Mercedes Benz E320 1997 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Mercedes-Benz Model: E320 Year: 1997 Chassis Code: W210 Codes Engine Code: M104.995 Engine Code Variant: E320 Sedan 👋 Introduction Market Position Market Position: Executive sedan positioned as a blend of luxury, comfort, and robust engineering, competing with other premium brands. Competitive Analysis Competitors: BMW 5 Series (E39), Audi A6 (C4/C5), Lexus GS 300, Volvo S80 Key Features Key Features: Renowned Mercedes-Benz build quality, comfortable ride, powerful inline-six engine, advanced safety features for its era. Model Significance Model Significance: The W210 E-Class marked a design departure from its predecessor, introducing a more rounded and aerodynamic shape. 📋 Manual Details Coverage Areas Coverage Areas: All mechanical, electrical, and bodywork systems Page Count Page Count: Approximately 1500-2000 (estimated for factory service manuals of this era) Manual Type Manual Type: Factory Service Repair Manual Content Type: Comprehensive, including diagnostic procedures, repair instructions, maintenance schedules, torque specifications, and wiring diagrams. Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, overhaul, lubrication system, cooling system, fuel system, emission control system Engine Electrical: Ignition system, starting system, charging system, engine control unit (ECU), sensors, actuators Transmission: Automatic transmission (722.6 '5G-TRONIC'), overhaul, diagnostics, control module Drivetrain: Driveshafts, differentials, axle shafts Suspension: Front suspension (MacPherson struts), rear suspension (multi-link), components, geometry, alignment Steering: Power steering system, steering gear, steering column, linkage Brakes: Front ventilated discs, rear solid discs, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), brake hydraulics, calipers, pads, rotors Electrical System: 12V electrical system, battery, alternator, starter, fuses, relays, wiring diagrams, lighting, power accessories HVAC: Heating, Ventilation, and Air Conditioning system, climate control, refrigerant, compressor, evaporator, heater core Body Interior: Interior trim, seats, dashboard, headliner, door panels, locks, windows Body Exterior: Body panels, doors, hood, trunk, bumpers, glass, weatherstripping Safety Systems: Airbags (SRS - Supplemental Restraint System), seatbelts Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups Diagnostics: Troubleshooting guides, symptom-based diagnostics, fault code interpretation (OBD-II) Repair: Component removal, installation, adjustment, rebuilding procedures for all major systems Specifications: Torque specifications, clearances, tolerances, alignment settings, fluid capacities Electrical Troubleshooting: Wiring diagrams interpretation, circuit testing, component diagnosis Rebuilds: Detailed instructions for engine and transmission overhauls Body Repair: Panel replacement, alignment, glass installation, door mechanisms, convertible top service (if applicable to specific variants, though not E320 sedan). Diagnostic Tools: Details on using OBD-II scanners and Mercedes-specific diagnostic tools (e.g., STAR DIAGNOSIS, though not directly covered by this manual's scope, it provides context for system identification). Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics. Troubleshooting Charts: Extensive charts correlating symptoms to potential causes and diagnostic steps. 📊 Manual Specifications File Format File Format: PDF Searchable Text: Yes Compatibility: Viewable on most devices with a PDF reader. Print Quality Print Quality: High-resolution scans suitable for printing Binding Type Binding Type: N/A (Digital) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Naturally aspirated, inline 6-cylinder, DOHC Displacement: 3.2 Liters (3199 cc) Bore X Stroke: 89.9 mm x 84.0 mm Engine Management: Sophisticated electronic engine management system managing fuel injection, ignition timing, and emission controls. Performance Horsepower: 228 hp @ 5500 rpm Torque: 230 lb-ft @ 3750 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Bosch Motronic ME 2.0 Fuel Type: Premium Unleaded Gasoline (91+ octane) Cooling System Coolant Capacity: Approximately 8.5 Liters (8.9 Quarts) Coolant Type: Mercedes-Benz approved Antifreeze/Coolant (e.g., G48) Lubrication System Oil Capacity: Approximately 8.0 Liters (8.5 Quarts) Oil Type: SAE 5W-40 or 0W-40 Synthetic Oil (MB 229.1 or 229.3 specification) 🔧 Transmission Standard Transmission Type: 5-speed Automatic (722.6 '5G-TRONIC') Optional Optional Transmission: None for E320 model in 1997 Features Transmission Features: Electronic control, driver-selectable modes (Comfort/Sport), adaptive shifting Fluid Capacity Transmission Fluid Capacity: Approximately 8.0 Liters (8.5 Quarts) for a complete fill (dry fill may be higher) Fluid Type Transmission Fluid Type: MB 236.10 specification automatic transmission fluid (ATF) 📐 Dimensions Exterior Length: 188.5 inches (4788 mm) Width: 70.2 inches (1783 mm) Height: 56.7 inches (1440 mm) Wheelbase: 111.5 inches (2832 mm) Weights Curb Weight: Approximately 3700-3850 lbs (1678-1746 kg) Gross Vehicle Weight Rating: Approximately 4700 lbs (2132 kg) Cargo Trunk Volume: Approximately 16.0 cubic feet (453 Liters) 🛡️ Safety Features Ratings NHTSA Front Impact Rating: 4 Stars (Driver), 4 Stars (Passenger) IIHS Side Impact Rating: Good (for vehicles of its era) Active Features Active Safety: ABS (Anti-lock Braking System), ESP (Electronic Stability Program), Traction Control System (ASR) Passive Features Passive Safety: Dual front airbags, front side-impact airbags (optional/standard depending on market), front and rear crumple zones, reinforced body structure 💡 Technology Features Infotainment Infotainment System: COMAND (Cockpit Management and Navigation) optional, otherwise premium cassette/CD player with AM/FM radio. Driver Assistance Driver Assistance Features: Cruise control, rain-sensing wipers (optional), automatic climate control. Connectivity Connectivity Options: Tele...
Detailed instructions for engine and transmission overhauls
Body Repair:
Panel replacement, alignment, glass installation, door mechanisms, convertible top service (if applicable to specific variants, though not E320 sedan).
Diagnostic Tools:
Details on using OBD-II scanners and Mercedes-specific diagnostic tools (e.g., STAR DIAGNOSIS, though not directly covered by this manual's scope, it provides context for system identification).
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics.
Troubleshooting Charts:
Extensive charts correlating symptoms to potential causes and diagnostic steps.
📊 Manual Specifications
File Format
File Format:
PDF
Searchable Text:
Yes
Compatibility:
Viewable on most devices with a PDF reader.
Print Quality
Print Quality:
High-resolution scans suitable for printing
Binding Type
Binding Type:
N/A (Digital)
Paper Type
Paper Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally aspirated, inline 6-cylinder, DOHC
Displacement:
3.2 Liters (3199 cc)
Bore X Stroke:
89.9 mm x 84.0 mm
Engine Management:
Sophisticated electronic engine management system managing fuel injection, ignition timing, and emission controls.
Performance
Horsepower:
228 hp @ 5500 rpm
Torque:
230 lb-ft @ 3750 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - Bosch Motronic ME 2.0
Every 10,000 miles (16,000 km) or 1 year, whichever comes first (with synthetic oil).
Transmission Fluid Change Interval:
Recommended every 40,000-60,000 miles (64,000-96,000 km) or per Mercedes-Benz service schedule.
Coolant Change Interval:
Every 2-3 years or as per service schedule.
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 (MB 331.0 specification)
Power Steering Fluid Type:
MB 236.3 specification hydraulic fluid
Known Issues
Known Issues:
Mass airflow sensor (MAF) issues, ignition coil failures, serpentine belt tensioner problems, biodegradable wiring insulation deterioration (for vehicles with specific harness types), headlight projector lens hazing, window regulator failures, rust in wheel wells and rocker panels.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mercedes-Benz has a long-standing reputation for engineering excellence, luxury, and durability, dating back to the invention of the automobile.
Model Evolution
Model Evolution W210:
The W210 replaced the W124 E-Class, introducing a significant styling update and modern technologies. The 1997 model year represents the early production phase of this generation.
Production
Production Period W210:
1995-2002
Manufacturing Locations:
Germany (Sindelfingen), South Africa, Egypt, Hungary
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
The W210 chassis, including the E320, was frequently recognized by automotive publications for its luxury and performance.
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