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1995 Mercedes S320 Service Repair Manual 95

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: S320 Year: 1995 Codes Chassis Code: W140 Engine Code: M104.990 👋 Introduction Market Position Market Segment: Full-size Luxury Sedan Target Audience: Affluent individuals...
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1995 Mercedes S320 Service Repair Manual 951995 Mercedes S320 Service Repair Manual 951995 Mercedes S320 Service Repair Manual 951995 Mercedes S320 Service Repair Manual 95
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
S320
Year:
1995
Codes
Chassis Code:
W140
Engine Code:
M104.990
👋 Introduction
Market Position
Market Segment:
Full-size Luxury Sedan
Target Audience:
Affluent individuals seeking prestige, comfort, safety, and advanced technology.
Competitive Analysis
Key Competitors 1995:
BMW 7 Series (E38), Lexus LS 400, Audi A8 (D2), Jaguar XJ Series
Key Features
Vehicle Key Features:
Exceptional build quality, plush interior, advanced suspension for ride comfort, powerful inline-six engine, robust safety features, quiet cabin, pioneering technologies for its era.
Manual Value Proposition
Manual Value:
Essential resource for owners and technicians to maintain and repair the complex systems of the 1995 Mercedes-Benz S320, ensuring longevity and optimal performance.
📋 Manual Details
Coverage Areas
Systems Covered:
Engine, Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Clutch, Manual Transmission, Automatic Transmission, Driveshaft, Differential, Axles, Suspension (Front and Rear), Steering, Brakes (Hydraulic, ABS), Body, Electrical System (Wiring Diagrams, Components), HVAC, SRS Airbag System, Security System, Diagnostic Procedures, Troubleshooting
Page Count
Approximate Page Count:
1500+
Manual Type
Manual Type:
Factory Authorized Service & Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain Components:
Engine mechanical, cylinder head, block, crankshaft, pistons, connecting rods, camshafts, valve train, fuel injection system (Bosch KE-Jetronic/HPE), ignition timing, emission control systems, cooling system operation, lubrication system, exhaust manifold, catalytic converter
Drivetrain Components:
Clutch operation and adjustment, manual transmission overhaul and repair, 4-speed automatic transmission (722.4) overhaul and repair, driveshaft universal joints, rear axle assembly, wheel bearings, CV joints
Chassis Components:
Front and rear suspension systems (independent, multi-link), shock absorbers, springs, control arms, anti-roll bars, steering system (recirculating ball, power steering pump), brake system (front ventilated discs, rear discs, ABS/ASR operation, hydraulic components)
Electrical And Electronics:
Complete wiring diagrams, starter system, charging system (alternator), battery, lighting (headlights, taillights, interior), ignition switch, power windows, power seats, mirrors, central locking, cruise control, instrument cluster functions, diagnostic port (OBD-I compliant with specific Mercedes protocols), SRS airbag system components and troubleshooting, climate control electronics
Procedures Included
Maintenance Procedures:
Oil and filter changes, air filter replacement, fuel filter replacement, spark plug replacement, coolant flush and replacement, brake fluid flush, transmission fluid and filter service, differential fluid change, belt inspection and replacement, battery maintenance, tire rotation and pressure checks
Repair And Overhaul:
Engine component replacement (e.g., head gasket, pistons, rings, bearings), cylinder head removal and reassembly, fuel injector testing and replacement, ignition coil replacement, radiator and water pump replacement, starter and alternator replacement, transmission internal component repair, suspension component replacement (bushings, ball joints, tie rods), brake caliper and rotor replacement, power steering system repair, headlight and taillight bulb replacement, window regulator replacement
Troubleshooting And Diagnostics:
Engine performance diagnostics, no-start conditions, cooling system leaks, brake system faults, electrical system malfunctions, HVAC system issues, ABS/ASR warning light troubleshooting, SRS system fault diagnosis, using Mercedes-specific diagnostic tools and procedures
Technical Depth
Technical Depth:
Comprehensive, including detailed diagrams, step-by-step instructions, torque specifications, special tool requirements, diagnostic trouble codes (DTCs) and their interpretations, electrical schematics, and component testing procedures. Suitable for professional technicians and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
File Format Details:
Searchable PDF with high-resolution images and diagrams. Optimized for digital viewing and printing.
Print Quality
Print Quality:
N/A (Digital Format)
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated, Inline 6-Cylinder
Engine Displacement:
3.2 Liters (3199 cc)
Bore X Stroke:
89.9 mm x 84.0 mm
Compression Ratio:
10.0:1
Valvetrain:
DOHC, 4 valves per cylinder, dual overhead camshafts
Performance
Horsepower:
228 hp @ 5500 rpm
Torque:
232 lb-ft @ 3750 rpm
Fuel System
Fuel System Type:
Electronic Fuel Injection (Bosch KE-Jetronic/HPE)
Recommended Fuel:
Premium Unleaded Gasoline (91 Octane or higher)
Cooling System
Cooling System Type:
Pressurized, liquid-cooled with electric fan
Lubrication System
Oil Capacity With Filter:
8.0 Liters (8.5 US Quarts)
Recommended Engine Oil:
SAE 0W-30 or 5W-30 Synthetic (API SG or higher)
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic
Transmission Model:
Mercedes-Benz 722.4
Optional
Optional Transmission:
N/A for S320 in 1995 (Manual transmission was available on other W140 models but not the S320)
Features
Transmission Features:
Electronic control, multiple shift modes (e.g., Economy/Sport), torque converter lock-up
Fluid Specifications
Automatic Transmission Fluid Type:
MB-Approval 236.2 or 236.7 (Dexron II E compatible)
Fluid Capacity
Automatic Transmission Fluid Capacity:
Approximately 7.5 Liters (7.9 US Quarts) for full fill
📐 Dimensions
Exterior
Length:
5113 mm (201.3 inches)
Width:
1886 mm (74.3 inches)
Height:
1487 mm (58.5 inches)
Wheelbase:
3040 mm (119.7 inches)
Weights
Curb Weight:
1960 kg (4321 lbs)
Gross Vehicle Weight Rating:
2500 kg (5512 lbs)
🛡️ Safety Features
Ratings
NHTSA Crash Test Rating:
Not explicitly rated by NHTSA in the modern sense, but designed to exceed contemporary safety standards.
Active Features
Active Safety Features:
Anti-lock Braking System (ABS), Acceleration Slip Regulation (ASR) traction control, power-assisted disc brakes all around (front ventilated), automatic locking differentials (optional, but more common on other W140 variants)
Passive Features
Passive Safety Features:
Supplemental Restraint System (SRS) airbags (driver and front passenger), energy-absorbing crumple zones, reinforced safety cage, side-impact protection, seatbelt pre-tensioners, advanced head restraints
💡 Technology Features
Infotainment
Infotainment System:
Original Becker Grand Prix or similar proprietary Mercedes-Benz audio system with cassette player, optional CD changer. Features include AM/FM radio, pre-set stations, tone controls.
Display Technology:
Analog gauges for speedometer, tachometer, fuel, and temperature. Central digital display for odometer, trip meter, and warning indicators.
Driver Assistance
Driver Assistance Features:
Cruise Control, Automatic Climate Control (with dual-zone capability), Rain-sensing wipers (optional/later models), Parktronic (optional/later models).
Connectivity
Connectivity Features:
N/A by modern standards. Primarily focused on in-car comfort and control. Antenna for radio and cellular phone (optional, early integrated systems).
Convenience Features
Convenience Features:
Power windows, power adjustable front seats with memory, heated front seats, power tilt/telescoping steering column, heated exterior mirrors, automatic antenna, interior ambient lighting.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Every 7,500 - 10,000 miles or 12 months, whichever comes first (synthetic oil recommended).
Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on driving conditions.
Fuel Filter Replacement:
Every 30,000 - 45,000 miles.
Spark Plug Replacement:
Every 30,000 - 40,000 miles (iridium or platinum recommended).
Coolant Replacement:
Every 30,000 - 60,000 miles or 2-4 years.
Transmission Fluid And Filter:
Every 40,000 - 60,000 miles.
Fluid Specifications
Brake Fluid Type:
DOT 4
Power Steering Fluid Type:
MB-Approval 236.3 (ATF Dexron II equivalent)
Coolant Type:
Ethylene Glycol based, Mercedes-Benz Specification 325.0 (e.g., Zerex G-05 or equivalent blue/green coolant)
Known Issues
Common Issues W140:
Distributor 'O' rings and vacuum lines (oil leaks), head gasket leaks (especially coolant), crankcase ventilation system blockages, idle control valve issues, vacuum line degradation leading to various system malfunctions, door lock actuator failures, window regulator issues, early ABC suspension issues (though not on the S320 as standard), MAF sensor calibration, OVP relay failures (overvoltage protection), CAN bus communication issues (less common on '95 but present in later W140s).
Specific M104 Issues:
Coil pack failures, spark plug wire degradation, oil cooler seals, timing chain tensioner and guide wear over time.
📚 Vehicle History
Brand Heritage
Mercedes Benz Heritage:
Founded on innovation and engineering excellence, Mercedes-Benz has a long history of producing luxury, safety, and performance vehicles since the early 20th century.
Model Evolution
W140 Generation:
The W140 generation, introduced in 1991, represented a significant technological leap from its predecessor (W126 S-Class), focusing on increased size, refinement, and advanced features. It was known for its substantial presence and technological sophistication.
Production
Production Years W140:
1991-1998
Manufacturing Location:
Germany
Model Positioning
S320 Positioning In Lineup:
The S320 served as the entry-level model within the W140 S-Class lineup, offering the core luxury and technology of the flagship sedan with a more accessible inline-six engine compared to the V8 and V12 variants.
🏆 Awards & Recognition
Recognitions
Automotive Awards W140:
While specific awards for the 1995 S320 are rare, the W140 generation was widely recognized for its engineering prowess and comfort, often being named in 'best luxury car' lists of its time by automotive publications.
Safety Recognition:
Consistently praised for its safety engineering and robust construction by automotive safety experts and critics.
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