W210. The 2004 model year represents an early production year of this generation.
Design Influence:
Carried over the four-headlight design language from its predecessor, but with a more modern interpretation.
Production
Production Locations:
Primary assembly in Sindelfingen, Germany, with additional production in other global facilities.
🏆 Awards & Recognition
Recognitions
Safety Awards:
Consistently received high safety ratings from NHTSA and IIHS, reflecting Mercedes-Benz's commitment to safety engineering.
Ratings
Reliability Perception:
While known for luxury and engineering, Mercedes-Benz vehicles of this era can have higher maintenance costs and require specialized knowledge for repairs, which this manual addresses.
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