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 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: Good 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...
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:
Good
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.
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