Mercedes Benz E420 Complete Workshop Service Repair Manual 1997

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: E420 Year: 1997 Codes Chassis Code: W210 Generation Generation Code: Second Generation (W210) 👋 Introduction Market Position Vehicle Segment: Mid-size luxury sedan. Target...

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标签: 1997 200 Car Cars E420 Mercedes Mercedes-benz

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

Year:

Codes

Chassis Code:

Generation

Generation Code:

Second Generation (W210)

👋 Introduction

Market Position

Vehicle Segment:

Mid-size luxury sedan.

Target Audience:

Discerning buyers seeking comfort, performance, and advanced technology.

Competitive Analysis

Key Competitors:

BMW 5 Series (E39), Audi A6 (C4/C5), Lexus GS300.

Key Features

Performance Orientation:

The E420, with its V8 engine, offered a significant performance upgrade over its 6-cylinder counterparts.

Luxury Appointments:

Known for its refined interior, build quality, and advanced features for its era.

Manual Value Proposition

Diy Savings:

Enables owners to perform complex maintenance and repairs, significantly reducing dealership or independent shop labor costs.

Accurate Information:

Provides manufacturer-accurate procedures and specifications, crucial for maintaining Mercedes-Benz vehicles correctly.

📋 Manual Details

Coverage Areas

All Models Engines Trim Transmissions:

Page Count

Estimated Page Count:

Varies by specific manual compilation, typically 1000-2500+ pages for a complete workshop manual.

Manual Type

Type:

Workshop Service and Repair Manual

Language

Language:

English

Format

Format:

Downloadable Digital Format (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, rebuild, timing, cooling system, lubrication system.

Engine Management:

Fuel injection system (KE-Jetronic variant for M119.960), ignition system, emissions control systems, electronic control unit (ECU) diagnostics and testing.

Transmission:

Automatic transmission (722.6 '722.6xx' 5G-TRONIC) service, diagnosis, overhaul, torque converter, hydraulic control unit.

Drivetrain:

Driveshafts, universal joints, differential, axles.

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment procedures.

Steering:

Power steering system, steering rack, linkage, steering column.

Brakes:

Hydraulic system, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), brake discs, calipers, pads, lines, bleeding procedures.

Electrical System:

Battery, charging system, starter, lighting, fuses, relays, wiring diagrams, power distribution.

Body And Chassis:

Body panels, doors, hood, trunk, interior trim, glass, weatherstripping, chassis components.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system service, refrigerant handling, blower motor, climate control unit.

Body Electronics:

Central locking, power windows, power seats, mirrors, immobilizer system, keyless entry (if equipped).

Procedures Included

Scheduled Maintenance:

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

Diagnostics Troubleshooting:

Systematic troubleshooting guides, fault code identification, symptom-based repair procedures.

Component Removal Installation:

Detailed instructions for removing and installing all major mechanical and electrical components.

Engine Rebuild:

Complete engine overhaul instructions, including cylinder head service, piston and connecting rod installation, crankshaft and bearing replacement.

Transmission Overhaul:

Detailed steps for rebuilding the 722.6 automatic transmission, including clutch pack replacement, valve body servicing, and solenoid testing.

Brake System Repair:

Brake pad/disc replacement, caliper service, ABS/ESP component testing and replacement, brake fluid flush.

Electrical Diagnostics:

Wiring diagram interpretation, component testing, circuit troubleshooting.

Bodywork Repair:

Dent repair, panel replacement, door alignment, glass replacement.

Technical Depth

Depth:

Comprehensive, covering everything from basic fluid changes to complete engine and transmission overhauls.

Diagnostic Codes:

Includes procedures for reading and interpreting diagnostic trouble codes (DTCs) from various ECUs.

Specifications:

Detailed torque specifications, clearances, fluid capacities, and diagnostic data.

📊 Manual Specifications

File Format

Format:

Searchable Text:

Yes (typical for well-produced PDF manuals)

Print Quality

Resolution:

High-resolution images and clear text (assumed for a quality manual).

Scalability:

Scalable for detailed viewing of diagrams and schematics.

Binding Type

Binding:

Not Applicable (Digital Download)

Paper Type

Paper Type:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M119.960

Engine Type:

4.2L V8 (SOHC, 32 valves)

Bore X Stroke:

89.0 mm x 84.0 mm

Compression Ratio:

10.0:1

Performance

Horsepower:

275 hp @ 5750 rpm

Torque:

295 lb-ft @ 3900 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (Bosch KE-Jetronic variant for this year/engine)

Fuel Type:

Premium Unleaded Gasoline (91+ Octane)

Lubrication

Oil Capacity:

Approx. 8.0 Liters (with filter change)

Ignition

Spark Plugs:

Typically Bosch F8DC4 or equivalent

🔧 Transmission

Standard

Transmission Type:

5-Speed Automatic (722.6 '722.6xx' 5G-TRONIC)

Optional

Optional Transmissions:

None for E420 model in 1997

Features

Features:

Electronic shift control, torque converter lock-up clutch, selectable driving modes (Comfort/Sport).

Fluid Specifications

Transmission Fluid:

MB Approval 236.10 or 236.12 (e.g., Mercedes-Benz ATF).

📐 Dimensions

Exterior

Length:

Approx. 190.7 inches (4843 mm)

Width:

Approx. 70.2 inches (1783 mm)

Height:

Approx. 57.0 inches (1448 mm)

Wheelbase:

Approx. 111.5 inches (2832 mm)

Weights

Curb Weight:

Approx. 3800-4000 lbs (1725-1815 kg), depending on options.

🛡️ Safety Features

Ratings

NHTSA Front Crash Test:

Not directly available for this specific sub-model/year in the same format as modern ratings, but generally considered very safe for its era.

IIHS Crash Test:

Good (for frontal offset tests in its class).

Active Features

Standard Anti-lock Braking System (ABS).

Optional or standard depending on market; likely includes Electronic Stability Program (ESP) or ASR (Acceleration Skid Control).

Passive Features

Airbags:

Driver and front passenger airbags, side airbags (optional).

Seatbelts:

Pretensioning seatbelts with force limiters.

💡 Technology Features

Infotainment

Audio System:

Premium sound system (e.g., Bose or Becker audio with CD/Cassette player).

Navigation:

Optional factory navigation system (COMAND 2.0 or predecessor).

Driver Assistance

Cruise Control:

Standard electronic cruise control.

Parking Sensors:

Optional front and rear PARKTRONIC parking assist sensors.

Connectivity

Cellular Phone:

Optional integrated cellular phone system (often analog).

Comfort Features

Climate Control:

Dual-zone automatic climate control.

Seat Features:

Electrically adjustable front seats with memory, heated front seats (optional).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500-10,000 miles (12,000-16,000 km) or 12 months, whichever comes first, with synthetic oil.

Transmission Fluid Change:

Recommended every 40,000-60,000 miles (64,000-96,000 km).

Coolant Flush:

Recommended every 30,000-40,000 miles (48,000-64,000 km) or 2-3 years.

Spark Plug Replacement:

Typically every 60,000-100,000 miles (96,000-160,000 km), depending on spark plug type.

Fluid Specifications

Engine Oil Type:

Full Synthetic SAE 0W-40 or 5W-40 meeting MB Approval 229.3 or 229.5.

Coolant Type:

Mercedes-Benz Approved Antifreeze/Coolant (e.g., G05 formulation or equivalent).

Brake Fluid Type:

DOT 4 High Performance Brake Fluid.

Known Issues

Crankshaft Position Sensor:

Can fail, leading to no-start or stalling issues.

Mass Air Flow Sensor:

Can become contaminated or fail, affecting engine performance and fuel economy.

Oil Cooler Seals:

Potential for leaks, especially the O-rings at the cooler lines.

Window Regulators:

Can wear out or break, causing windows to fail to operate.

Rust And Corrosion:

Prone to rust in wheel wells, rocker panels, and door bottoms if not properly maintained or if exposed to harsh climates.

Valve Cover Gaskets:

Common source of oil leaks, especially with age.

📚 Vehicle History

Brand Heritage

Brand Origin:

Germany, founded 1926, synonymous with engineering excellence and luxury.

Model Evolution

W210 Introduction:

The W210 generation of the E-Class was introduced in 1995, replacing the W124. It marked a significant styling departure with its 'four-eyed' quad-headlight design.

E420 Positioning:

The E420 was a high-performance variant within the E-Class lineup, offering the potent M119 V8 engine, previously used in higher-tier models like the S-Class and SL.

Production

Production Years:

W210 E420 produced from 1995 to 1997 (in North America). The W210 was produced globally until 2002.

Manufacturing Locations:

Primarily Germany, with some assembly in other global locations.

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The W210 chassis generally received positive reviews, though specific E420 awards might be less prominent than general model accolades.

Automotive Journalism Reviews:

Consistently praised for its ride quality, build quality, and potent V8 performance.

Certifications

Safety Certifications:

Met or exceeded all federal motor vehicle safety standards (FMVSS) of the era.