2003 Mercedes S-Class (W220) Service and Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: S-Class Model Code: W220 Year: 2003 Generation Generation Name: Third Generation S-Class Generation Years: 1998-2005 👋 Introduction Market Position Segment: Full-size Luxury Sedan...

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

S-Class

Model Code:

Year:

Generation

Generation Name:

Third Generation S-Class

Generation Years:

1998-2005

👋 Introduction

Market Position

Segment:

Full-size Luxury Sedan

Target Audience:

Affluent consumers seeking comfort, safety, and advanced technology

Competitive Analysis

Key Competitors 2003:

BMW 7 Series (E65/E66), Audi A8 (D3), Lexus LS 430, Jaguar XJ

Key Features Vehicle

Advanced Suspension:

Optional Active Body Control (ABC) system for superior ride comfort and handling

Safety Innovation:

Sensotronic Brake Control (SBC) system (standard on many models for 2003) offering brake-by-wire technology

Cabin Technology:

COMAND infotainment system with navigation, premium audio, and advanced climate control

Key Features Manual

Dealer Level Diagnostics:

Provides the same level of detail and diagnostic capability as used by authorized Mercedes-Benz service centers.

Vehicle Specificity:

Not generic; directly applicable to the 2003 W220 S-Class, ensuring accuracy for all its unique systems.

📋 Manual Details

Coverage Areas

Coverage Scope:

All models and all repairs A-Z for 2003 S-Class (W220)

Page Count

Estimated Page Count:

1000+

Manual Type

Manual Type:

Service and Repair Manual

Intended Audience:

Dealership Technicians, Professional Mechanics, Advanced DIYers

Language

Language:

English

Format

Format:

Digital (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing, lubrication system, cooling system

Engine Performance:

Fuel injection, ignition, emissions control, turbocharging (if applicable), engine management system (ECU)

Transmission Manual:

Automatic transmission (e.g., 5G-TRONIC/7G-TRONIC variants), torque converter, transmission control module (TCM), gearsets, hydraulic systems

Drivetrain:

Driveshafts, CV joints, differentials, axles

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, Active Body Control (ABC) system (if applicable)

Steering:

Power steering system, steering rack, steering column, steering angle sensor

Brakes:

Brake system, ABS, ESP, SBC (Sensotronic Brake Control) system (if applicable), brake discs, pads, calipers, hydraulic lines, parking brake

Electrical System:

Battery, alternator, starter, wiring diagrams, fuses, relays, lighting system, body control modules (BCM), CAN bus communication

Climate Control:

Automatic climate control system, HVAC components, refrigerant, fans, sensors, control units

Infotainment:

COMAND infotainment system, navigation, audio system, telephone integration

Body And Trim:

Exterior body panels, interior trim, doors, windows, sunroof, seats, bumpers

Safety Systems:

Airbag system (SRS), seat belts, occupant sensors

Procedures Included

Routine Maintenance:

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

Diagnostic Procedures:

Troubleshooting guides for common symptoms, fault code interpretation, diagnostic tool usage (e.g., Star Diagnosis/XENTRY)

Repair Procedures:

Step-by-step instructions for component removal, installation, and adjustment

Overhaul Procedures:

Detailed instructions for engine and transmission rebuilds

Electrical Troubleshooting:

Wiring diagrams, component testing, module diagnosis and replacement

Special Tools:

Identification and usage of specialized tools required for specific repairs

Technical Depth

Depth Of Information:

Comprehensive, vehicle-specific, detailed technical specifications, torque values, diagnostic procedures, and repair instructions.

Accuracy:

Exact same information used by Mercedes-Benz dealership technicians

📊 Manual Specifications

File Format

File Format:

Digital (likely PDF or similar e-book format)

Searchability:

Likely searchable text for quick information retrieval

Print Quality

Print Quality Expectation:

High resolution for clear diagrams and text (if printed)

Binding Type

Binding Type Expectation:

Professional binding if physical (e.g., perfect bound, spiral bound)

Paper Type

Paper Type Expectation:

Durable paper stock suitable for workshop use (if printed)

⚙️ Engine Specifications

Primary Engine

Engine Options 2003:

S350 (M112 E37), S430 (M113 E43), S500 (M113 E50), S600 (M137 E58 - V12), AMG S55 (M113 E55 ML - Supercharged)

S430 Engine Type:

4.3L V8 (M113 E43)

S500 Engine Type:

5.0L V8 (M113 E50)

Performance

S430 Horsepower:

275 hp @ 5750 rpm (approx.)

S500 Horsepower:

302 hp @ 5600 rpm (approx.)

S55 Amg Horsepower:

493 hp @ 6100 rpm (approx.)

S500 Torque:

339 lb-ft @ 3250 rpm (approx.)

Fuel System

Fuel Injection:

Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (91+ octane recommended)

🔧 Transmission

Standard

Transmission Type:

5-speed automatic (5G-TRONIC) for most models, 7-speed automatic (7G-TRONIC) introduced later in the generation (check specific model/market)

Transmission Control:

Electronic Transmission Control Module (ETM)

Optional

All Wheel Drive:

Optional 4MATIC all-wheel drive system available on select models (e.g., S430 4MATIC, S500 4MATIC)

Features

Transmission Modes:

Comfort (C) and Sport (S) modes

Fluid Type

Automatic Transmission Fluid:

MB-Approval 236.10 (e.g., ATF 3403 M-115)

📐 Dimensions

Exterior

Wheelbase Sedan:

119.7 inches (3040 mm)

Length Sedan:

199.9 inches (5078 mm)

Width Sedan:

73.6 inches (1870 mm)

Height Sedan:

57.3 inches (1455 mm)

Weights

Curb Weight S430:

approx. 4000 lbs (1814 kg)

Curb Weight S500:

approx. 4150 lbs (1882 kg)

Gross Vehicle Weight Rating:

Varies by model, consult specific vehicle documentation.

🛡️ Safety Features

Ratings

NHTSA Front Crash Test Rating:

5-Star (Driver), 5-Star (Passenger)

IIHS Front Offset Crash Test Rating:

Active Features

Antilock Braking System:

Standard ABS

Electronic Stability Control:

Standard ESP (Electronic Stability Program)

Brake Assist:

Standard BAS (Brake Assist System)

Sensotronic Brake Control:

Standard SBC (Sensotronic Brake Control) on many 2003 models

Passive Features

Airbags:

Front airbags, side airbags, window airbags (curtain airbags)

Seatbelts:

Pretensioning front seat belts with load limiters

Child Seat Anchors:

LATCH system (lower anchors and tethers for children) may be present depending on market and specific configuration.

💡 Technology Features

Infotainment

Comand System:

Centralized control for navigation, audio, climate, and vehicle settings. Early versions used CD-ROM based navigation.

Audio Options:

Bose premium audio system was a popular option.

Driver Assistance

Distronic:

Optional adaptive cruise control system that maintains a set distance from the vehicle ahead.

Parking Assist:

Optional parking sensors (front and rear) for enhanced parking maneuvers.

Connectivity

Telephone Integration:

Optional integrated hands-free telephone system.

Can Bus Architecture:

Extensive use of CAN (Controller Area Network) bus for communication between various electronic control units (ECUs).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000 miles or 12 months, depending on driving conditions and oil quality used (consult manual for specific interval).

Transmission Fluid Service:

Recommended at 30,000-60,000 miles, or as specified by the maintenance schedule. Crucial for longevity, especially with 5G-TRONIC/7G-TRONIC.

Brake Fluid Flush:

Typically every 2 years, regardless of mileage, due to hygroscopic nature of brake fluid.

Coolant Change:

Initial change typically at 100,000 miles, then every 30,000-50,000 miles thereafter (using specified coolant).

Fluid Specifications

Engine Oil Specification:

MB-Approval 229.5 (e.g., Mobil 1 0W-40, Shell Helix Ultra 0W-40)

Coolant Specification:

MB-Approval 325.0 or 326.0 (typically a silicate-free, long-life coolant)

Power Steering Fluid:

MB-Approval 343.0 or 344.0

Known Issues

Air Suspension Struts:

Can develop leaks over time, leading to vehicle sag (especially common with ABC system).

Ignition Coils:

Premature failure of ignition coils can lead to misfires and rough running.

Window Regulators:

Motor or regulator failure can prevent windows from operating.

Sbc System Faults:

Sensotronic Brake Control (SBC) can develop faults, often indicated by dashboard warnings and requiring specialized diagnosis/replacement of the SBC hydraulic unit or pump.

Conductor Plate In Transmission:

Common failure point in the automatic transmission's valve body, leading to shifting issues or transmission failure.

📚 Vehicle History

Brand Heritage

Manufacturer History:

Mercedes-Benz has a long-standing reputation for luxury, engineering excellence, and safety innovations since its inception.

Model Evolution

W220 Introduction:

The W220 generation succeeded the W140 and represented a significant shift towards more agile handling and advanced technology, while maintaining luxurious comfort.

W220 Design Philosophy:

Focused on reducing weight, improving aerodynamics, and integrating cutting-edge electronic systems.

Production

Production Years W220:

1998-2005

Manufacturing Locations:

Primary production in Sindelfingen, Germany.

🏆 Awards & Recognition

Recognitions

Car And Driver Best 10:

Often featured on Car and Driver's 10Best lists in its earlier years, highlighting its blend of luxury, performance, and technology.

Motortrend Car Of The Year:

While not a winner for 2003, the S-Class line has historically been a strong contender and recipient of various awards.

Certifications

Euro Ncap Rating:

The W220 S-Class achieved strong safety ratings in European NCAP tests.