🏷️ Basic Information

Make:

Mercedes-Benz

Model:

ML500

Year:

2004

Product Type:

Service & Repair Manual Software

Chassis Code:

W163

Vin Decoder Prefix:

WDB

👋 Introduction

Positioning:

The 2004 Mercedes-Benz ML500 (W163 generation) positioned itself as a luxury mid-size SUV with a focus on comfort, performance, and advanced features, competing with vehicles like the BMW X5 and Lexus RX series.

Competitors:

Primary competitors included the BMW X5 (E53), Lexus RX 330, Audi A6 allroad, and Volvo XC90. The ML500 offered a potent V8 engine and a more truck-like feel compared to some rivals.

Features:

Standard 4MATIC all-wheel drive, powerful M113 V8 engine, luxurious interior appointments, optional third-row seating, advanced safety systems.

Value:

This official software manual provides in-depth, accurate repair and maintenance information essential for owners and technicians to maintain the performance and longevity of their 2004 ML500, saving on dealership costs.

📋 Manual Details

Engine:

Yes

Transmission:

Yes

Drivetrain:

Yes

Suspension:

Yes

Brakes:

Yes

Steering:

Yes

Electrical System:

Yes

Climate Control:

Yes

Body And Interior:

Yes

Diagnostic Troubleshooting:

Yes

Maintenance Schedules:

Yes

Technical Specifications:

Yes

Wiring Diagrams:

Yes

Estimated Pages:

Extensive (Software-based, not a fixed page count)

Type:

Official Service and Repair Manual

Language:

English

Format:

Software (Digital Download)

📖 Manual Coverage

Engine Management:

Detailed diagnostics, component testing, ECU parameters, fuel injection, ignition timing, emission controls.

Transmission Control:

5-speed automatic transmission (722.6) diagnostics, fluid service, solenoid operation, torque converter.

4Matic AWD:

All-wheel drive system operation, transfer case, differentials, electronic control.

Suspension And Steering:

Independent front and rear suspension, components, alignment procedures, power steering system, components.

Braking System:

Anti-lock Braking System (ABS), Electronic Stability Program (ESP), brake pad/rotor replacement, brake fluid service, hydraulic system diagnostics.

Body Electronics:

Lighting systems, power windows, mirrors, seats, central locking, alarm system, fuse and relay locations.

Climate Control HVAC:

Automatic climate control operation, refrigerant service, blower motor, blend doors, cabin filter replacement.

Infotainment And Navigation:

COMAND system (if equipped), audio system, navigation system troubleshooting.

Safety Systems:

Airbag system (SRS), seat belt pre-tensioners, system diagnostics.

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt replacement.

Major Repairs:

Engine overhaul, transmission rebuild, suspension component replacement, brake caliper replacement.

Troubleshooting Guides:

Step-by-step diagnostic flowcharts for common and uncommon faults.

Component Replacement:

Detailed instructions for replacing starters, alternators, fuel pumps, radiators, etc.

Specifications And Tolerances:

Torque specifications, clearances, and technical data for all major components.

Wiring Diagram Interpretation:

Guidance on understanding and utilizing complex electrical schematics.

Depth:

Comprehensive: Covers routine maintenance, diagnostic procedures, component-level repair, and overhaul instructions.

📊 Manual Specifications

Format Details:

Proprietary software with searchable interface, often executable on Windows OS. May require specific installation or activation.

Quality:

N/A (Digital Software)

Binding:

N/A (Digital Software)

Paper:

N/A (Digital Software)

⚙️ Engine Specifications

Engine Code:

M113 E50

Engine Type:

V8, SOHC (Single Overhead Cam)

Displacement:

4966 cc (5.0 Liters)

Horsepower:

288 hp @ 5,500 rpm

Torque:

325 lb-ft @ 3,750 rpm

Fuel Delivery:

Sequential Multi-Port Fuel Injection (SFI)

Recommended Fuel:

Premium Unleaded Gasoline (91 octane or higher)

Coolant Type:

MB Spec 325.0 / G05 Antifreeze (Blue)

Oil Capacity:

8.5 Liters (8.9 US Quarts)

Recommended Oil:

Mobil 1 0W-40 or equivalent (MB Approved 229.5)

Spark Plugs:

Bosch FGR7KQE0U or equivalent (Platinum, long life)

🔧 Transmission

Transmission Type:

5-speed Automatic Transmission

Transmission Model:

722.6 (Mercedes-Benz 5G-Tronic)

Drivetrain:

4MATIC All-Wheel Drive

Transmission Fluid Type:

MB Spec 236.10 / MB Spec 236.14 (ATF) - Typically Shell ATF 134 or equivalent

Transmission Fluid Capacity:

Approx. 8.5 Liters (1700 or 001 989 22 03)

📐 Dimensions

Length:

189.1 inches (4,803 mm)

Width:

75.2 inches (1,910 mm)

Height:

70.5 inches (1,791 mm)

Wheelbase:

111.0 inches (2,820 mm)

Curb Weight:

4,640 lbs (2,105 kg)

Gross Vehicle Weight Rating Gvwr:

5,842 lbs (2,650 kg)

Cargo Volume Seats Up:

36.5 cubic feet (1,033 L)

Cargo Volume Seats Down:

79.4 cubic feet (2,248 L)

🛡️ Safety Features

NHTSA Frontal Crash Driver:

5 Stars

NHTSA Frontal Crash Passenger:

5 Stars

NHTSA Side Impact Driver:

5 Stars

NHTSA Side Impact Passenger:

5 Stars

IIHS Frontal Offset:

Good

Esp:

Standard Electronic Stability Program

ABS:

Standard Anti-lock Braking System

Traction Control:

Standard Traction Control System (TC/ASR)

Airbags:

Frontal airbags for driver and passenger, front side-impact airbags, optional rear side-impact airbags.

Seatbelts:

3-point height-adjustable seatbelts with pretensioners and force limiters.

💡 Technology Features

Infotainment System:

Optional COMAND (Cockpit Management and Navigation) system featuring a 6.5-inch color display, AM/FM radio, CD player, and optional GPS navigation. Harman Kardon premium audio system available.

Driver Assistance Features:

ABS, ESP, Traction Control (ASR), ParkTronic parking assist system (optional).

Connectivity Options:

Cellular phone pre-wiring and integration (optional).

Comfort Technology:

Dual-zone automatic climate control, heated front seats, power-adjustable front seats with memory, cruise control.

🔧 Maintenance

Oil Change Interval:

Every 10,000 miles or 1 year, whichever comes first (using approved synthetic oil).

Transmission Service Interval:

Every 40,000 - 60,000 miles (refer to manual for specific type of service).

Coolant Flush Interval:

Every 2 years or 30,000 miles.

Spark Plug Replacement Interval:

Approximately 100,000 miles (for platinum tipped plugs).

Brake Fluid Flush Interval:

Every 2 years.

Power Steering Fluid:

Pentosin CHF 11S or equivalent (MB Spec 343.0)

Brake Fluid:

DOT 4 Plus (MB Spec 331.0)

Common Problems:

Mass Air Flow (MAF) sensor issues, Idle Air Control (IAC) valve problems, Crankshaft Position Sensor (CPS) failure, oil cooler seals leaking, transmission conductor plate issues, SRS warning light illumination, front suspension clunks (control arm bushings).

📚 Vehicle History

Mercedes Benz Legacy:

Mercedes-Benz, a pioneer in automotive engineering, has a rich history dating back to the invention of the automobile by Karl Benz in 1886. Known for luxury, safety, and innovation.

W163 Generation History:

The W163 M-Class debuted in 1997. The 2004 model represents the facelifted version, introduced for the 2002 model year, featuring updated styling and powertrain options. The ML500 specifically replaced the ML430 with a more powerful V8.

Manufacturing Location:

Tuscaloosa, Alabama, USA (for North American market)

W163 Production Run:

1997-2005

🏆 Awards & Recognition

Safety Award Example:

The W163 M-Class, including the 2004 ML500, received top safety ratings from government agencies like NHTSA, reflecting Mercedes-Benz's commitment to occupant protection.

Kbb Value Indicator:

While not an award, KBB.com and similar resources would have ranked its resale value based on segment and condition.

Oem Certification:

This manual is 'Officially Licensed', indicating it is a genuine Mercedes-Benz service and repair manual, ensuring accuracy and completeness.