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Mercedes Benz E320 1997 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: E320 Year: 1997 Generation Chassis Code: W210 Codes Engine Code: M104.995 (3.2L Inline-6) 👋 Introduction Market Position Positioning: Premium executive sedan, renowned for its luxury, comfort, and engineering prowess. Targeted at discerning buyers valuing refinement and performance. Competitive Analysis Competitors: BMW 5 Series (E39), Audi A6 (C4/C5), Lexus GS, Cadillac DeVille. Key Features Features: Robust M104 inline-six engine, advanced (for its time) electronic systems, luxurious interior, excellent ride quality, solid build quality. 📋 Manual Details Coverage Areas Systems Covered: Engine, Drivetrain, Suspension, Steering, Brakes, Fuel System, Electrical System, HVAC, Bodywork, Diagnostics, Troubleshooting, Maintenance Page Count Pages: Estimated 1500+ pages (comprehensive) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed engine removal, disassembly, inspection, assembly, overhaul procedures for the M104.995 engine. Engine Management: Fuel injection system (KE-Jetronic variant or early EFI), ignition system, engine control module (ECM) operation, sensor testing. Transmission: Automatic transmission (722.6 '5G-Tronic') repair, adjustment, fluid changes, electronic control unit (TCU) diagnostics. Drivetrain: Rear-wheel drive system, driveshafts, differentials, axle shafts, wheel bearings. Suspension: Front and rear suspension systems, shock absorbers, springs, control arms, bushings, alignment specifications. Steering: Power steering system, steering column, steering rack, tie rods, troubleshooting. Brakes: Hydraulic brake system, ABS (Anti-lock Braking System), brake pad and rotor replacement, brake fluid flush, caliper service. Electrical System: 12V electrical system, battery, alternator, starter, fuses, relays, lighting system, wiring diagrams, diagnostic trouble codes (DTCs). HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, compressor, refrigerant recharge, blower motor, climate control unit. Body And Interior: Body panel removal and installation, door mechanisms, glass replacement, interior trim, seats, safety restraints. Diagnostics: On-board diagnostics (OBD-II) system, diagnostic tools, troubleshooting flowcharts, common faults and their solutions. Instrument Cluster: Operation, diagnosis, and repair of gauges, warning lights, and the driver information display. Lighting System: Headlights, taillights, interior lighting, fog lights, and their associated control modules and switches. Security System: Keyless entry, immobilizer system (if equipped), central locking operation and troubleshooting. Emissions Control: Catalytic converter, oxygen sensors, EGR (if applicable), and related emission control components and testing procedures. Procedures Included Scheduled Maintenance: Detailed oil change intervals, filter replacements, fluid checks and changes, spark plug replacement, drive belt inspection/replacement. Component Removal Installation: Step-by-step instructions for removing and installing major and minor components across all vehicle systems. Troubleshooting Guides: Systematic guides for diagnosing and resolving common and uncommon vehicle problems. Wiring Diagrams: Comprehensive, color-coded wiring diagrams for all electrical systems, facilitating fault tracing. Torque Specifications: Precise torque values for all critical fasteners and bolts. Diagnostic Trouble Codes: Coverage for identifying, interpreting, and clearing OBD-II diagnostic trouble codes (DTCs) specific to Mercedes-Benz systems. Alignment Specifications: Detailed front and rear wheel alignment specifications including camber, caster, and toe angles. Tire Wheel Data: Recommended tire sizes, inflation pressures, and wheel bolt patterns (e.g., 5x112). Technical Depth Depth: Comprehensive: Covers routine maintenance to complete engine and transmission rebuilds, complex electrical diagnostics, and bodywork repairs. Diagnostic Tools: Guidance on using factory or equivalent diagnostic tools (e.g., Star Diagnosis, although specific version for 1997 might be noted) for advanced diagnostics. 📊 Manual Specifications File Format Format Details: Searchable PDF, allowing quick access to specific information. High-resolution scans for clarity. Searchability: Yes, full text search capability enabled for efficient information retrieval. Print Quality Quality: High-resolution scans of original factory manual pages, ensuring legibility of text and diagrams. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 3.2L (3199 cc) Naturally Aspirated Inline-6 Cylinder Engine Code: M104.995 Performance Horsepower: 217 hp @ 5,500 rpm (approx.) Torque: 229 lb-ft @ 3,750 rpm (approx.) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - likely KE-Jetronic or early ME system variations. Fuel Type: Premium Unleaded Gasoline (91+ Octane) Engine Management ECM: Engine Control Module (ECM) for managing fuel, ignition, and emissions. 🔧 Transmission Standard Type: 5-speed Automatic (722.6 '5G-Tronic') Optional Optional Type: None (5-speed automatic was standard for E320 Sedan and Wagon) Features Features: Electronic control, comfort/sport modes, torque converter lock-up for improved efficiency. Fluid Specifications Fluid Type: MB 236.10 or MB 236.14 (Dexron III/Mercon compatible prior to 236.10) 📐 Dimensions Exterior Length: 190.3 inches (Sedan) Width: 70.2 inches Height: 56.7 inches (Sedan) Weights Curb Weight: Approx. 3,600 - 3,800 lbs (depending on body style and options) 🛡️ Safety Features Ratings NHTSA Front Driver: 4 Stars (1997 Model Year) NHTSA Front Passenger: 4 Stars (1997 Model Year) Active Features ABS: Standard Anti-lock Braking System (ABS) Esp: Optional Electronic Stability Program (ESP) available on later models, might be present on some 1997 E320s. Passive Features Airbags: Driver and front passenger airbags; optional side airbags available. Seatbelts: Pre-tensioning front seat belts. 💡 Technology Features Infotainment Head Unit: Factory-installed AM/FM stereo with cassette player; optional CD changer and navigation system (APS). Speakers: Typically...
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Mercedes Benz E320 1997 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
E320
Year:
1997
Generation
Chassis Code:
W210
Codes
Engine Code:
M104.995 (3.2L Inline-6)
👋 Introduction
Market Position
Positioning:
Premium executive sedan, renowned for its luxury, comfort, and engineering prowess. Targeted at discerning buyers valuing refinement and performance.
Competitive Analysis
Competitors:
BMW 5 Series (E39), Audi A6 (C4/C5), Lexus GS, Cadillac DeVille.
Key Features
Features:
Robust M104 inline-six engine, advanced (for its time) electronic systems, luxurious interior, excellent ride quality, solid build quality.
📋 Manual Details
Coverage Areas
Systems Covered:
Engine, Drivetrain, Suspension, Steering, Brakes, Fuel System, Electrical System, HVAC, Bodywork, Diagnostics, Troubleshooting, Maintenance
Page Count
Pages:
Estimated 1500+ pages (comprehensive)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed engine removal, disassembly, inspection, assembly, overhaul procedures for the M104.995 engine.
Engine Management:
Fuel injection system (KE-Jetronic variant or early EFI), ignition system, engine control module (ECM) operation, sensor testing.
Transmission:
Automatic transmission (722.6 '5G-Tronic') repair, adjustment, fluid changes, electronic control unit (TCU) diagnostics.
Drivetrain:
Rear-wheel drive system, driveshafts, differentials, axle shafts, wheel bearings.
Suspension:
Front and rear suspension systems, shock absorbers, springs, control arms, bushings, alignment specifications.
Steering:
Power steering system, steering column, steering rack, tie rods, troubleshooting.
Brakes:
Hydraulic brake system, ABS (Anti-lock Braking System), brake pad and rotor replacement, brake fluid flush, caliper service.
Electrical System:
12V electrical system, battery, alternator, starter, fuses, relays, lighting system, wiring diagrams, diagnostic trouble codes (DTCs).
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, compressor, refrigerant recharge, blower motor, climate control unit.
Body And Interior:
Body panel removal and installation, door mechanisms, glass replacement, interior trim, seats, safety restraints.
Diagnostics:
On-board diagnostics (OBD-II) system, diagnostic tools, troubleshooting flowcharts, common faults and their solutions.
Instrument Cluster:
Operation, diagnosis, and repair of gauges, warning lights, and the driver information display.
Lighting System:
Headlights, taillights, interior lighting, fog lights, and their associated control modules and switches.
Security System:
Keyless entry, immobilizer system (if equipped), central locking operation and troubleshooting.
Emissions Control:
Catalytic converter, oxygen sensors, EGR (if applicable), and related emission control components and testing procedures.
Procedures Included
Scheduled Maintenance:
Detailed oil change intervals, filter replacements, fluid checks and changes, spark plug replacement, drive belt inspection/replacement.
Component Removal Installation:
Step-by-step instructions for removing and installing major and minor components across all vehicle systems.
Troubleshooting Guides:
Systematic guides for diagnosing and resolving common and uncommon vehicle problems.
Wiring Diagrams:
Comprehensive, color-coded wiring diagrams for all electrical systems, facilitating fault tracing.
Torque Specifications:
Precise torque values for all critical fasteners and bolts.
Diagnostic Trouble Codes:
Coverage for identifying, interpreting, and clearing OBD-II diagnostic trouble codes (DTCs) specific to Mercedes-Benz systems.
Alignment Specifications:
Detailed front and rear wheel alignment specifications including camber, caster, and toe angles.
Tire Wheel Data:
Recommended tire sizes, inflation pressures, and wheel bolt patterns (e.g., 5x112).
Technical Depth
Depth:
Comprehensive: Covers routine maintenance to complete engine and transmission rebuilds, complex electrical diagnostics, and bodywork repairs.
Diagnostic Tools:
Guidance on using factory or equivalent diagnostic tools (e.g., Star Diagnosis, although specific version for 1997 might be noted) for advanced diagnostics.
📊 Manual Specifications
File Format
Format Details:
Searchable PDF, allowing quick access to specific information. High-resolution scans for clarity.
Searchability:
Yes, full text search capability enabled for efficient information retrieval.
Print Quality
Quality:
High-resolution scans of original factory manual pages, ensuring legibility of text and diagrams.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
3.2L (3199 cc) Naturally Aspirated Inline-6 Cylinder
Engine Code:
M104.995
Performance
Horsepower:
217 hp @ 5,500 rpm (approx.)
Torque:
229 lb-ft @ 3,750 rpm (approx.)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - likely KE-Jetronic or early ME system variations.
Fuel Type:
Premium Unleaded Gasoline (91+ Octane)
Engine Management
ECM:
Engine Control Module (ECM) for managing fuel, ignition, and emissions.
🔧 Transmission
Standard
Type:
5-speed Automatic (722.6 '5G-Tronic')
Optional
Optional Type:
None (5-speed automatic was standard for E320 Sedan and Wagon)
Features
Features:
Electronic control, comfort/sport modes, torque converter lock-up for improved efficiency.
Fluid Specifications
Fluid Type:
MB 236.10 or MB 236.14 (Dexron III/Mercon compatible prior to 236.10)
📐 Dimensions
Exterior
Length:
190.3 inches (Sedan)
Width:
70.2 inches
Height:
56.7 inches (Sedan)
Weights
Curb Weight:
Approx. 3,600 - 3,800 lbs (depending on body style and options)
🛡️ Safety Features
Ratings
NHTSA Front Driver:
4 Stars (1997 Model Year)
NHTSA Front Passenger:
4 Stars (1997 Model Year)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Esp:
Optional Electronic Stability Program (ESP) available on later models, might be present on some 1997 E320s.
Passive Features
Airbags:
Driver and front passenger airbags; optional side airbags available.
Seatbelts:
Pre-tensioning front seat belts.
💡 Technology Features
Infotainment
Head Unit:
Factory-installed AM/FM stereo with cassette player; optional CD changer and navigation system (APS).
Speakers:
Typically 6-8 speaker system depending on trim and options.
Driver Assistance
Cruise Control:
Standard electronic cruise control.
Rain Sensing Wipers:
Optional rain-sensing windshield wipers.
Connectivity
Telematics:
Early telematics systems might be present depending on market and options.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Approximately every 7,500 - 10,000 miles or annually, whichever comes first (dependent on oil type used).
Transmission Fluid Change:
Recommended every 30,000 - 60,000 miles, or as per severe service schedule. Crucial for 722.6 transmission longevity.
Spark Plugs:
Typically replaced every 60,000 - 100,000 miles (depending on type: standard vs. platinum/iridium).
Fluid Specifications
Engine Oil Capacity:
Approx. 8.0 quarts (with filter)
Engine Oil Type:
MB 229.1 specification (e.g., 0W-40, 5W-40, 5W-30 synthetic)
Coolant Type:
Mercedes-Benz approved coolant (e.g., G05 or equivalent)
Brake Fluid Type:
DOT 4
Known Issues
Known Issues:
Cracked dashboard (MB-Tex material), biodegradable wiring harness insulation issues (early W210s), blower motor resistor failure, front SAM module water ingress, rear window regulator issues, ABS/ESP sensor failures, serpentine belt tensioner pulley wear.
📚 Vehicle History
Brand Heritage
Heritage:
Mercedes-Benz has a long-standing reputation for engineering excellence, luxury, safety, and durability dating back to the early 20th century.
Model Evolution
Evolution:
The W210 E-Class replaced the W124 generation, introducing a more rounded and aerodynamic design. The E320 was a key model in this generation, offering a balance of performance and refinement.
Production
Production Years:
W210 generation produced from 1995 to 2002. The 1997 E320 falls within the initial phase of the W210 lifecycle.
Manufacturing Locations:
Primarily Germany, with some production in other global facilities.
🏆 Awards & Recognition
Recognitions
Industry Recognition:
Generally well-regarded for its build quality, comfort, and refinement. Often praised by automotive journalists for its driving dynamics and luxury appointments for its era.
Ratings
Reliability Reputation:
Mixed. While the core mechanicals (engine, transmission) are robust, specific electronic components and certain trim pieces were subject to premature wear or failure, as noted in known issues.
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