Mercedes Benz E300 E Class Complete Workshop Service Repair Manual 1995 1996

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: E-Class Sub Model: E300 Model Code: W210 Model Variant: Sedan Generation Generation Code: W210 (Second Generation) Generation Years: 1995-2002 Codes Engine Code: M104.945 (E300 D Diesel), M111.975 (E300 E Gasoline - Export) Chassis Code: W210 👋 Introduction Market Position Segment: Executive Sedan / Mid-size Luxury Sedan Brand Perception: Known for luxury, build quality, safety, and engineering innovation. Competitive Analysis Direct Competitors: BMW 5 Series (E39), Audi A6 (C4/C5), Lexus GS, Volvo S70/S80. Key Features Design Philosophy: W210 introduced a new design language for Mercedes-Benz, moving away from the more squared-off designs of its predecessor, featuring a more aerodynamic and flowing profile with distinctive quad headlights. Performance Focus: The E300 designation typically points towards either a diesel (E300 D) or a less common, often export-market, gasoline engine variant. This manual will cover the specific powertrain provided. 📋 Manual Details Coverage Areas Region Covered: Global (North America, Europe, Asia - specifications may vary by market) Page Count Estimated Page Count: ~1500-2500 pages (typical for a complete workshop manual of this era) Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Engine mechanical, engine electrical, fuel system, ignition system, cooling system, lubrication system, emission control systems, turbocharging (if applicable). Transmission: Automatic transmission (e.g., 722.6 '5G-Tronic'), manual transmission (less common for E300 in this era), transmission control module (TCM). Drivetrain: Driveshafts, differentials, axle shafts, wheel bearings. Suspension: Front suspension (e.g., MacPherson strut), rear suspension (multi-link independent), shock absorbers, springs, bushings, control arms, anti-roll bars. Brakes: Front and rear disc brakes, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), brake fluid, brake lines, master cylinder, calipers, parking brake. Steering: Power steering system, steering rack, steering column, tie rods, power steering fluid. Electrical: 12V electrical system, battery, alternator, starter, fuses, relays, wiring diagrams for all systems, lighting, instrumentation, body control module (BCM). HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, evaporator, condenser, climate control module. Body And Trim: Exterior body panels, interior trim, doors, windows, locks, mirrors, sunroof, bumpers, seats. Restraints: Airbag system (SRS - Supplemental Restraint System), seat belts. Diagnostics: On-Board Diagnostics (OBD-II), diagnostic trouble codes (DTCs), diagnostic procedures, scan tool usage. Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and top-offs, belt inspections and replacement, spark plug replacement, general inspection points. Engine Repair: Engine removal and installation, cylinder head removal and installation, piston and ring replacement, crankshaft and bearing service, valve train repair. Transmission Repair: Transmission fluid and filter change, transmission overhaul, torque converter replacement, transmission control module (TCM) diagnostics and replacement. Brake Service: Brake pad and rotor replacement, brake caliper service, brake bleeding, ABS system diagnosis and repair. Suspension And Steering Repair: Strut and shock absorber replacement, ball joint and control arm replacement, tie rod end replacement, power steering pump and rack service. Electrical Diagnostics: Troubleshooting wiring issues, starter and alternator testing, battery testing and replacement, fuse and relay diagnosis, lighting system repair. HVAC Service: Refrigerant recharge, component replacement (compressor, condenser, evaporator), leak detection, blower motor replacement. Bodywork And Interior: Door panel removal, window regulator repair, lock mechanism service, seat removal, trim piece replacement. Troubleshooting: Step-by-step diagnostic procedures for common drivability and system faults. Technical Depth Depth: Comprehensive: Covers everything from routine maintenance to complete engine and transmission overhauls, including detailed diagnostic trees and specifications. Diagnostic Focus: Advanced diagnostic procedures for electronic control modules (ECMs), sensors, actuators, and communication networks. Wiring Diagrams: Detailed, system-specific wiring diagrams for all electrical components and circuits. Torque Specifications: Precise torque values for all critical fasteners and components. Special Tools: Identification and usage instructions for specialized Mercedes-Benz tools required for specific repairs. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Text-searchable (allows for quick finding of specific terms and procedures) Print Quality Print Readability: High resolution images and text for clear printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type Diesel: Inline 6-Cylinder, Turbocharged Diesel (OM606.912 variant often used for E300D) Engine Type Gasoline: Inline 4-Cylinder, Fuel-Injected Gasoline (M111.975, e.g., E300 2.8L, common in some markets) Performance Diesel Displacement Diesel: 2.996 cc (3.0 Liters) Horsepower Diesel: Approx. 134-148 hp (depending on specific market tune) Torque Diesel: Approx. 180-192 lb-ft (depending on specific market tune) Performance Gasoline Displacement Gasoline: 2.8 Liter (approx. 2799 cc) Horsepower Gasoline: Approx. 193 hp Torque Gasoline: Approx. 199 lb-ft Fuel System Fuel Type Diesel: Diesel Fuel Fuel Type Gasoline: Unleaded Gasoline Injection System: Direct Injection (Diesel - EDC), Multi-point Fuel Injection (Gasoline - EFI) 🔧 Transmission Standard Transmission Type: 5-Speed Automatic (722.6 '5G-Tronic') was very common for E300 models. Optional Transmission Type Optional: A 5-speed manual transmission might have been available in certain markets or for specific engine variants, though less common. Features Automatic Features: Electronic control,...

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

E-Class

Sub Model:

Model Code:

Model Variant:

Sedan

Generation

Generation Code:

W210 (Second Generation)

Generation Years:

1995-2002

Codes

Engine Code:

M104.945 (E300 D Diesel), M111.975 (E300 E Gasoline - Export)

Chassis Code:

👋 Introduction

Market Position

Segment:

Executive Sedan / Mid-size Luxury Sedan

Brand Perception:

Known for luxury, build quality, safety, and engineering innovation.

Competitive Analysis

Direct Competitors:

BMW 5 Series (E39), Audi A6 (C4/C5), Lexus GS, Volvo S70/S80.

Key Features

Design Philosophy:

W210 introduced a new design language for Mercedes-Benz, moving away from the more squared-off designs of its predecessor, featuring a more aerodynamic and flowing profile with distinctive quad headlights.

Performance Focus:

The E300 designation typically points towards either a diesel (E300 D) or a less common, often export-market, gasoline engine variant. This manual will cover the specific powertrain provided.

📋 Manual Details

Coverage Areas

Region Covered:

Global (North America, Europe, Asia - specifications may vary by market)

Page Count

Estimated Page Count:

~1500-2500 pages (typical for a complete workshop manual of this era)

Manual Type

Type:

Complete Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine:

Engine mechanical, engine electrical, fuel system, ignition system, cooling system, lubrication system, emission control systems, turbocharging (if applicable).

Transmission:

Automatic transmission (e.g., 722.6 '5G-Tronic'), manual transmission (less common for E300 in this era), transmission control module (TCM).

Drivetrain:

Driveshafts, differentials, axle shafts, wheel bearings.

Suspension:

Front suspension (e.g., MacPherson strut), rear suspension (multi-link independent), shock absorbers, springs, bushings, control arms, anti-roll bars.

Brakes:

Front and rear disc brakes, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), brake fluid, brake lines, master cylinder, calipers, parking brake.

Steering:

Power steering system, steering rack, steering column, tie rods, power steering fluid.

Electrical:

12V electrical system, battery, alternator, starter, fuses, relays, wiring diagrams for all systems, lighting, instrumentation, body control module (BCM).

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, evaporator, condenser, climate control module.

Body And Trim:

Exterior body panels, interior trim, doors, windows, locks, mirrors, sunroof, bumpers, seats.

Restraints:

Airbag system (SRS - Supplemental Restraint System), seat belts.

Diagnostics:

On-Board Diagnostics (OBD-II), diagnostic trouble codes (DTCs), diagnostic procedures, scan tool usage.

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, belt inspections and replacement, spark plug replacement, general inspection points.

Engine Repair:

Engine removal and installation, cylinder head removal and installation, piston and ring replacement, crankshaft and bearing service, valve train repair.

Transmission Repair:

Transmission fluid and filter change, transmission overhaul, torque converter replacement, transmission control module (TCM) diagnostics and replacement.

Brake Service:

Brake pad and rotor replacement, brake caliper service, brake bleeding, ABS system diagnosis and repair.

Suspension And Steering Repair:

Strut and shock absorber replacement, ball joint and control arm replacement, tie rod end replacement, power steering pump and rack service.

Electrical Diagnostics:

Troubleshooting wiring issues, starter and alternator testing, battery testing and replacement, fuse and relay diagnosis, lighting system repair.

HVAC Service:

Refrigerant recharge, component replacement (compressor, condenser, evaporator), leak detection, blower motor replacement.

Bodywork And Interior:

Door panel removal, window regulator repair, lock mechanism service, seat removal, trim piece replacement.

Troubleshooting:

Step-by-step diagnostic procedures for common drivability and system faults.

Technical Depth

Depth:

Comprehensive: Covers everything from routine maintenance to complete engine and transmission overhauls, including detailed diagnostic trees and specifications.

Diagnostic Focus:

Advanced diagnostic procedures for electronic control modules (ECMs), sensors, actuators, and communication networks.

Wiring Diagrams:

Detailed, system-specific wiring diagrams for all electrical components and circuits.

Torque Specifications:

Precise torque values for all critical fasteners and components.

Special Tools:

Identification and usage instructions for specialized Mercedes-Benz tools required for specific repairs.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Text-searchable (allows for quick finding of specific terms and procedures)

Print Quality

Print Readability:

High resolution images and text for clear printing.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type Diesel:

Inline 6-Cylinder, Turbocharged Diesel (OM606.912 variant often used for E300D)

Engine Type Gasoline:

Inline 4-Cylinder, Fuel-Injected Gasoline (M111.975, e.g., E300 2.8L, common in some markets)

Performance Diesel

Displacement Diesel:

2.996 cc (3.0 Liters)

Horsepower Diesel:

Approx. 134-148 hp (depending on specific market tune)

Torque Diesel:

Approx. 180-192 lb-ft (depending on specific market tune)

Performance Gasoline

Displacement Gasoline:

2.8 Liter (approx. 2799 cc)

Horsepower Gasoline:

Approx. 193 hp

Torque Gasoline:

Approx. 199 lb-ft

Fuel System

Fuel Type Diesel:

Diesel Fuel

Fuel Type Gasoline:

Unleaded Gasoline

Injection System:

Direct Injection (Diesel - EDC), Multi-point Fuel Injection (Gasoline - EFI)

🔧 Transmission

Standard

Transmission Type:

5-Speed Automatic (722.6 '5G-Tronic') was very common for E300 models.

Optional

Transmission Type Optional:

A 5-speed manual transmission might have been available in certain markets or for specific engine variants, though less common.

Features

Automatic Features:

Electronic control, multiple shift modes (e.g., Comfort, Sport), lock-up torque converter for improved efficiency.

Fluid Specifications

Automatic Transmission Fluid:

MB 236.10 or MB 236.14 approved ATF (e.g., Pentosin ATF1, Fuchs Titan ATF 4134).

📐 Dimensions

Exterior

Length:

Approx. 4850 mm (190.9 in)

Width:

Approx. 1799 mm (70.8 in)

Height:

Approx. 1434 mm (56.5 in)

Wheelbase

Wheelbase:

Approx. 2833 mm (111.5 in)

Weights

Curb Weight:

Approx. 1600-1700 kg (3527-3748 lbs) depending on engine and options.

🛡️ Safety Features

Ratings

Crash Test Results:

Generally performed well in contemporary crash tests, reflecting Mercedes-Benz's focus on safety. Specific ratings would vary by testing agency (e.g., NHTSA, Euro NCAP) and test year.

Active Features

Active Safety:

ABS (Anti-lock Braking System), ESP (Electronic Stability Program) became increasingly standard or available during this generation. Traction Control System (ASR).

Passive Features

Passive Safety:

Frontal airbags, side airbags (often optional or standard on higher trims), crumple zones, reinforced passenger cell, seatbelt pre-tensioners.

💡 Technology Features

Infotainment

Infotainment System:

COMAND (Cockpit Management and Navigation) system often optional or standard on higher trims, featuring CD player, radio, and navigation. Basic cassette/radio units also common.

Driver Assistance

Driver Assistance Features:

Cruise control, parking assist sensors (optional), rain-sensing wipers (optional).

Connectivity

Connectivity Features:

Limited by modern standards. Features like telephone integration (often via cradle) were available as options.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000-15,000 km (6,000-9,000 miles) or annually, depending on driving conditions and manufacturer recommendations (e.g., 'Service A' or 'Service B').

Transmission Fluid Interval:

Recommended at 60,000-100,000 km (40,000-60,000 miles) for the 722.6 transmission, or as indicated by the car's service indicator system.

Coolant Flush Interval:

Typically every 2-4 years or 30,000-60,000 km.

Fluid Specifications

Engine Oil Specification:

API SJ or higher, ACEA A3/B3 or A3/B4, viscosity grade 0W-40, 5W-40, or 5W-30 (refer to manual for specific engine and climate).

Coolant Specification:

MB 325.0 specification coolant (antifreeze/summer coolant) or an equivalent phosphate-free silicate-stabilized OAT coolant (often blue or purple).

Brake Fluid Specification:

DOT 4 (e.g., MB 331.0 specification).

Known Issues

Common Wear Items:

Front end components (ball joints, control arm bushings), radiator, vacuum lines, OVP relay (for some engine management components), crank position sensor, catalytic converter (especially on older models), rust (particularly in wheel wells and rocker panels).

Diesel Specific Issues:

Glow plugs, injection pump issues (less common on inline-6 OM606), vacuum leaks affecting turbo operation and EGR.

Gasoline Specific Issues:

Mass Air Flow (MAF) sensor issues, ignition coil pack problems, potential for head gasket leaks on some M111 variants under high mileage.

📚 Vehicle History

Brand Heritage

Heritage:

Mercedes-Benz has a long-standing reputation for engineering excellence, luxury, and safety dating back to the invention of the automobile.

Model Evolution

Predecessor:

W124 E-Class (known for its robust build quality and reliability).

Successor:

W211 E-Class (launched in 2002).

Production

Production Years For Model:

1995-2002 for the W210 generation, with specific E300 variants concentrated in the earlier to mid-years of this range.

Manufacturing Locations:

Primarily Germany (Sindelfingen, Bremen), with potential assembly in other international locations.

🏆 Awards & Recognition

Recognitions

Industry Awards:

The W210 E-Class was generally well-received critically upon release for its refined ride, safety, and advanced features for its time. Specific awards would vary by publication and region.

Ratings

Reliability Perception:

Reputation for strong build quality, but certain electronic components and wear items can require attention at higher mileages. Diesel models often praised for longevity.