Mercedes Benz E420 Complete Workshop Service Repair Manual 1997
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🏷️ Basic Information Identification Make: Mercedes-Benz Model: E420 Year: 1997 Codes Chassis Code: W210 Generation Generation Code: Second Generation (W210) 👋 Introduction Market Position Vehicle Segment: Mid-size luxury sedan. Target Audience: Discerning buyers seeking comfort, performance, and advanced technology. Competitive Analysis Key Competitors: BMW 5 Series (E39), Audi A6 (C4/C5), Lexus GS300. Key Features Performance Orientation: The E420, with its V8 engine, offered a significant performance upgrade over its 6-cylinder counterparts. Luxury Appointments: Known for its refined interior, build quality, and advanced features for its era. Manual Value Proposition Diy Savings: Enables owners to perform complex maintenance and repairs, significantly reducing dealership or independent shop labor costs. Accurate Information: Provides manufacturer-accurate procedures and specifications, crucial for maintaining Mercedes-Benz vehicles correctly. 📋 Manual Details Coverage Areas All Models Engines Trim Transmissions: True Page Count Estimated Page Count: Varies by specific manual compilation, typically 1000-2500+ pages for a complete workshop manual. Manual Type Type: Workshop Service and Repair Manual Language Language: English Format Format: Downloadable Digital Format (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, rebuild, timing, cooling system, lubrication system. Engine Management: Fuel injection system (KE-Jetronic variant for M119.960), ignition system, emissions control systems, electronic control unit (ECU) diagnostics and testing. Transmission: Automatic transmission (722.6 '722.6xx' 5G-TRONIC) service, diagnosis, overhaul, torque converter, hydraulic control unit. Drivetrain: Driveshafts, universal joints, differential, axles. Suspension: Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment procedures. Steering: Power steering system, steering rack, linkage, steering column. Brakes: Hydraulic system, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), brake discs, calipers, pads, lines, bleeding procedures. Electrical System: Battery, charging system, starter, lighting, fuses, relays, wiring diagrams, power distribution. Body And Chassis: Body panels, doors, hood, trunk, interior trim, glass, weatherstripping, chassis components. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system service, refrigerant handling, blower motor, climate control unit. Body Electronics: Central locking, power windows, power seats, mirrors, immobilizer system, keyless entry (if equipped). Procedures Included Scheduled Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement. Diagnostics Troubleshooting: Systematic troubleshooting guides, fault code identification, symptom-based repair procedures. Component Removal Installation: Detailed instructions for removing and installing all major mechanical and electrical components. Engine Rebuild: Complete engine overhaul instructions, including cylinder head service, piston and connecting rod installation, crankshaft and bearing replacement. Transmission Overhaul: Detailed steps for rebuilding the 722.6 automatic transmission, including clutch pack replacement, valve body servicing, and solenoid testing. Brake System Repair: Brake pad/disc replacement, caliper service, ABS/ESP component testing and replacement, brake fluid flush. Electrical Diagnostics: Wiring diagram interpretation, component testing, circuit troubleshooting. Bodywork Repair: Dent repair, panel replacement, door alignment, glass replacement. Technical Depth Depth: Comprehensive, covering everything from basic fluid changes to complete engine and transmission overhauls. Diagnostic Codes: Includes procedures for reading and interpreting diagnostic trouble codes (DTCs) from various ECUs. Specifications: Detailed torque specifications, clearances, fluid capacities, and diagnostic data. 📊 Manual Specifications File Format Format: PDF Searchable Text: Yes (typical for well-produced PDF manuals) Print Quality Resolution: High-resolution images and clear text (assumed for a quality manual). Scalability: Scalable for detailed viewing of diagrams and schematics. Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: M119.960 Engine Type: 4.2L V8 (SOHC, 32 valves) Bore X Stroke: 89.0 mm x 84.0 mm Compression Ratio: 10.0:1 Performance Horsepower: 275 hp @ 5750 rpm Torque: 295 lb-ft @ 3900 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (Bosch KE-Jetronic variant for this year/engine) Fuel Type: Premium Unleaded Gasoline (91+ Octane) Lubrication Oil Capacity: Approx. 8.0 Liters (with filter change) Ignition Spark Plugs: Typically Bosch F8DC4 or equivalent 🔧 Transmission Standard Transmission Type: 5-Speed Automatic (722.6 '722.6xx' 5G-TRONIC) Optional Optional Transmissions: None for E420 model in 1997 Features Features: Electronic shift control, torque converter lock-up clutch, selectable driving modes (Comfort/Sport). Fluid Specifications Transmission Fluid: MB Approval 236.10 or 236.12 (e.g., Mercedes-Benz ATF). 📐 Dimensions Exterior Length: Approx. 190.7 inches (4843 mm) Width: Approx. 70.2 inches (1783 mm) Height: Approx. 57.0 inches (1448 mm) Wheelbase: Approx. 111.5 inches (2832 mm) Weights Curb Weight: Approx. 3800-4000 lbs (1725-1815 kg), depending on options. 🛡️ Safety Features Ratings NHTSA Front Crash Test: Not directly available for this specific sub-model/year in the same format as modern ratings, but generally considered very safe for its era. IIHS Crash Test: Good (for frontal offset tests in its class). Active Features ABS: Standard Anti-lock Braking System (ABS). Esp: Optional or standard depending on market; likely includes Electronic Stability Program (ESP) or ASR (Acceleration Skid Control). Passive Features Airbags: Driver and front passenger airbags, side airbags (optional). Seatbelts: Pretensioning seatbelts with force limiters. 💡 Technology Features Infotainment Audio System: Premium sound system (e.g., Bose or Becker audio with CD/Cassette player). Navigation: Optional factory navigation system (COMAND 2.0...
Fuel injection system (KE-Jetronic variant for M119.960), ignition system, emissions control systems, electronic control unit (ECU) diagnostics and testing.
Transmission:
Automatic transmission (722.6 '722.6xx' 5G-TRONIC) service, diagnosis, overhaul, torque converter, hydraulic control unit.
MB Approval 236.10 or 236.12 (e.g., Mercedes-Benz ATF).
📐 Dimensions
Exterior
Length:
Approx. 190.7 inches (4843 mm)
Width:
Approx. 70.2 inches (1783 mm)
Height:
Approx. 57.0 inches (1448 mm)
Wheelbase:
Approx. 111.5 inches (2832 mm)
Weights
Curb Weight:
Approx. 3800-4000 lbs (1725-1815 kg), depending on options.
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
Not directly available for this specific sub-model/year in the same format as modern ratings, but generally considered very safe for its era.
IIHS Crash Test:
Good (for frontal offset tests in its class).
Active Features
ABS:
Standard Anti-lock Braking System (ABS).
Esp:
Optional or standard depending on market; likely includes Electronic Stability Program (ESP) or ASR (Acceleration Skid Control).
Passive Features
Airbags:
Driver and front passenger airbags, side airbags (optional).
Seatbelts:
Pretensioning seatbelts with force limiters.
💡 Technology Features
Infotainment
Audio System:
Premium sound system (e.g., Bose or Becker audio with CD/Cassette player).
Navigation:
Optional factory navigation system (COMAND 2.0 or predecessor).
Driver Assistance
Cruise Control:
Standard electronic cruise control.
Parking Sensors:
Optional front and rear PARKTRONIC parking assist sensors.
Connectivity
Cellular Phone:
Optional integrated cellular phone system (often analog).
Comfort Features
Climate Control:
Dual-zone automatic climate control.
Seat Features:
Electrically adjustable front seats with memory, heated front seats (optional).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500-10,000 miles (12,000-16,000 km) or 12 months, whichever comes first, with synthetic oil.
Transmission Fluid Change:
Recommended every 40,000-60,000 miles (64,000-96,000 km).
Coolant Flush:
Recommended every 30,000-40,000 miles (48,000-64,000 km) or 2-3 years.
Spark Plug Replacement:
Typically every 60,000-100,000 miles (96,000-160,000 km), depending on spark plug type.
Fluid Specifications
Engine Oil Type:
Full Synthetic SAE 0W-40 or 5W-40 meeting MB Approval 229.3 or 229.5.
Coolant Type:
Mercedes-Benz Approved Antifreeze/Coolant (e.g., G05 formulation or equivalent).
Brake Fluid Type:
DOT 4 High Performance Brake Fluid.
Known Issues
Crankshaft Position Sensor:
Can fail, leading to no-start or stalling issues.
Mass Air Flow Sensor:
Can become contaminated or fail, affecting engine performance and fuel economy.
Oil Cooler Seals:
Potential for leaks, especially the O-rings at the cooler lines.
Window Regulators:
Can wear out or break, causing windows to fail to operate.
Rust And Corrosion:
Prone to rust in wheel wells, rocker panels, and door bottoms if not properly maintained or if exposed to harsh climates.
Valve Cover Gaskets:
Common source of oil leaks, especially with age.
📚 Vehicle History
Brand Heritage
Brand Origin:
Germany, founded 1926, synonymous with engineering excellence and luxury.
Model Evolution
W210 Introduction:
The W210 generation of the E-Class was introduced in 1995, replacing the W124. It marked a significant styling departure with its 'four-eyed' quad-headlight design.
E420 Positioning:
The E420 was a high-performance variant within the E-Class lineup, offering the potent M119 V8 engine, previously used in higher-tier models like the S-Class and SL.
Production
Production Years:
W210 E420 produced from 1995 to 1997 (in North America). The W210 was produced globally until 2002.
Manufacturing Locations:
Primarily Germany, with some assembly in other global locations.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The W210 chassis generally received positive reviews, though specific E420 awards might be less prominent than general model accolades.
Automotive Journalism Reviews:
Consistently praised for its ride quality, build quality, and potent V8 performance.
Certifications
Safety Certifications:
Met or exceeded all federal motor vehicle safety standards (FMVSS) of the era.