Mercedes Benz E320 1997 Full Service Repair Manual
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🏷️ Basic Information Identification Make: Mercedes-Benz Model: E320 Year: 1997 Codes Chassis Code: W210 Engine Code: M104.995 👋 Introduction Market Position Segment: Mid-size Luxury Sedan Target Audience: Owners and independent repair shops seeking in-depth technical information. Competitive Analysis Competitors 1997: BMW 5 Series (E39), Audi A6 (C4/C5), Lexus GS300, Volvo S90. Key Features Chassis Design: W210 chassis introduced a more modern, rounded design compared to the W124. Known for its excellent ride comfort and build quality. Engine Technology: The M104 inline-six engine is renowned for its smoothness and durability, utilizing a sophisticated multi-valve head and fuel injection system. 📋 Manual Details Coverage Areas Description: Covers all aspects of repair, maintenance, rebuilding, refurbishment, and restoration for the 1997 Mercedes-Benz E320. Page Count Estimated Pages: 1500+ Manual Type Type: Full Service Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, cylinder head, pistons, crankshaft, timing components, oil system. Engine Electrical: Ignition system, fuel injection (H სისტემა), starter, alternator, sensors (crankshaft, camshaft, MAP, O2), ECU diagnostics. Transmission Automatic: 5-speed automatic transmission (722.6 '5G-Tronic'), valve body, torque converter, shift solenoids, fluid service. Brakes: Hydraulic system, ABS (Anti-lock Braking System), brake discs, pads, calipers, lines, fluid replacement. Suspension Steering: Front and rear suspension components (struts, control arms, bushings), power steering system, steering gear, wheel alignment specifications. Fuel System: Fuel pump, fuel filter, fuel injectors, fuel pressure regulator, evaporative emissions control (EVAP). Cooling System: Radiator, water pump, thermostat, coolant hoses, cooling fan, heater core. Exhaust System: Exhaust manifold, catalytic converter, mufflers, O2 sensors, pipework. Body Interior: Body panel removal and installation, door mechanisms, upholstery, trim, HVAC controls, lighting. Electrical Body: Headlights, taillights, interior lighting, power windows, power seats, central locking, wipers, horn. Procedures Included Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, fluid checks and top-offs. Troubleshooting: Diagnostic procedures for common and uncommon faults, wiring diagrams, symptom-to-cause analysis. Repair: Step-by-step repair instructions for all major and minor mechanical and electrical components. Rebuilding: Detailed procedures for engine and transmission rebuilding. Refurbishment Restoration: Guidance on restoring and refurbishing various vehicle systems and components. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls. Diagnostic Tools: Information relevant to using Mercedes-Benz diagnostic tools (e.g., Star Diagnosis) for electronic systems. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick information retrieval. Print Quality Printability: Printable pages. Binding Type Binding: N/A (Digital format) Paper Type Paper Quality: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 6-cylinder, 24-valve DOHC (M104.995) Displacement: 3.2 Liters (3199 cc) Performance Horsepower: 217 hp @ 5500 rpm Torque: 229 lb-ft (310 Nm) @ 3750 rpm Fuel System Injection System: Bosch H Electronic Fuel Injection (H) Fuel Type: Unleaded Premium Unleaded Gasoline (91+ octane) Engine Components Block Material: Aluminum Alloy Head Material: Aluminum Alloy Bore X Stroke: 89.9 mm x 84.0 mm Compression Ratio: 10.0:1 🔧 Transmission Standard Type: 5-speed Automatic (722.6 '5G-Tronic') Optional Transmission Type: N/A (Standard for E320) Features Transmission Control: Electronic Control Unit (ECU) with multiple shift modes (e.g., Comfort, Sport). Fluid Type: Mercedes-Benz Automatic Transmission Fluid (ATF) - e.g., MB-Approval 236.10 or 236.14 (check specific service bulletin) Components Torque Converter Capacity: Variable 📐 Dimensions Exterior Length: 189.4 inches (4811 mm) Width: 70.2 inches (1783 mm) Height: 56.1 inches (1425 mm) Wheelbase: 111.5 inches (2832 mm) Weights Curb Weight: Approximately 3600-3800 lbs (1630-1725 kg) Gross Vehicle Weight Rating Gvwr: Approximately 4500-4700 lbs (2040-2130 kg) Cargo Trunk Volume: Approximately 15.1 cu ft (428 L) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4 Stars (1997) NHTSA Front Impact Passenger: 4 Stars (1997) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional (ASR - Acceleration Skid Regulation) Passive Features Airbags Front: Driver and front passenger airbags Seatbelts: 3-point inertia-reel seatbelts with pretensioners Body Structure: Integrated safety cell with crumple zones. 💡 Technology Features Infotainment Audio System: Factory premium audio system, often with cassette and/or CD player. Some models may have optional Bose sound system. Navigation: Optional factory navigation system (often a rudimentary CRT display system). Driver Assistance Cruise Control: Standard electronically controlled cruise control. Connectivity Phone Integration: Optional factory-installed cellular phone integration (typically requiring an external antenna and handset). 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 - 10,000 miles (12,000 - 16,000 km) or annually, using synthetic oil. Transmission Fluid Interval: Every 30,000 - 60,000 miles (50,000 - 100,000 km), or as per service indicator. Early W210s may require more frequent service. Air Filter Replacement: Every 15,000 - 30,000 miles (24,000 - 48,000 km). Spark Plug Replacement: Every 60,000 - 100,000 miles (96,000 - 160,000 km) for iridium-tipped plugs. Fluid Specifications Engine Oil Capacity: Approximately 8.0 liters (8.5 US quarts) with filter change. Engine Oil Specification: API SG/SH or higher, SAE 0W-40 or 5W-40 synthetic recommended for optimal performance and protection....
Diagnostic procedures for common and uncommon faults, wiring diagrams, symptom-to-cause analysis.
Repair:
Step-by-step repair instructions for all major and minor mechanical and electrical components.
Rebuilding:
Detailed procedures for engine and transmission rebuilding.
Refurbishment Restoration:
Guidance on restoring and refurbishing various vehicle systems and components.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls.
Diagnostic Tools:
Information relevant to using Mercedes-Benz diagnostic tools (e.g., Star Diagnosis) for electronic systems.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text for quick information retrieval.
Print Quality
Printability:
Printable pages.
Binding Type
Binding:
N/A (Digital format)
Paper Type
Paper Quality:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 6-cylinder, 24-valve DOHC (M104.995)
Displacement:
3.2 Liters (3199 cc)
Performance
Horsepower:
217 hp @ 5500 rpm
Torque:
229 lb-ft (310 Nm) @ 3750 rpm
Fuel System
Injection System:
Bosch H Electronic Fuel Injection (H)
Fuel Type:
Unleaded Premium Unleaded Gasoline (91+ octane)
Engine Components
Block Material:
Aluminum Alloy
Head Material:
Aluminum Alloy
Bore X Stroke:
89.9 mm x 84.0 mm
Compression Ratio:
10.0:1
🔧 Transmission
Standard
Type:
5-speed Automatic (722.6 '5G-Tronic')
Optional
Transmission Type:
N/A (Standard for E320)
Features
Transmission Control:
Electronic Control Unit (ECU) with multiple shift modes (e.g., Comfort, Sport).
Fluid Type:
Mercedes-Benz Automatic Transmission Fluid (ATF) - e.g., MB-Approval 236.10 or 236.14 (check specific service bulletin)
Components
Torque Converter Capacity:
Variable
📐 Dimensions
Exterior
Length:
189.4 inches (4811 mm)
Width:
70.2 inches (1783 mm)
Height:
56.1 inches (1425 mm)
Wheelbase:
111.5 inches (2832 mm)
Weights
Curb Weight:
Approximately 3600-3800 lbs (1630-1725 kg)
Gross Vehicle Weight Rating Gvwr:
Approximately 4500-4700 lbs (2040-2130 kg)
Cargo
Trunk Volume:
Approximately 15.1 cu ft (428 L)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4 Stars (1997)
NHTSA Front Impact Passenger:
4 Stars (1997)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional (ASR - Acceleration Skid Regulation)
Passive Features
Airbags Front:
Driver and front passenger airbags
Seatbelts:
3-point inertia-reel seatbelts with pretensioners
Body Structure:
Integrated safety cell with crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory premium audio system, often with cassette and/or CD player. Some models may have optional Bose sound system.
Navigation:
Optional factory navigation system (often a rudimentary CRT display system).
Driver Assistance
Cruise Control:
Standard electronically controlled cruise control.
Connectivity
Phone Integration:
Optional factory-installed cellular phone integration (typically requiring an external antenna and handset).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 - 10,000 miles (12,000 - 16,000 km) or annually, using synthetic oil.
Transmission Fluid Interval:
Every 30,000 - 60,000 miles (50,000 - 100,000 km), or as per service indicator. Early W210s may require more frequent service.
Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km).
Spark Plug Replacement:
Every 60,000 - 100,000 miles (96,000 - 160,000 km) for iridium-tipped plugs.
Fluid Specifications
Engine Oil Capacity:
Approximately 8.0 liters (8.5 US quarts) with filter change.
Engine Oil Specification:
API SG/SH or higher, SAE 0W-40 or 5W-40 synthetic recommended for optimal performance and protection.
Coolant Type:
Mercedes-Benz G48 (Antifreeze/Coolant) or equivalent.
Brake Fluid Type:
DOT 4
Known Issues
Crankshaft Position Sensor:
Failure can lead to no-start or intermittent stalling.
Mass Air Flow Sensor Maf:
Can become dirty or fail, affecting engine performance and fuel economy.
Transmission Conductor Plate:
Failure of the conductor plate in the 722.6 transmission can cause shifting problems.
Window Regulators:
Plastic components can degrade, leading to power window failure.
Wiring Harness Insulation:
In some older models, insulation on wiring harnesses can become brittle and degrade.
📚 Vehicle History
Brand Heritage
Brand Legacy:
Mercedes-Benz has a long-standing reputation for engineering excellence, safety, and luxury automotive manufacturing since its inception.
Model Evolution
W210 Introduction:
The W210 E-Class replaced the W124 in 1995 (for the 1996 model year). It marked a significant departure in styling, featuring a more rounded and aerodynamic profile with distinctive quad headlamps.
E320 Significance:
The E320 was the primary six-cylinder model in the W210 range, offering a balance of performance and refinement. It was a strong seller and represented the core of the E-Class offering.
Production
Production Years W210:
1995-2002
Manufacturing Locations:
Germany (Sindelfingen), USA (Tuscaloosa - some variants).
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
The W210 E-Class, including various E320 variants, was frequently recognized on Car and Driver's 10 Best lists in the mid-to-late 1990s for its excellent balance of luxury, performance, and safety.
Ratings
Safety Awards:
Generally received high safety ratings from various automotive safety organizations of its era.
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