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Mercedes Benz W220 S Class Service Repair Manual 1998-2006

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: S-Class Chassis Code: W220 Generation Generation Designation: Fifth Generation Model Years Covered: 1998-2006 Codes Engine Codes Covered: M112, M113, M113 E55, M137, OM612,...
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Mercedes Benz W220 S Class Service Repair Manual 1998-2006
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
S-Class
Chassis Code:
W220
Generation
Generation Designation:
Fifth Generation
Model Years Covered:
1998-2006
Codes
Engine Codes Covered:
M112, M113, M113 E55, M137, OM612, OM613, OM628
👋 Introduction
Market Position
Segment:
Full-size Luxury Sedan
Target Audience:
Discerning luxury car owners, independent repair shops specializing in European vehicles, DIY mechanics with advanced skills.
Competitive Analysis
Key Competitors:
BMW 7 Series (E38/E65), Audi A8 (D2/D3), Lexus LS (XF20), Jaguar XJ (X308/X350).
Key Features
Distinctive Technologies:
Active Body Control (ABC) suspension, COMAND infotainment system, biometric driver recognition (optional early models), innovative interior design.
Manual Value Proposition
Completeness:
The most comprehensive digital resource available for the W220 chassis, offering factory-level detail often missing in consumer-grade manuals.
📋 Manual Details
Coverage Areas
Engine Variants:
S280, S320, S350, S430, S500, S55 AMG, S600, S65 AMG (including various CDI diesel variants)
Drivetrain Options:
Rear-Wheel Drive (RWD), All-Wheel Drive (4MATIC)
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Complete Service and Repair Manual (Factory Workshop Manual Equivalent)
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical (including timing systems, cylinder heads, pistons, crankshaft), fuel system (injection, pumps, filters), ignition system, cooling system, exhaust system, emissions control.
Transmission:
Automatic transmission (e.g., 722.6 '7G-TRONIC' and earlier variants), differential, driveshafts, axle components.
Chassis And Suspension:
Active Body Control (ABC) suspension system, conventional suspension components (struts, springs, control arms), steering system (hydraulic power steering, steering rack), wheel bearings.
Brakes:
Hydraulic brake system (ABS, EBD, BAS), brake discs, pads, calipers, lines, parking brake.
Electrical System:
Complete wiring diagrams, battery, alternator, starter, lighting system (headlights, taillights, interior lighting), fuse boxes, relays, power distribution.
Body And Interior:
Body shell, doors, windows, sunroof, seat adjustments, climate control system (HVAC), dashboard, interior trim, seat belts, airbags.
Electronics And Comfort:
COMAND infotainment system, navigation, climate control modules, power seats, power mirrors, central locking, keyless entry, parking assist.
Procedures Included
Maintenance:
Oil change intervals and specifications, filter replacement (oil, air, fuel, cabin), spark plug replacement, brake fluid flush, coolant flush, transmission fluid service.
Troubleshooting:
Diagnostic procedures for common malfunctions, error code interpretation, symptom-based troubleshooting guides, electrical diagnostic flowcharts.
Repair And Overhaul:
Engine overhaul, transmission rebuild procedures, suspension component replacement, brake system repair, electrical component repair, body panel replacement.
Special Procedures:
ABC suspension hydraulic system bleeding and repair, COMAND system diagnostics and updates, CAN bus communication troubleshooting, key programming.
Technical Depth
Depth:
Comprehensive from basic maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and component-level repairs.
📊 Manual Specifications
File Format
File Type:
Searchable PDF
Print Quality:
High-resolution, printable pages
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine Gas
Engine Code Popular:
M113.940 (4.3L V8)
Displacement Popular:
4.3 liters (4266 cc)
Configuration Popular:
SOHC V8
Horsepower Popular:
275 hp @ 6000 rpm
Torque Popular:
295 lb-ft @ 3250 rpm
Fuel System:
Electronic Fuel Injection (EFI) with Sequential Multi-Port Fuel Injection (SFI)
Primary Engine Diesel
Engine Code Diesel Popular:
OM613.961 (3.2L Inline-6 Turbodiesel)
Displacement Diesel Popular:
3.2 liters (3199 cc)
Configuration Diesel Popular:
DOHC Inline-6 Turbocharged
Horsepower Diesel Popular:
197 hp @ 4400 rpm
Torque Diesel Popular:
369 lb-ft @ 1800 rpm
Performance
Top Speed Governed:
155 mph (250 km/h) electronically limited
Fuel System
Fuel Type Gas:
Premium Unleaded Gasoline (91+ octane recommended)
Fuel Type Diesel:
Diesel Fuel
🔧 Transmission
Standard
Standard Transmission Type:
5-speed Automatic (e.g., 722.6 for most models)
Optional
Optional Transmission Type:
7-speed Automatic (722.9 '7G-TRONIC' introduced later in the W220 generation for some models)
Features
Transmission Features:
Touchshift manual shifting, Comfort/Sport modes, electronically controlled.
Fluid Specifications
Transmission Fluid Type:
MB Approved Automatic Transmission Fluid (e.g., ATF 3353, ATF 134, or equivalent)
📐 Dimensions
Exterior
Wheelbase:
116.7 inches (2965 mm)
Overall Length:
199.9 inches (5078 mm)
Overall Width:
73.6 inches (1870 mm)
Overall Height:
57.5 inches (1460 mm)
Weights
Curb Weight Approx:
3,900 - 4,500 lbs (1769 - 2041 kg) depending on engine and equipment
Gross Vehicle Weight Rating Approx:
5,300 - 5,700 lbs (2404 - 2585 kg)
Towing Capacity:
Not typically specified or recommended for towing.
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
5-Star (when tested)
IIHS Side Impact Rating:
Good (when tested)
Active Features
Active Safety Systems:
Anti-lock Braking System (ABS), Electronic Stability Program (ESP), Traction Control System (TCS), Brake Assist System (BAS), Electronic Brake-force Distribution (EBD).
Passive Features
Passive Safety Features:
Multi-stage front airbags, side airbags, window airbags, front active head restraints, seat belt pretensioners, crumple zones.
Optional Safety Features
Optional Safety Features:
Distronic (adaptive cruise control), Parktronic (parking assist), Bi-Xenon headlamps with active curve illumination.
💡 Technology Features
Infotainment
Infotainment System:
COMAND (Cockpit Management and Navigation) system with integrated radio, CD player, navigation, and optional telephone/changer.
Display Technology:
Color LCD screen integrated into the dashboard.
Driver Assistance
Driver Assistance Systems:
Distronic (Adaptive Cruise Control), Parktronic (Parking Sensors), Rain-sensing wipers, Automatic headlamp activation.
Connectivity
Connectivity Features:
Optional Bluetooth connectivity, telematics systems (e.g., Tele Aid), CD changer.
Comfort Features
Comfort Technologies:
Multi-zone automatic climate control, heated and ventilated seats, dynamic multi-contour seats, power-adjustable steering column, keyless-go.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 miles (16,000 km) or 1 year, whichever comes first (flexible service system). Refer to the manual for exact conditions.
Air Filter Replacement Interval:
Every 30,000 miles (48,000 km) or as needed based on driving conditions.
Spark Plug Replacement Interval:
Varies by engine: Iridium spark plugs typically last up to 100,000 miles (160,000 km).
Fluid Specifications
Engine Oil Specification Gas:
MB 229.5 Specification (e.g., SAE 0W-40, 5W-40, or 5W-30 depending on climate and specific engine).
Engine Oil Specification Diesel:
MB 229.51 or MB 229.52 Specification (Low SAPS oil, e.g., SAE 5W-30).
Coolant Type:
Mercedes-Benz Approved Antifreeze/Coolant (Glysantin G48 or equivalent, typically a silicate-containing, blue-green coolant).
Brake Fluid Type:
DOT 4 Plus (MB Spec 331.0)
Known Issues
Common Failures Electrical:
EIS (Electronic Ignition Switch) failure, SAM (Signal Acquisition Module) issues, window regulator failures, CAN bus communication errors.
Common Failures Mechanical:
ABC suspension hydraulic leaks (struts, lines), balance shaft wear (M271 engine in some variants), oil cooler leaks, transmission conductor plate issues.
Common Failures Interior:
Headliner sagging, pixelated instrument cluster displays, HVAC blower motor failures.
📚 Vehicle History
Brand Heritage
Mercedes Benz Legacy:
Pioneering luxury and engineering since the early 20th century, known for safety, comfort, and innovation.
Model Evolution
W220 Introduction:
Introduced in late 1998 for the 1999 model year, representing a significant redesign from the W140 S-Class with a focus on reduced weight, improved aerodynamics, and advanced technology.
W220 Facelift:
Received a significant facelift for the 2003 model year, featuring updated front and rear styling, new engine options (e.g., 7G-TRONIC transmission), and improved interior electronics.
Production
Production Period:
1998-2006
Manufacturing Locations:
Germany (Sindelfingen Plant), South Africa, Brazil, China (locally assembled models).
🏆 Awards & Recognition
Recognitions
Awards And Accolades:
The W220 S-Class was widely recognized for its technological advancements, safety, and comfort, consistently ranking among the top luxury sedans of its era.
Ratings
Safety Ratings Overall:
Consistently high safety ratings from various organizations due to advanced safety systems and robust construction.
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