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Mercedes Benz S Class W220 1999-2005 Full Service & Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: S-Class Chassis Code: W220 Model Years: 1999, 2000, 2001, 2002, 2003, 2004, 2005 Codes Engine Codes: M112 (V6), M113 (V8), M275 (V12 Bi-Turbo)...
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Sku: 183132
Mercedes Benz S Class W220 1999-2005 Full Service & Repair ManualMercedes Benz S Class W220 1999-2005 Full Service & Repair ManualMercedes Benz S Class W220 1999-2005 Full Service & Repair Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
S-Class
Chassis Code:
W220
Model Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005
Codes
Engine Codes:
M112 (V6), M113 (V8), M275 (V12 Bi-Turbo)
Transmission Codes:
722.6 (5-speed Automatic)
👋 Introduction
Market Position
Market Position:
Flagship luxury sedan representing Mercedes-Benz's pinnacle of comfort, technology, and engineering.
Competitive Analysis
Competitors:
BMW 7 Series (E65/E66), Audi A8 (D3), Lexus LS (XF30), Jaguar XJ (X308/X350).
Key Features
Key Features:
Advanced ABC suspension, powerful V8/V12 engines, luxurious interior, extensive electronic features, focus on ride comfort.
Target Audience
Target Audience:
Owners, independent repair shops, enthusiast DIY mechanics specializing in luxury European vehicles.
📋 Manual Details
Coverage Areas
Geographical Coverage:
Global (Factory Standard)
Page Count
Estimated Page Count:
1000+
Manual Type
Manual Type:
Factory Service and Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, diagnosis, timing, cooling, lubrication, fuel delivery, emission control systems.
Engine Electrical:
Ignition system, fuel injection control (EIS, ME), sensor diagnostics, ECU identification and testing.
Transmission:
722.6 5-speed Automatic Transmission: operation, diagnostics, solenoid testing, fluid service, overhaul procedures.
Chassis Suspension:
Active Body Control (ABC) system, conventional suspension components, alignment procedures, shock absorber replacement.
Brakes:
ABS, ESP, SBC (if applicable to later W220), brake pad and rotor replacement, hydraulic system bleeding, parking brake.
Steering:
Power steering system, steering column components, diagnosis of steering assist issues.
Electrical Body:
Lighting systems, power windows, locks, mirrors, seats, sunroof, interior climate control (HVAC), keyless entry.
Comfort Electronics:
COMAND infotainment, seat memory, climate control logic, ambient lighting, parking assist.
Diagnostics:
OBD-II diagnostics, STAR diagnostic system (SDS) codes and interpretations, troubleshooting charts.
Body And Trim:
Panel removal and installation, interior trim components, door mechanisms.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid level checks and top-offs.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, brake system servicing.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults, fault code interpretation.
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems.
Special Tools:
Identification and use of Mercedes-Benz specific tools required for repairs.
Technical Depth
Depth Of Coverage:
Complete factory-level diagnostic and repair procedures, suitable for professional technicians and advanced DIYers.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, printable pages.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Searchability
Searchable Text:
Yes (text-searchable PDF)
⚙️ Engine Specifications
Primary Engine
Base Engine Variant:
S320 (W220) - M112 E32 (3.2L V6)
Performance S320:
Approx. 221 hp @ 6000 rpm, 236 lb-ft @ 3000-4500 rpm
Engine S430:
S430 (W220) - M113 E43 (4.3L V8)
Performance S430:
Approx. 295 hp @ 5500 rpm, 302 lb-ft @ 3600 rpm
Engine S500:
S500 (W220) - M113 E50 (5.0L V8)
Performance S500:
Approx. 302 hp @ 5600 rpm, 339 lb-ft @ 3100-4200 rpm
Engine S600:
S600 (W220) - M275 E55ML (5.5L V12 Bi-Turbo)
Performance S600:
Approx. 493 hp @ 5000 rpm, 590 lb-ft @ 1800-3500 rpm
Fuel System
Fuel Injection Type:
Electronic Fuel Injection (EFI)
Recommended Fuel:
Premium Unleaded Gasoline (91+ Octane)
Engine Management
ECU Type:
Bosch Motronic (e.g., ME 2.8, ME 2.9, ME 9.7)
🔧 Transmission
Standard
Standard Transmission:
5-Speed Automatic (722.6)
Optional
Optional Transmission:
N/A (All models featured automatic transmission)
Features
Transmission Features:
TouchShift manual shifting, electronically controlled, adaptive shift programs.
Fluid Specifications
Transmission Fluid Type:
MB 236.10 or MB 236.12 (e.g., ATF 4/5 Speed)
📐 Dimensions
Exterior
Wheelbase:
Approx. 116.7 inches (2965 mm)
Length:
Approx. 199.5 inches (5067 mm)
Width:
Approx. 73.2 inches (1859 mm)
Height:
Approx. 57.4 inches (1458 mm)
Weights
Curb Weight S320:
Approx. 3850 lbs (1750 kg)
Curb Weight S500:
Approx. 4100 lbs (1860 kg)
Gross Vehicle Weight Rating:
Varies by model, typically around 5000-5500 lbs
Wheel Tire
Wheelbase Long Wheelbase:
Approx. 121.5 inches (3086 mm) for LWB variants
Standard Wheel Size:
16-inch or 17-inch alloy wheels
Standard Tire Size:
225/60R16, 225/55R17
Bolt Pattern:
5x112mm
Center Bore:
66.5mm
🛡️ Safety Features
Ratings
NHTSA Ratings:
Generally considered very safe, though specific ratings may vary by year and testing protocol. Equipped with advanced safety features.
Active Features
Active Safety Systems:
Anti-lock Braking System (ABS), Electronic Stability Program (ESP), Brake Assist (BAS).
Passive Features
Airbags:
Front airbags, side airbags, window airbags (curtain airbags).
Seatbelts:
Pre-tensioning seatbelts, load limiters.
Body Structure:
High-strength steel safety cell, crumple zones.
💡 Technology Features
Infotainment
Infotainment System:
COMAND (Cockpit Management and Navigation) system, offering audio, navigation, and climate control integration.
Audio Options:
Bose premium sound system available.
Driver Assistance
Driver Assistance Features:
Distronic (adaptive cruise control), Parktronic (parking assist), rain-sensing wipers, automatic climate control.
Connectivity
Connectivity Options:
Early integration of telematics systems, optional voice control.
Comfort Features
Comfort Features:
Multi-contour power seats with heating and ventilation, keyless-go entry and start, soft-close doors.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 miles or 12 months, using synthetic oil, subject to ASSYST service indicator.
Transmission Service Interval:
Recommended every 40,000-60,000 miles for the 722.6 transmission.
Abc Service Interval:
Fluid and filter change recommended every 30,000-40,000 miles for Active Body Control (ABC) system.
Fluid Specifications
Engine Oil Specification:
MB 229.5 (e.g., Mobil 1 0W-40, Castrol Syntec 0W-30/5W-30)
Coolant Specification:
MB 325.0 or MB 326.0 (Ethylene Glycol based, blue or green)
Brake Fluid Specification:
DOT 4 Plus (e.g., MB 331.0)
Known Issues
Common Issues:
ABC suspension hydraulic leaks (struts, lines), EIS (Electronic Ignition Switch) failure, SAM module issues, oil cooler leaks, transmission conductor plate failure, catalytic converter issues (especially on V12).
Maintenance Tips:
Regularly inspect ABC system for leaks, maintain battery health, use correct diagnostic tools for electronic issues, follow scheduled maintenance diligently.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mercedes-Benz has a long-standing reputation for engineering luxury, comfort, and safety in automobiles, dating back to the late 19th century.
Model Evolution
W220 Introduction:
The W220 replaced the W140 S-Class, focusing on a more streamlined design, reduced weight, and improved handling while maintaining luxury and technological sophistication.
W220 Facelift:
A significant facelift occurred for the 2003 model year, introducing updated styling, improved powertrains, and revised interior features.
Production
Production Years:
1998-2005 (for the W220 generation).
Manufacturing Locations:
Germany (Sindelfingen)
🏆 Awards & Recognition
Recognitions
Industry Recognitions:
Consistently ranked among the top luxury sedans of its era for comfort, refinement, and advanced technology.
Ratings
Consumer Ratings:
Praised for ride quality and quiet cabin, though some owners reported higher than average maintenance costs for advanced systems.
Certifications
Certifications:
Compliant with all relevant automotive safety and emissions standards for its production period.
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