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Mercedes S Class W220 Complete Workshop Service Repair Manual 1999 2000 2001 2002 2003 2004 2005

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: S Class Chassis Code: W220 Model Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005 👋 Introduction Market Position Segment: Full-size Luxury Sedan...
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Mercedes S Class W220 Complete Workshop Service Repair Manual 1999 2000 2001 2002 2003 2004 2005
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
S Class
Chassis Code:
W220
Model Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005
👋 Introduction
Market Position
Segment:
Full-size Luxury Sedan
Brand Perception:
Represents the pinnacle of Mercedes-Benz engineering, comfort, and technology for its era.
Competitive Analysis
Key Competitors:
BMW 7 Series (E65/E66), Audi A8 (D3), Lexus LS (XF30), Jaguar XJ (X350).
Key Features
Innovation:
Pioneered technologies like AIRMATIC suspension, COMAND infotainment system, and advanced safety features.
Comfort And Luxury:
Exceptional ride quality, premium interior materials, advanced climate control, and extensive comfort features.
📋 Manual Details
Coverage Areas
Manual Type:
Complete Workshop Service Repair Manual
Language:
English
Format:
Digital Download (likely PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanicals (all variants), fuel system, ignition system, exhaust system, engine management, cooling system, lubrication system.
Transmission:
Automatic transmission (722.6 family) repair, overhaul, diagnostics, electronic control module (ETC).
Chassis And Suspension:
Front and rear suspension (including AIRMATIC air suspension and ABC active body control), steering system, wheel alignment specifications.
Braking System:
Hydraulic brake system, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), brake disc and pad replacement, bleeding procedures.
Electrical System:
Wiring diagrams, starter, alternator, battery, lighting systems (headlights, taillights, interior), fuses, relays, diagnostic connector (OBD-II).
Body And Interior:
Body panel removal/installation, doors, hood, trunk, interior trim, seats, climate control system (HVAC), power windows, locks, sunroof.
Safety Systems:
Airbag system (SRS), seatbelt pre-tensioners, occupant classification system.
Diagnostic Troubleshooting:
Trouble codes (DTCs), diagnostic procedures, symptom-based troubleshooting guides for various systems.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, fluid level checks and top-offs.
Component Replacement:
Detailed steps for replacing major components like starter, alternator, fuel pump, brake pads, suspension arms, sensors.
Diagnostic Procedures:
Step-by-step guides for diagnosing common and complex issues using diagnostic tools and multimeter readings.
System Overhaul:
Instructions for complete overhaul of powertrain components, transmissions, and certain chassis systems.
Electrical Diagnostics:
Troubleshooting wiring faults, sensor issues, and control module problems using wiring diagrams.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and specifications.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes (assumed for a quality digital manual)
Printable:
Yes (assumed)
Resolution:
High-resolution for clear diagrams and text (assumed)
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Options:
M112 (4.3L V8, 5.0L V8), M113 (5.8L V12 - S600), M275 (5.5L Bi-Turbo V12 - S65 AMG), OM628 (4.0L V8 Diesel - S400 CDI), OM642 (3.2L V6 Diesel - S320 CDI, introduced later).
Performance
S500 Engine:
5.0L V8 (M113 E50), approximately 302 hp @ 5600 rpm, 339 lb-ft torque @ 3250 rpm.
S600 Engine:
5.8L V12 (M113 E58), approximately 362 hp @ 5500 rpm, 391 lb-ft torque @ 3500 rpm.
S65 Amg Engine:
5.5L Bi-Turbo V12 (M275 E55 LA), approximately 604 hp @ 5500 rpm, 738 lb-ft torque @ 2000-4000 rpm (electronically limited).
Fuel System
Fuel Delivery:
Electronic fuel injection (EFI).
Fuel Type:
Premium Unleaded Gasoline (91 AKI or higher), Diesel for CDI models.
🔧 Transmission
Standard
Transmission Type:
5-speed automatic (722.6 '7G-TRONIC' introduced later in the W220 lifecycle).
Optional
Transmission Options:
Later models may feature the 7-speed 7G-TRONIC automatic transmission.
Features
Transmission Features:
TouchShift manual shifting, Comfort/Sport modes, adaptive shifting.
📐 Dimensions
Exterior
Wheelbase Standard:
119.5 inches (3035 mm)
Wheelbase Long Wheelbase:
121.5 inches (3086 mm)
Length:
Approx. 199.9 - 203.1 inches (5077 - 5159 mm) depending on wheelbase.
Width:
Approx. 73.0 inches (1854 mm)
Height:
Approx. 57.1 inches (1450 mm)
Weights
Curb Weight:
Approx. 4,000 - 4,500+ lbs (1815 - 2040+ kg) depending on engine and configuration.
Gross Vehicle Weight Rating:
Varies by model, typically around 5,500 - 6,000+ lbs.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-Star (as per typical ratings for vehicles of this era and class, specific W220 data may vary by test year).
IIHS Side Impact:
Good (as per typical ratings for vehicles of this era and class, specific W220 data may vary by test year).
Active Features
Electronic Stability Program:
Standard (ESP).
Antilock Braking System:
Standard (ABS) with Brake Assist.
Traction Control:
Standard (ASR).
Passive Features
Airbags:
Frontal airbags (driver/passenger), side airbags, curtain airbags, optional rear side airbags.
Seatbelts:
3-point active seatbelts with pretensioners and force limiters, belt height adjusters.
💡 Technology Features
Infotainment
Comand System:
Centralized control system for navigation, audio, climate, and vehicle settings. Early versions used CD-ROM navigation.
Audio Options:
Bose premium sound system, Harmon Kardon Logic 7 audio.
Driver Assistance
Adaptive Cruise Control:
Optional DISTRONIC adaptive cruise control.
Parking Assistance:
Optional PARKTRONIC parking sensors (front and rear).
Night Vision:
Optional infrared night vision system (NVS).
Connectivity
Telematics:
Optional telematics services, hands-free communication (e.g., Bluetooth integration).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 miles or 12 months, whichever comes first (using synthetic oil). Check specific model year for ASSYST service indicator.
Major Service Interval:
Significant service often around 30,000-50,000 miles, including spark plugs, transmission fluid/filter, coolant, and brake fluid.
Fluid Specifications
Engine Oil:
Mobil 1 0W-40 or equivalent synthetic API SN/SM/SL, MB-Approval 229.5.
Transmission Fluid:
MB 236.14 (for 722.6/7G-TRONIC) or MB 236.10/236.12 (for earlier 722.6 variants), e.g., Pentosin ATF 134 or Mobil ATF 134.
Coolant:
MB 325.0 (blue) or MB 325.5 (violet) silicate-free antifreeze, mixed 50/50 with distilled water.
Brake Fluid:
DOT 4 Plus (MB 331.0).
Known Issues
Air Suspension:
AIRMATIC strut leaks, compressor failure, valve block issues. ABC system can be complex and expensive to repair if leaks or hydraulic failures occur.
Electronics:
CAN bus communication faults, COMAND system glitches, door control module failures, xenons ballast issues.
Engine Cooling:
Plastic thermostat housing cracking, coolant leaks from hoses, radiator issues.
Drivetrain:
Transmission conductor plate failure (common on earlier 722.6), driveshaft flex disc wear.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Germany
Brand Focus:
Luxury vehicles, performance automobiles, and commercial vehicles.
Model Evolution
Predecessor:
Mercedes-Benz W140 S-Class.
Successor:
Mercedes-Benz W221 S-Class.
Production
Production Start Year:
1998 (for model year 1999)
Production End Year:
2005 (for model year 2005)
Manufacturing Locations:
Sindelfingen, Germany; Beijing, China (joint venture); Tuscaloosa, Alabama, USA (some specific variants or assembly).
🏆 Awards & Recognition
Recognitions
Best Luxury Sedan:
Frequently cited as a benchmark for luxury, comfort, and technology in its class by automotive journalists and publications.
Industry Accolades:
Received numerous awards and positive reviews for its innovative features, refined ride, and build quality upon its release.
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