2004 Mercedes S-Class (W220) Service and Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: S-Class Model Code: W220 Year: 2004 Codes Chassis Code: W220 Generation Generation Name: Third Generation S-Class Generation Years: 1998-2005 👋 Introduction Market Position Segment: Full-size Luxury Sedan Competitors 2004: BMW 7 Series (E65/E66), Audi A8 (D3), Lexus LS 430, Jaguar XJ, Porsche Panamera (later) Target Audience: Affluent consumers seeking high levels of comfort, technology, and prestige. Competitive Analysis W220 Strengths: Advanced technology (ABC, Distronic, SBC), refined ride quality, superior interior materials, strong brand heritage. W220 Weaknesses: Complex electronics leading to potential repair costs, some initial reliability concerns with early models. Key Features Flagship Status: Represents the pinnacle of Mercedes-Benz engineering and luxury. Design Philosophy: Elegant, understated styling with a focus on aerodynamic efficiency and sophisticated interior design. Technology Introduction: Pioneered technologies like Active Body Control (ABC) and Sensotronic Brake Control (SBC) in mass production. 📋 Manual Details Coverage Areas All Models Covered: Yes Repair Scope: A-Z (All Repairs) Vehicle Specificity: Vehicle Specific (Not Generic) Technician Use: Official Dealership Technician Manual Page Count Estimated Page Count: Refer to actual manual for precise count (typically 2000+ pages for comprehensive W220 service manuals) Manual Type Type: Service and Repair Manual Language Language: English Format Format: Likely Digital (PDF), though physical copies exist 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, assembly, disassembly, component testing, specifications Engine Management: Fuel injection, ignition, emissions control, ECU diagnostics, sensors, actuators Transmission Automatic: 722.6 (5-Speed Automatic) overhaul, service, diagnostics, control module Drivetrain: Axles, driveshafts, differentials, wheel bearings, CV joints Suspension: ABC (Active Body Control) system, airmatic suspension, struts, shocks, control arms, bushings, links Steering: Power steering system, steering rack, tie rods, steering column Brakes: Hydraulic system, ABS, ESP, SBC (Sensotronic Brake Control), brake pads, rotors, calipers, lines, bleeding procedures Electrical System: 12V system, alternator, battery, starter, wiring diagrams, fuses, relays Body Control Module: BCM, CAN bus system, diagnostics, component location Lighting: Headlights (including Xenon/Bi-Xenon), taillights, interior lighting, control modules Climate Control: Automatic climate control (THERMATIC/THERMOTRONIC), HVAC system, A/C compressor, refrigerant, blower motor, actuators Comfort Systems: Power seats, memory seats, heated/ventilated seats, power windows, sunroof, door locks, soft-close doors, trunk automation Infotainment Audio: COMAND system, radio, navigation, CD changer, speaker system, telematics Safety Systems: Airbags, seatbelt pre-tensioners, SRS module, seat occupancy sensors Driver Assistance: Distronic (adaptive cruise control), PARKTRONIC (parking sensors), rain sensor, light sensor Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting, component testing procedures Component Replacement: Detailed step-by-step instructions for replacing all major and minor components Major Overhaul: Engine and transmission rebuild procedures Diagnostic Procedures: Use of diagnostic tools (e.g., STAR DAS), reading live data, actuator tests Calibration Procedures: SBC calibration, suspension calibration, steering angle sensor calibration Bodywork Repair: Panel removal and installation, dent repair, paint refinishing guidelines Wiring Diagrams: Comprehensive, color-coded wiring schematics for all systems Technical Depth Depth: Comprehensive: From basic fluid checks to complete engine and transmission rebuilds, including advanced electronic diagnostics. Diagnostic Tools: References and procedures for using Mercedes-Benz proprietary diagnostic equipment (e.g., STAR DAS). Torque Specifications: Detailed torque values for all fasteners. Clearances And Tolerances: Precise measurements for component clearances and wear limits. Special Tools: Identification and usage of specialized Mercedes-Benz tools required for specific procedures. 📊 Manual Specifications File Format Format: Digital (PDF) is common, allowing for searchability and easy navigation. Physical printed manuals also exist. Searchability: High (if PDF with text recognition) Print Quality Print Quality: High (for official manuals, clear diagrams and text) Binding Type Binding Type: N/A for digital. For physical: Typically spiral-bound or comb-bound for ease of use on a workbench. Paper Type Paper Type: N/A for digital. For physical: High-quality, durable paper suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Engine Family: Mercedes-Benz M112 (V6) and M113 (V8) families Engine 2004 Options: S350 (3.7L V6), S430 (4.3L V8), S500 (5.0L V8), S55 AMG (5.4L V8 Supercharged), S600 (5.5L V12 Twin-Turbocharged) Engine Displacement S430: 4266 cc Engine Displacement S500: 4966 cc Engine Displacement S55 Amg: 5439 cc Engine Displacement S600: 5513 cc Performance Horsepower S430: 275 hp @ 6000 rpm Torque S430: 295 lb-ft @ 3250 rpm Horsepower S500: 302 hp @ 6100 rpm Torque S500: 339 lb-ft @ 3250 rpm Horsepower S55 Amg: 493 hp @ 6100 rpm Torque S55 Amg: 516 lb-ft @ 2750-4000 rpm Horsepower S600: 493 hp @ 5000 rpm Torque S600: 590 lb-ft @ 1800-3500 rpm Fuel System Fuel Type: Premium Unleaded Gasoline (91+ octane recommended) Injection System: Electronic Fuel Injection (EFI) Forced Induction: Supercharger (S55 AMG), Twin-Turbochargers (S600) 🔧 Transmission Standard Transmission Type: 5-Speed Automatic (722.6 '7G-TRONIC' predecessor) Optional Optional Transmission: N/A for 2004 model year; 7G-TRONIC introduced later in W220 lifecycle. Features Shift Modes: Comfort (C) and Sport (S) modes Transmission Fluid Spec: MB 236.10 (e.g., Pentosin ATF1, Mobil ATF 134) 📐 Dimensions Exterior Length:...

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

S-Class

Model Code:

Year:

Codes

Chassis Code:

Generation

Generation Name:

Third Generation S-Class

Generation Years:

1998-2005

👋 Introduction

Market Position

Segment:

Full-size Luxury Sedan

Competitors 2004:

BMW 7 Series (E65/E66), Audi A8 (D3), Lexus LS 430, Jaguar XJ, Porsche Panamera (later)

Target Audience:

Affluent consumers seeking high levels of comfort, technology, and prestige.

Competitive Analysis

W220 Strengths:

Advanced technology (ABC, Distronic, SBC), refined ride quality, superior interior materials, strong brand heritage.

W220 Weaknesses:

Complex electronics leading to potential repair costs, some initial reliability concerns with early models.

Key Features

Flagship Status:

Represents the pinnacle of Mercedes-Benz engineering and luxury.

Design Philosophy:

Elegant, understated styling with a focus on aerodynamic efficiency and sophisticated interior design.

Technology Introduction:

Pioneered technologies like Active Body Control (ABC) and Sensotronic Brake Control (SBC) in mass production.

📋 Manual Details

Coverage Areas

All Models Covered:

Repair Scope:

A-Z (All Repairs)

Vehicle Specificity:

Vehicle Specific (Not Generic)

Technician Use:

Official Dealership Technician Manual

Page Count

Estimated Page Count:

Refer to actual manual for precise count (typically 2000+ pages for comprehensive W220 service manuals)

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Likely Digital (PDF), though physical copies exist

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, assembly, disassembly, component testing, specifications

Engine Management:

Fuel injection, ignition, emissions control, ECU diagnostics, sensors, actuators

Transmission Automatic:

722.6 (5-Speed Automatic) overhaul, service, diagnostics, control module

Drivetrain:

Axles, driveshafts, differentials, wheel bearings, CV joints

Suspension:

ABC (Active Body Control) system, airmatic suspension, struts, shocks, control arms, bushings, links

Steering:

Power steering system, steering rack, tie rods, steering column

Brakes:

Hydraulic system, ABS, ESP, SBC (Sensotronic Brake Control), brake pads, rotors, calipers, lines, bleeding procedures

Electrical System:

12V system, alternator, battery, starter, wiring diagrams, fuses, relays

Body Control Module:

BCM, CAN bus system, diagnostics, component location

Lighting:

Headlights (including Xenon/Bi-Xenon), taillights, interior lighting, control modules

Climate Control:

Automatic climate control (THERMATIC/THERMOTRONIC), HVAC system, A/C compressor, refrigerant, blower motor, actuators

Comfort Systems:

Power seats, memory seats, heated/ventilated seats, power windows, sunroof, door locks, soft-close doors, trunk automation

Infotainment Audio:

COMAND system, radio, navigation, CD changer, speaker system, telematics

Safety Systems:

Airbags, seatbelt pre-tensioners, SRS module, seat occupancy sensors

Driver Assistance:

Distronic (adaptive cruise control), PARKTRONIC (parking sensors), rain sensor, light sensor

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection

Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting, component testing procedures

Component Replacement:

Detailed step-by-step instructions for replacing all major and minor components

Major Overhaul:

Engine and transmission rebuild procedures

Diagnostic Procedures:

Use of diagnostic tools (e.g., STAR DAS), reading live data, actuator tests

Calibration Procedures:

SBC calibration, suspension calibration, steering angle sensor calibration

Bodywork Repair:

Panel removal and installation, dent repair, paint refinishing guidelines

Wiring Diagrams:

Comprehensive, color-coded wiring schematics for all systems

Technical Depth

Depth:

Comprehensive: From basic fluid checks to complete engine and transmission rebuilds, including advanced electronic diagnostics.

Diagnostic Tools:

References and procedures for using Mercedes-Benz proprietary diagnostic equipment (e.g., STAR DAS).

Torque Specifications:

Detailed torque values for all fasteners.

Clearances And Tolerances:

Precise measurements for component clearances and wear limits.

Special Tools:

Identification and usage of specialized Mercedes-Benz tools required for specific procedures.

📊 Manual Specifications

File Format

Format:

Digital (PDF) is common, allowing for searchability and easy navigation. Physical printed manuals also exist.

Searchability:

High (if PDF with text recognition)

Print Quality

Print Quality:

High (for official manuals, clear diagrams and text)

Binding Type

Binding Type:

N/A for digital. For physical: Typically spiral-bound or comb-bound for ease of use on a workbench.

Paper Type

Paper Type:

N/A for digital. For physical: High-quality, durable paper suitable for workshop environments.

⚙️ Engine Specifications

Primary Engine

Engine Family:

Mercedes-Benz M112 (V6) and M113 (V8) families

Engine 2004 Options:

S350 (3.7L V6), S430 (4.3L V8), S500 (5.0L V8), S55 AMG (5.4L V8 Supercharged), S600 (5.5L V12 Twin-Turbocharged)

Engine Displacement S430:

4266 cc

Engine Displacement S500:

4966 cc

Engine Displacement S55 Amg:

5439 cc

Engine Displacement S600:

5513 cc

Performance

Horsepower S430:

275 hp @ 6000 rpm

Torque S430:

295 lb-ft @ 3250 rpm

Horsepower S500:

302 hp @ 6100 rpm

Torque S500:

339 lb-ft @ 3250 rpm

Horsepower S55 Amg:

493 hp @ 6100 rpm

Torque S55 Amg:

516 lb-ft @ 2750-4000 rpm

Horsepower S600:

493 hp @ 5000 rpm

Torque S600:

590 lb-ft @ 1800-3500 rpm

Fuel System

Fuel Type:

Premium Unleaded Gasoline (91+ octane recommended)

Injection System:

Electronic Fuel Injection (EFI)

Forced Induction:

Supercharger (S55 AMG), Twin-Turbochargers (S600)

🔧 Transmission

Standard

Transmission Type:

5-Speed Automatic (722.6 '7G-TRONIC' predecessor)

Optional

Optional Transmission:

N/A for 2004 model year; 7G-TRONIC introduced later in W220 lifecycle.

Features

Shift Modes:

Comfort (C) and Sport (S) modes

Transmission Fluid Spec:

MB 236.10 (e.g., Pentosin ATF1, Mobil ATF 134)

📐 Dimensions

Exterior

Length:

Approx. 199.1 inches (Standard Wheelbase)

Width:

Approx. 73.7 inches

Height:

Approx. 57.7 inches

Wheelbase Standard:

116.7 inches

Wheelbase Long:

121.5 inches (for models like S500L)

Weights

Curb Weight S430:

Approx. 3900 lbs

Curb Weight S500:

Approx. 4100 lbs

Gross Vehicle Weight Rating:

Varies by model, consult specific vehicle data.

Cargo

Trunk Volume:

Approx. 17.7 cubic feet

🛡️ Safety Features

Ratings

NHTSA Front Impact:

5-Star (Typical for this era and segment)

IIHS Side Impact:

Good (Typical for this era and segment)

Active Features

Standard Anti-lock Braking System

Standard Electronic Stability Program (ESP)

Sensotronic Brake Control (Standard on S430/S500/S600, optional on S350)

Distronic:

Optional Adaptive Cruise Control

Parktronic:

Optional Parking Assist System

Passive Features

Airbags Front:

Dual-stage front airbags

Airbags Side:

Front and rear side-impact airbags

Airbags Curtain:

Window airbags (head protection)

Seatbelts:

3-point inertia-reel seatbelts with pre-tensioners and belt-force limiters

Supplemental Restraint System (SRS) with occupant classification

💡 Technology Features

Infotainment

Comand System:

Central display for navigation, radio, climate control, and vehicle settings.

Navigation:

Optional GPS navigation system with CD-ROM maps.

Audio System:

Bose premium sound system available, with CD changer.

Driver Assistance

Distronic Operation:

Uses radar to maintain a set distance from the vehicle ahead.

Parktronic Operation:

Audible and visual warnings for obstacles during parking.

Rain Light Sensor:

Automatic control of windshield wipers and headlights.

Connectivity

Telematics:

Optional Tele Aid emergency calling system.

Bluetooth:

Optional integrated Bluetooth hands-free communication system.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000 miles or 12 months (whichever comes first), depending on driving conditions and oil used. Consult manual for specific service indicator reset.

Major Service Interval:

Intervals vary (e.g., 30,000, 60,000 miles) for spark plugs, transmission service, coolant, etc. Refer to manual for detailed A/B service schedules.

Fluid Specifications

Engine Oil:

MB 229.5 (e.g., Mobil 1 0W-40 Synthetic)

Coolant:

MB 325.0 (Antifreeze/Coolant concentrate)

Brake Fluid:

DOT 4 Plus (MB 331.0)

Power Steering Fluid:

MB 343.0 (Mineral oil based, often Pentosin CHF 11S or equivalent)

Windshield Washer Fluid:

Approved washer fluid concentrate (e.g., Sonax)

Known Issues

Abc Suspension:

Leakage in hydraulic lines, pump failure, valve body issues, strut seal failures. Regular fluid changes and filter replacement are crucial.

Sbc System:

High-pressure pump failure, accumulator wear, sensor issues. Requires specialized tools and procedures for service.

Electronics:

Various module failures (e.g., SAM modules, door control modules), CAN bus communication errors, EIS (Electronic Ignition Switch) issues.

Air Suspension Sprung:

Airmatic compressor failure, air spring leaks (though ABC is more prevalent on higher trims).

Cooling System:

Water pump leaks, thermostat housing failures, radiator hose degradation.

Interior Trim:

Headliner sagging, dashboard material delamination (especially in warm climates).

Maintenance Schedule Details

Brakes Pad Rotor Life:

Varies greatly with driving style, but typically 30,000-60,000 miles for pads and 60,000-100,000 miles for rotors.

📚 Vehicle History

Brand Heritage

Mercedes Benz Legacy:

Over a century of automotive innovation and luxury car manufacturing.

S Class Lineage:

The S-Class has been Mercedes-Benz's flagship luxury sedan since the W116 generation in 1972.

Model Evolution

W220 Introduction:

Introduced in 1998 (for the 1999 model year) as a replacement for the W140 S-Class.

W220 Facelift:

Received a significant facelift for the 2003 model year, including updated styling, new engines, and further technological integration.

W220 Production End:

Production concluded in 2005, succeeded by the W221 S-Class.

Production

Manufacturing Locations:

Mainly Sindelfingen, Germany

🏆 Awards & Recognition

Recognitions

Car Of The Year:

While not directly winning 'Car of the Year' in major US publications for 2004, the S-Class consistently ranks high in luxury sedan comparisons.

Best Resale Value:

Typically ranks well in luxury segment, though depreciation can be steep for all luxury vehicles.

Safety Awards:

Consistently received high safety ratings from organizations like NHTSA and IIHS.

Ratings

Consumer Reports Reliability:

Reliability scores varied for the W220 generation; specific model year reports would provide more detail. Early years had more issues than facelifted models.

Certifications

Manufacturers Certification:

This manual is the official factory service manual, representing the highest level of certification for repair documentation.