1996-2003 Mercedes E-Class (W210) Service and Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: E-Class Chassis Code: W210 Model Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 Generation Generation Name: Second Generation E-Class Generation Introduction Year: 1995 (as 1996 model year) Generation End Year: 2002 (as 2003 model year) Codes Internal Chassis Code: W210 👋 Introduction Market Position Market Segment: Executive Sedan/Wagon, competing with BMW 5 Series, Audi A6, Lexus GS. Target Audience For Manual: Mercedes-Benz E-Class W210 owners, independent repair shops, DIY mechanics, automotive enthusiasts. Competitive Analysis Key Selling Points Of Vehicle: Build quality, comfort, safety, advanced engineering for its time, luxury features. Key Features Vehicle Design Philosophy: Blend of luxury, comfort, safety, and robust engineering, marking a significant evolution from its predecessor (W124). Manual Value Proposition: Empowers owners and technicians with accurate, dealership-level information to maintain and repair the W210 E-Class effectively, preserving its longevity and performance. 📋 Manual Details Coverage Areas Coverage Scope: All Models & All Repairs A-Z Vehicle Specificity: Vehicle Specific - Not Generic Repair Information Technician Usage: Exact same manual used by dealership technicians Page Count Estimated Page Count: Extensive, likely over 1000 pages (typical for comprehensive service manuals of this era) Manual Type Type: Service and Repair Manual Language Language: English Format Format: Likely Print or PDF (Product description implies physical manual or digital equivalent) 📖 Manual Coverage Systems Covered Engine: Engine mechanicals, diagnostics, overhaul, specific engine variants (e.g., M111, M112, M113, OM604, OM605, OM606, OM611, OM612, OM613) Fuel System: Fuel injection (Bosch Motronic/ME, Lucas/Delphi), fuel pumps, injectors, pressure regulators, fuel tank, lines Ignition System: Ignition coils, spark plugs, distributorless ignition systems (DIS), crank/cam sensors, ignition control module (ICM) Cooling System: Radiator, water pump, thermostat, cooling fans (electric/viscous), coolant hoses, heater core, climate control integration Exhaust System: Exhaust manifolds, catalytic converters, mufflers, oxygen sensors, emissions control systems (EGR, secondary air injection) Transmission: Automatic transmission (e.g., 722.6 '5G-TRONIC'), manual transmission (e.g., Getrag 716.600), shift linkage, torque converter, transmission control module (TCM) Drivetrain: Driveshafts, CV joints, differential, axles, rear-wheel drive (RWD) or 4MATIC all-wheel drive (AWD) systems Brakes: Hydraulic systems, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), brake discs, pads, calipers, master cylinder, brake lines, parking brake Suspension: Front and rear suspension components, shock absorbers, struts, control arms, ball joints, bushings, coil springs, sway bars Steering: Power steering system, steering rack/box, tie rods, steering column, steering angle sensor Electrical System: 12V battery, alternator, starter motor, fuse boxes, relays, wiring diagrams, lighting systems Body And Chassis: Body panel removal/installation, frame structure, doors, hood, trunk, bumpers, glass, seals Interior: Dashboard, seating, trim panels, airbags, seat belts, headliner, carpets HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, climate control, refrigerant, compressor, evaporator, heater core, blower motor Infotainment: Radio, CD changer, navigation system (if equipped), speaker systems, antenna Diagnostics: On-Board Diagnostics (OBD-II) system, fault codes (DTCs), diagnostic tools, troubleshooting flowcharts Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt replacement Troubleshooting: System-specific fault diagnosis, symptom-based troubleshooting guides, wiring diagrams for electrical issues Repair: Engine component replacement, transmission repair, brake system overhauls, suspension component replacement, electrical component repair Overhaul: Engine rebuild procedures, transmission overhaul, differential rebuild Installation: Component installation and removal, accessory installation guidance Adjustments: Throttle body adjustments, idle speed control, parking brake adjustments Specifications: Torque specifications for all fasteners, electrical specifications, performance data Technical Depth Depth: Comprehensive: from basic fluid changes to full engine and transmission rebuilds, including detailed diagnostic procedures. 📊 Manual Specifications File Format Digital Format Quality: If PDF, expect high-resolution, searchable text and clear diagrams. If printed, high-quality paper and binding. Print Quality Print Quality: Professional, dealership-grade quality with clear diagrams and legible text. Binding Type Binding Type: Likely perfect binding or spiral binding for ease of use in a workshop environment. Paper Type Paper Type: Durable paper stock suitable for workshop environments, often with glossy pages for diagrams. ⚙️ Engine Specifications Primary Engine Engine Variants: Wide range including Inline-4, Inline-6, V6, V8 gasoline, and Diesel engines (e.g., E200, E230, E240, E280, E320, E420, E430, E55 AMG, E200D, E220D, E250D, E290TD, E300TD, E320CDI). Engine Variant Detail M111 Engine Code Example: M111 (2.0L, 2.3L I4) Engine Variant Detail M112 Engine Code Example: M112 (2.4L, 2.6L, 2.8L V6) Engine Variant Detail M113 Engine Code Example: M113 (4.3L, 5.0L V8) Engine Variant Detail Om604 Engine Code Example: OM604 (2.0L, 2.2L Diesel I4) Engine Variant Detail Om605 Engine Code Example: OM605 (2.5L Diesel I5) Engine Variant Detail Om606 Engine Code Example: OM606 (3.0L Diesel I6, Turbocharged) Engine Variant Detail Om611 Engine Code Example: OM611 (2.1L Diesel I4, Common Rail) Engine Variant Detail Om612 Engine Code Example: OM612 (2.7L Diesel I5, Common Rail) Engine Variant Detail Om613 Engine Code Example: OM613 (3.2L Diesel I6, Common Rail) Performance Horsepower Range: Approx. 136 hp (E200 Diesel) to 349 hp (E55 AMG) Torque Range: Approx. 205 Nm (E200 Diesel) to...

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Tags: 1996 1997 1998 1999 2000 2001 2002 2003 Car Cars E-Class Mercedes Mercedes-benz Misc W210

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

E-Class

Chassis Code:

Model Years Covered:

1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003

Generation

Generation Name:

Second Generation E-Class

Generation Introduction Year:

1995 (as 1996 model year)

Generation End Year:

2002 (as 2003 model year)

Codes

Internal Chassis Code:

👋 Introduction

Market Position

Market Segment:

Executive Sedan/Wagon, competing with BMW 5 Series, Audi A6, Lexus GS.

Target Audience For Manual:

Mercedes-Benz E-Class W210 owners, independent repair shops, DIY mechanics, automotive enthusiasts.

Competitive Analysis

Key Selling Points Of Vehicle:

Build quality, comfort, safety, advanced engineering for its time, luxury features.

Key Features

Vehicle Design Philosophy:

Blend of luxury, comfort, safety, and robust engineering, marking a significant evolution from its predecessor (W124).

Manual Value Proposition:

Empowers owners and technicians with accurate, dealership-level information to maintain and repair the W210 E-Class effectively, preserving its longevity and performance.

📋 Manual Details

Coverage Areas

Coverage Scope:

All Models & All Repairs A-Z

Vehicle Specificity:

Vehicle Specific - Not Generic Repair Information

Technician Usage:

Exact same manual used by dealership technicians

Page Count

Estimated Page Count:

Extensive, likely over 1000 pages (typical for comprehensive service manuals of this era)

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Likely Print or PDF (Product description implies physical manual or digital equivalent)

📖 Manual Coverage

Systems Covered

Engine:

Engine mechanicals, diagnostics, overhaul, specific engine variants (e.g., M111, M112, M113, OM604, OM605, OM606, OM611, OM612, OM613)

Fuel System:

Fuel injection (Bosch Motronic/ME, Lucas/Delphi), fuel pumps, injectors, pressure regulators, fuel tank, lines

Ignition System:

Ignition coils, spark plugs, distributorless ignition systems (DIS), crank/cam sensors, ignition control module (ICM)

Cooling System:

Radiator, water pump, thermostat, cooling fans (electric/viscous), coolant hoses, heater core, climate control integration

Exhaust System:

Exhaust manifolds, catalytic converters, mufflers, oxygen sensors, emissions control systems (EGR, secondary air injection)

Transmission:

Automatic transmission (e.g., 722.6 '5G-TRONIC'), manual transmission (e.g., Getrag 716.600), shift linkage, torque converter, transmission control module (TCM)

Drivetrain:

Driveshafts, CV joints, differential, axles, rear-wheel drive (RWD) or 4MATIC all-wheel drive (AWD) systems

Brakes:

Hydraulic systems, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), brake discs, pads, calipers, master cylinder, brake lines, parking brake

Suspension:

Front and rear suspension components, shock absorbers, struts, control arms, ball joints, bushings, coil springs, sway bars

Steering:

Power steering system, steering rack/box, tie rods, steering column, steering angle sensor

Electrical System:

12V battery, alternator, starter motor, fuse boxes, relays, wiring diagrams, lighting systems

Body And Chassis:

Body panel removal/installation, frame structure, doors, hood, trunk, bumpers, glass, seals

Interior:

Dashboard, seating, trim panels, airbags, seat belts, headliner, carpets

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, climate control, refrigerant, compressor, evaporator, heater core, blower motor

Infotainment:

Radio, CD changer, navigation system (if equipped), speaker systems, antenna

Diagnostics:

On-Board Diagnostics (OBD-II) system, fault codes (DTCs), diagnostic tools, troubleshooting flowcharts

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt replacement

Troubleshooting:

System-specific fault diagnosis, symptom-based troubleshooting guides, wiring diagrams for electrical issues

Repair:

Engine component replacement, transmission repair, brake system overhauls, suspension component replacement, electrical component repair

Overhaul:

Engine rebuild procedures, transmission overhaul, differential rebuild

Installation:

Component installation and removal, accessory installation guidance

Adjustments:

Throttle body adjustments, idle speed control, parking brake adjustments

Specifications:

Torque specifications for all fasteners, electrical specifications, performance data

Technical Depth

Depth:

Comprehensive: from basic fluid changes to full engine and transmission rebuilds, including detailed diagnostic procedures.

📊 Manual Specifications

File Format

Digital Format Quality:

If PDF, expect high-resolution, searchable text and clear diagrams. If printed, high-quality paper and binding.

Print Quality

Print Quality:

Professional, dealership-grade quality with clear diagrams and legible text.

Binding Type

Binding Type:

Likely perfect binding or spiral binding for ease of use in a workshop environment.

Paper Type

Paper Type:

Durable paper stock suitable for workshop environments, often with glossy pages for diagrams.

⚙️ Engine Specifications

Primary Engine

Engine Variants:

Wide range including Inline-4, Inline-6, V6, V8 gasoline, and Diesel engines (e.g., E200, E230, E240, E280, E320, E420, E430, E55 AMG, E200D, E220D, E250D, E290TD, E300TD, E320CDI).

Engine Variant Detail M111

Engine Code Example:

M111 (2.0L, 2.3L I4)

Engine Variant Detail M112

Engine Code Example:

M112 (2.4L, 2.6L, 2.8L V6)

Engine Variant Detail M113

Engine Code Example:

M113 (4.3L, 5.0L V8)

Engine Variant Detail Om604

Engine Code Example:

OM604 (2.0L, 2.2L Diesel I4)

Engine Variant Detail Om605

Engine Code Example:

OM605 (2.5L Diesel I5)

Engine Variant Detail Om606

Engine Code Example:

OM606 (3.0L Diesel I6, Turbocharged)

Engine Variant Detail Om611

Engine Code Example:

OM611 (2.1L Diesel I4, Common Rail)

Engine Variant Detail Om612

Engine Code Example:

OM612 (2.7L Diesel I5, Common Rail)

Engine Variant Detail Om613

Engine Code Example:

OM613 (3.2L Diesel I6, Common Rail)

Performance

Horsepower Range:

Approx. 136 hp (E200 Diesel) to 349 hp (E55 AMG)

Torque Range:

Approx. 205 Nm (E200 Diesel) to 525 Nm (E55 AMG)

Fuel System

Fuel Injection Systems:

Multi-point fuel injection (MPI), Sequential Electronic Fuel Injection (SEFI), Common Rail Direct Injection (CDI for diesel)

🔧 Transmission

Standard

Standard Transmission Type:

Typically 5-speed automatic (722.6 '5G-TRONIC') for most models, with some offering 4-speed automatic or 5/6-speed manual transmissions.

Optional

Optional Transmission Types:

5-speed manual (e.g., Getrag 716.600), 4-speed automatic (722.4), 4MATIC all-wheel drive system with automatic transmission.

Features

Transmission Features:

Electronic shift control, lock-up torque converter, winter/sport modes (on some automatics), adaptive shifting logic.

📐 Dimensions

Exterior

Length:

Approx. 4817-4874 mm (Sedan), 4850-4870 mm (Wagon)

Width:

Approx. 1799 mm

Height:

Approx. 1442 mm (Sedan), 1462-1495 mm (Wagon)

Wheelbase:

Approx. 2833 mm

Cargo

Cargo Volume Sedan:

Approx. 500 liters (17.6 cu ft)

Cargo Volume Wagon:

Approx. 510-1640 liters (18.0-57.9 cu ft)

Weights

Curb Weight Range:

Approx. 1500-1800 kg (depending on engine and equipment)

Gross Vehicle Weight Rating:

Typically around 2100-2300 kg

🛡️ Safety Features

Ratings

NHTSA Front Driver:

Not specifically rated for this era, but known for robust safety cage construction.

NHTSA Front Passenger:

Not specifically rated for this era, but known for robust safety cage construction.

IIHS Side Impact:

Not specifically rated for this era, but known for robust safety cage construction.

Active Features

Active Safety Systems:

ABS (Anti-lock Braking System), ESP (Electronic Stability Program - introduced later in the W210 lifecycle), Traction Control System (ASR - Acceleration Slip Regulation).

Passive Features

Passive Safety Features:

Dual front airbags, side airbags (optional), seat belt pretensioners, crumple zones, reinforced safety cell.

💡 Technology Features

Infotainment

Infotainment Systems:

Becker Audio systems (various levels), optional CD changer, cassette player, optional navigation systems (e.g., Comand 2.0).

Driver Assistance

Driver Assistance Features:

Cruise control, Rain-sensing wipers (optional), Parking Assist (optional), ABS, ASR, ESP (later models).

Connectivity

Connectivity Features:

Limited by modern standards; basic analog phone system integration (optional) or direct cellular connection in later stages.

Other Technology

Other Features:

Dual-zone climate control (optional), heated/ventilated seats (optional), power adjustable steering column, Xenon headlamps (optional, post-facelift).

🔧 Maintenance

Service Intervals

Oil Change Interval Benz Spec:

Typically every 15,000 km or 12 months, whichever comes first (using synthetic oil).

Major Service Interval:

e.g., 60,000 km or 4 years (for spark plug replacement, transmission fluid service, etc. - consult manual for specifics).

Fluid Specifications

Engine Oil Specification:

MB 229.1 or 229.3 (synthetic), viscosity grade depending on climate (e.g., 0W-40, 5W-40, 5W-30).

Coolant Specification:

MB 325.0 or 326.0 (ethylene glycol based, 50/50 mix with distilled water).

Automatic Transmission Fluid:

MB 236.10 or 236.12 (e.g., Dexron III equivalent, or specific MB ATF). Consult manual for precise fluid type for 722.6 transmission.

Brake Fluid Specification:

DOT 4.

Known Issues

Common Wear Items:

Front suspension bushings and ball joints, crankcase ventilation (CCV) system (especially on early M111 engines), MAF sensor issues, ABS/ESP sensor failures, rust (particularly on wheel arches, door bottoms, and trunk lid).

Common Electrical Issues:

Cracked solder joints on the instrument cluster (common in pre-facelift models), SAM module issues, wiring harness degradation.

Common Engine Issues:

Head gasket leaks (less common than some rivals), ignition coil failures, OVP relay failures (on some older models).

Common Diesel Issues:

Glow plug issues, injector seal leaks, turbocharger problems (on turbocharged variants), rust.

📚 Vehicle History

Brand Heritage

Mercedes Benz Legacy:

Mercedes-Benz has a long history of engineering excellence, safety innovation, and luxury vehicle production dating back to the late 19th century.

Model Evolution

W210 Design Influence:

The W210 represented a significant departure from the more angular W124, adopting a more aerodynamic and rounded design with the signature 'four-eyed' headlights.

Facelift Details:

Received a significant facelift in 2000 (for the 2001 model year) with revised headlights, bumpers, side mirrors with integrated turn signals, and interior updates.

Production

Production Period:

1995-2002

Manufacturing Locations:

Primary production in Germany (Sindelfingen), with some assembly in other global locations.

Production Volume:

Millions of units produced globally, making it a highly successful model for Mercedes-Benz.

🏆 Awards & Recognition

Recognitions

Jd Power Initial Quality:

Generally ranked well for quality and reliability, though some specific issues were noted in early model years by consumer reports.

Consumer Reports Ratings:

Varied by model year and specific engine, but often praised for safety, comfort, and build quality, with some mechanical and electrical issues reported.

Certifications

Euro Ncap Rating:

Achieved 4 stars in Euro NCAP testing (for early W210 models), reflecting good crash protection for its time.