🏷️ Basic Information Identification Make: Mercedes-Benz Model: V220 Model Line: V-Class (W638/2) Product Name: Mercedes Benz V220 1999-2005 Full Service & Repair Manual Download PDF Generation Generation Code: W638/2 Production Years Covered: 1999-2005 Codes Internal Chassis Code: W638/2 👋 Introduction Market Position Vehicle Segment: Compact MPV / Minivan Target Audience: Families, commercial users requiring passenger transport Competitive Analysis Key Competitors: Volkswagen Sharan, Ford Galaxy, Renault Espace, Chrysler Voyager Key Features Vehicle Attributes: Versatile interior, comfortable ride, premium brand image Manual Value Proposition Manual Benefit: Empowers owners and independent workshops to perform professional-level servicing and repairs, saving on dealership costs. Manual Advantage: Provides access to factory-level technical data, often unavailable to the general public. 📋 Manual Details Coverage Areas Coverage Scope: Complete factory service and repair Geographic Coverage: Global (specifications for common markets) Page Count Estimated Page Count: Hundreds (exact number not specified, but described as very detailed) Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English (implied by product description and common availability of such manuals) Format Download Format: PDF Licensing Licensing Terms: Lifetime use, no expiry, no renewal fees Compatibility Operating System Compatibility: Windows and macOS 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, cylinder head, pistons, crankshaft, timing, lubrication, cooling Engine Management: Fuel injection systems, ignition systems, engine control module (ECM) diagnostics, emissions control Transmission Manual: Manual transmission overhaul, clutch, gearbox components Transmission Automatic: Automatic transmission overhaul, torque converter, valve body, electronic controls (if applicable) Drivetrain: Front-wheel drive system, driveshafts, differential Suspension And Steering: Front and rear suspension, shock absorbers, springs, steering rack, power steering system Brakes: Brake system diagnosis, ABS, front and rear brakes, brake fluid, hydraulic system Electrical System: Battery, charging system, starter, lighting, fuses, relays, wiring diagrams Body And Chassis: Body panel repair, interior trim, glass, doors, tailgate, chassis components HVAC: Heating, ventilation, and air conditioning system diagnosis and repair Body Electronics: Central locking, power windows, mirrors, wipers, comfort features Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement Troubleshooting: Systematic diagnosis of common and uncommon faults, fault codes interpretation Repair Procedures: Step-by-step instructions for all major component repairs and replacements Rebuilds: Detailed instructions for engine and transmission rebuilds Diagnostics: On-board diagnostics (OBD-II) procedures, sensor testing, actuator testing Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems Technical Depth Depth Of Coverage: Comprehensive, from basic maintenance to complete engine/transmission overhauls Visual Aids: Hundreds of detailed photos, diagrams, and exploded views Diagnostic Charts: Troubleshooting flowcharts and diagnostic trees 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text (typical for professional PDF manuals) Print Quality Print Capability: Printable (single page or entire manual) Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code Common: OM611 (2.2L Diesel), M111 (2.3L Petrol - less common in V220, more in V230/V280 variants, but can be present) Engine Type V220 Diesel: 2.2L Inline-4 Turbocharged Diesel (CDI) Performance Horsepower V220 Diesel: Approx. 120-140 hp (depending on variant, e.g., V220 CDI) Torque V220 Diesel: Approx. 270-330 Nm (depending on variant) Fuel System Fuel System Type Diesel: Common Rail Direct Injection (CDI) Engine Ancillaries Cooling System: Liquid-cooled, thermostatically controlled Lubrication System: Forced lubrication with oil pump and filter 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission (Getrag or MB variant) Optional Transmission Type Optional: 5-speed Automatic Transmission (e.g., NAG3) Features Drive Layout: Front-Wheel Drive (FWD) Fluid Specifications Automatic Transmission Fluid Spec: MB 236.10 or equivalent (e.g., ATF) Manual Transmission Fluid Spec: MB 235.4 or equivalent (e.g., SAE 75W-90 GL-4/GL-5) 📐 Dimensions Exterior Body Styles: Compact MPV Length: Approx. 4,216 mm (standard wheelbase) Width: Approx. 1,811 mm Height: Approx. 1,779 mm Weights Curb Weight: Approx. 1,700 - 1,850 kg (depending on engine and configuration) 🛡️ Safety Features Ratings Crash Test Information: Euro NCAP (results vary by test year and specific configuration, but generally provided decent protection for its era) Active Features Antilock Braking System: Standard (ABS) Electronic Stability Program: Optional (ESP) on later models or higher trims Traction Control: Standard or Optional (ASR) Passive Features Airbags: Front airbags for driver and passenger, optional side airbags 💡 Technology Features Infotainment Infotainment System: Basic Audi-A-System with cassette or CD player, optional navigation. Driver Assistance Driver Assistance Features: Cruise control (optional), parking sensors (less common in early models). Connectivity Connectivity Options: Limited by era; typically auxiliary input for audio devices. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 15,000 km or 12 months (flexible service system - ASSYST, check manual for specifics) Major Service Interval: Varies by component (e.g., timing belt/chain check, transmission service, brake fluid flush) Fluid Specifications Engine Oil Specification: MB 229.1 or MB 229.3 (e.g., 5W-40, 10W-40 synthetic or semi-synthetic) Coolant Specification: MB 325.0 or MB 326.0 (Glycol-based antifreeze) Brake Fluid Specification: DOT 4 Known Issues Common Diesel Issues: Glow plug...