1996 Mercedes-Benz S500 Service & Repair Manual Software
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🏷️ Basic Information Identification Make: Mercedes-Benz Model: S500 Year: 1996 Codes Chassis Code: W140 Engine Code: M119 👋 Introduction Market Position Positioning: The 1996 S500 represented the pinnacle of Mercedes-Benz luxury and engineering for its era, competing with other high-end sedans from brands like BMW (7 Series) and Lexus (LS Series). This manual targets owners and independent repair shops seeking professional-grade information. Competitive Analysis Competition: Competed directly against the BMW 7 Series (E38), Lexus LS 400, and Cadillac DeVille. The S500 was known for its robust engineering, comfort, and advanced (for the time) technology. Key Features Features: The W140 S-Class was a technological showcase, featuring advanced safety systems, luxurious appointments, and a powerful V8 engine. This manual reflects the complexity and sophistication of the vehicle. 📋 Manual Details Coverage Areas Coverage: Comprehensive service, repair, diagnostic, and maintenance procedures for the 1996 Mercedes-Benz S500 (W140 chassis). Page Count Estimated Page Count: 1500+ Manual Type Type: Official Service and Repair Manual Software Language Language: English Format Format: Software (likely digital format like PDF or proprietary software) 📖 Manual Coverage Systems Covered Engine: Detailed coverage of the M119 5.0L V8 engine, including maintenance, diagnosis, repair of fuel injection, ignition system, cooling, lubrication, and emissions control. Transmission: Service and repair of the 722.6 5-speed automatic transmission (electronic controlled), including adjustments, diagnostics, and overhaul. Suspension Steering: Comprehensive coverage of the independent suspension system (front and rear), shock absorbers, springs, bushings, and the recirculating ball steering system. Brakes: Detailed information on the Anti-lock Braking System (ABS), ASR (Acceleration Slip Regulation), brake fluid specifications, caliper service, rotor replacement, and hydraulic system diagnostics. Electrical Electronics: Extensive coverage of the vehicle's electrical system, including wiring diagrams, fuse box layouts, lighting, power windows, seats, mirrors, climate control, SRS (airbag) system, and ECU diagnosis. Body Chassis: Information on body panel repair, door mechanisms, locks, hinges, interior trim, convertible top (if applicable), and chassis component maintenance. Climate Control: Diagnosis and repair of the automatic climate control system (Thermotronic), including AC compressor, refrigerant, HVAC blower, and sensor troubleshooting. Driver Assistance: Details on systems like cruise control, traction control (ASR), and potentially early forms of electronic stability control if equipped. Procedures Included Maintenance: Routine maintenance tasks such as oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, and belt inspections. Troubleshooting: Systematic diagnostic procedures for common and complex issues, including fault code interpretation and symptom-based troubleshooting guides. Repair Rebuild: Step-by-step instructions for component removal, installation, and overhaul for major vehicle systems. Wiring Diagrams: Complete and detailed electrical wiring diagrams for all vehicle systems, crucial for electrical diagnosis and repair. Technical Specifications: Torque specifications, clearances, fluid capacities, electrical values, and other critical technical data for accurate repairs. Diagnostic Procedures: Procedures for using diagnostic tools (e.g., Star Diagnosis systems) and interpreting diagnostic trouble codes (DTCs). Technical Depth Depth: Expert-level technical depth, covering everything from basic maintenance to complete engine and transmission rebuilds, complex electrical diagnostics, and bodywork. 📊 Manual Specifications File Format Format: Digital software, likely searchable and potentially with interactive diagrams. May be delivered as PDF, executable, or web-based access. Print Quality Quality: High-resolution digital content ensuring clarity of diagrams, text, and images. Printable pages if delivered in PDF format. Binding Type Binding: N/A (Software format) Paper Type Paper: N/A (Software format) ⚙️ Engine Specifications Primary Engine Engine: M119 V8 SOHC (4-valve per cylinder) Displacement: 5.0 Liters (4973 cc) Performance Horsepower: Approx. 315 hp @ 5600 rpm Torque: Approx. 347 lb-ft @ 3900 rpm Fuel System Injection System: Bosch LH-Jetronic electronic fuel injection with mass airflow sensor (MAF). Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) 🔧 Transmission Standard Transmission Type: 722.6xx 5-Speed Automatic (NAG - Neue Automatik Getriebe) Optional Optional Transmission: N/A (All 1996 S500 models featured the 5-speed automatic) Features Electronic Control: Electronically controlled with multiple shift modes (e.g., Comfort, Sport) and adaptive learning. Fluid Type: Mercedes-Benz Specification 236.10 Automatic Transmission Fluid (e.g., Shell ATF 134 or equivalent). 📐 Dimensions Exterior Wheelbase: 119.7 inches (3040 mm) Length: 201.3 inches (5113 mm) Width: 73.6 inches (1869 mm) Height: 58.1 inches (1476 mm) Weights Curb Weight: Approx. 4400 - 4600 lbs (2000 - 2100 kg) 🛡️ Safety Features Ratings NHTSA Rating: NHTSA ratings for this era are not always directly comparable. However, the W140 was engineered with a very robust safety cell and advanced passive safety features for its time. Active Features ABS: Standard Anti-lock Braking System (ABS). Asr: Standard Acceleration Slip Regulation (ASR) traction control. Passive Features Airbags: Driver and front passenger airbags. Side airbags may have been optional or standard depending on market and specific options. Seatbelts: Pretensioning front seatbelts, inertia reel seatbelts for all occupants. Body Structure: High-strength steel safety cage construction. 💡 Technology Features Infotainment Audio System: High-quality factory stereo systems, often with cassette and CD changer options. Some may have optional navigation systems. Driver Assistance Cruise...
The 1996 S500 represented the pinnacle of Mercedes-Benz luxury and engineering for its era, competing with other high-end sedans from brands like BMW (7 Series) and Lexus (LS Series). This manual targets owners and independent repair shops seeking professional-grade information.
Competitive Analysis
Competition:
Competed directly against the BMW 7 Series (E38), Lexus LS 400, and Cadillac DeVille. The S500 was known for its robust engineering, comfort, and advanced (for the time) technology.
Key Features
Features:
The W140 S-Class was a technological showcase, featuring advanced safety systems, luxurious appointments, and a powerful V8 engine. This manual reflects the complexity and sophistication of the vehicle.
📋 Manual Details
Coverage Areas
Coverage:
Comprehensive service, repair, diagnostic, and maintenance procedures for the 1996 Mercedes-Benz S500 (W140 chassis).
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Official Service and Repair Manual Software
Language
Language:
English
Format
Format:
Software (likely digital format like PDF or proprietary software)
📖 Manual Coverage
Systems Covered
Engine:
Detailed coverage of the M119 5.0L V8 engine, including maintenance, diagnosis, repair of fuel injection, ignition system, cooling, lubrication, and emissions control.
Transmission:
Service and repair of the 722.6 5-speed automatic transmission (electronic controlled), including adjustments, diagnostics, and overhaul.
Suspension Steering:
Comprehensive coverage of the independent suspension system (front and rear), shock absorbers, springs, bushings, and the recirculating ball steering system.
Brakes:
Detailed information on the Anti-lock Braking System (ABS), ASR (Acceleration Slip Regulation), brake fluid specifications, caliper service, rotor replacement, and hydraulic system diagnostics.
Electrical Electronics:
Extensive coverage of the vehicle's electrical system, including wiring diagrams, fuse box layouts, lighting, power windows, seats, mirrors, climate control, SRS (airbag) system, and ECU diagnosis.
Body Chassis:
Information on body panel repair, door mechanisms, locks, hinges, interior trim, convertible top (if applicable), and chassis component maintenance.
Climate Control:
Diagnosis and repair of the automatic climate control system (Thermotronic), including AC compressor, refrigerant, HVAC blower, and sensor troubleshooting.
Driver Assistance:
Details on systems like cruise control, traction control (ASR), and potentially early forms of electronic stability control if equipped.
Procedures Included
Maintenance:
Routine maintenance tasks such as oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, and belt inspections.
Troubleshooting:
Systematic diagnostic procedures for common and complex issues, including fault code interpretation and symptom-based troubleshooting guides.
Repair Rebuild:
Step-by-step instructions for component removal, installation, and overhaul for major vehicle systems.
Wiring Diagrams:
Complete and detailed electrical wiring diagrams for all vehicle systems, crucial for electrical diagnosis and repair.
Technical Specifications:
Torque specifications, clearances, fluid capacities, electrical values, and other critical technical data for accurate repairs.
Diagnostic Procedures:
Procedures for using diagnostic tools (e.g., Star Diagnosis systems) and interpreting diagnostic trouble codes (DTCs).
Technical Depth
Depth:
Expert-level technical depth, covering everything from basic maintenance to complete engine and transmission rebuilds, complex electrical diagnostics, and bodywork.
📊 Manual Specifications
File Format
Format:
Digital software, likely searchable and potentially with interactive diagrams. May be delivered as PDF, executable, or web-based access.
Print Quality
Quality:
High-resolution digital content ensuring clarity of diagrams, text, and images. Printable pages if delivered in PDF format.
Binding Type
Binding:
N/A (Software format)
Paper Type
Paper:
N/A (Software format)
⚙️ Engine Specifications
Primary Engine
Engine:
M119 V8 SOHC (4-valve per cylinder)
Displacement:
5.0 Liters (4973 cc)
Performance
Horsepower:
Approx. 315 hp @ 5600 rpm
Torque:
Approx. 347 lb-ft @ 3900 rpm
Fuel System
Injection System:
Bosch LH-Jetronic electronic fuel injection with mass airflow sensor (MAF).
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
🔧 Transmission
Standard
Transmission Type:
722.6xx 5-Speed Automatic (NAG - Neue Automatik Getriebe)
Optional
Optional Transmission:
N/A (All 1996 S500 models featured the 5-speed automatic)
Features
Electronic Control:
Electronically controlled with multiple shift modes (e.g., Comfort, Sport) and adaptive learning.
NHTSA ratings for this era are not always directly comparable. However, the W140 was engineered with a very robust safety cell and advanced passive safety features for its time.
Active Features
ABS:
Standard Anti-lock Braking System (ABS).
Asr:
Standard Acceleration Slip Regulation (ASR) traction control.
Passive Features
Airbags:
Driver and front passenger airbags. Side airbags may have been optional or standard depending on market and specific options.
Seatbelts:
Pretensioning front seatbelts, inertia reel seatbelts for all occupants.
Body Structure:
High-strength steel safety cage construction.
💡 Technology Features
Infotainment
Audio System:
High-quality factory stereo systems, often with cassette and CD changer options. Some may have optional navigation systems.
Driver Assistance
Cruise Control:
Standard electronic cruise control.
Parking Assist:
Optional parking sensors (Parktronic) were introduced later in the W140's lifecycle, but likely not standard on 1996 models. The manual would cover any integrated systems.
Connectivity
Connectivity:
Limited connectivity by modern standards. Primarily features for integrated communication systems if optioned (e.g., car phone pre-wiring).
Comfort Features
Power Accessories:
Power windows, power mirrors, power seats with memory, power tilt/telescoping steering column, heated seats, soft-close doors.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 - 10,000 miles (12,000 - 16,000 km) or as indicated by the Flexible Service System (FSS) on later models, though manual typically states fixed intervals.
Transmission Fluid Interval:
Mercedes-Benz recommended fluid and filter change approximately every 40,000-60,000 miles (60,000-100,000 km), though often considered 'lifetime' by some consumers, professional maintenance is advised.
Fluid Specifications
Engine Oil Spec:
MB 229.1 or MB 229.3 (e.g., 10W-40, 5W-40 synthetic depending on climate). Refer to manual for precise viscosity recommendations.
Coolant Spec:
Mercedes-Benz Specification 325.0 or 326.0 (Ethylene Glycol based coolant, typically blue/green).
Brake Fluid Spec:
DOT 4
Known Issues
Engine M119 Common:
Timing chain tensioner wear (can lead to chain stretching), distributorless ignition system (DIS) coil pack failure, oil leaks from valve cover gaskets and crank seals, vacuum hose deterioration.
Window regulators and motors, door lock actuators, climate control blower motor resistor, sensor failures (e.g., ABS sensors, MAF sensor), CAN bus communication issues.
Suspension Common:
Hydraulic self-leveling suspension component wear (e.g., accumulators, pumps), front suspension bushings and ball joint wear, strut mount failure.
Cooling System Common:
Plastic coolant reservoir cracks, water pump seal leaks, thermostat housing leaks.
📚 Vehicle History
Brand Heritage
Heritage:
Mercedes-Benz has a long-standing reputation for building high-quality, durable, and technologically advanced luxury vehicles. The S-Class lineage represents the flagship sedan of the brand.
Model Evolution
W140 Introduction:
The W140 chassis S-Class was introduced in 1991 and represented a significant advancement over its predecessor (W126). It was larger, heavier, and more technologically sophisticated, aiming to set new benchmarks in automotive engineering and luxury.
W140 Facelift:
The 1996 model year incorporates a significant facelift which included updated styling, revised powertrain management, and enhancements to electronic systems. This manual specifically covers post-facelift models.
Production
Production Years:
1991-1998 (W140 chassis)
Manufacturing Location:
Germany (primarily Sindelfingen Plant)
🏆 Awards & Recognition
Recognitions
Prestigious Awards:
While specific awards for the 1996 model year are hard to pinpoint generically, the W140 S-Class was widely recognized as a benchmark for automotive luxury, engineering, and safety by numerous automotive publications globally during its production run.
Ratings
Safety Engineering:
Consistently rated highly for its structural integrity and occupant protection by safety organizations of the time, influencing future safety design standards.