Description
Factory Mercedes S Class S320CDI S400CDI Workshop Manual (2000–2005)
This is the official factory-level service manual for the W220 Mercedes S Class diesel variants sold in the US and worldwide from 2000 through 2005. Whether you’re tackling routine maintenance or a major drivetrain overhaul, this resource delivers the depth that dealer technicians depend on.
Powertrain & Drive Coverage
| Component | Variants Covered |
|---|---|
| Petrol | N/A |
| Diesel | OM613 3.2L inline-6 turbodiesel (S320CDI); OM628 4.0L V8 turbodiesel (S400CDI) |
| Transmissions | 5-speed automatic |
| Drive | RWD |
| Model Years | 2000–2005 |
| Badge Twins | W220 platform; standard wheelbase and long-wheelbase (L) body styles |
Common S Class Repairs Covered
| System | Procedures |
|---|---|
| Air Suspension (AIRMATIC) | Strut replacement, compressor diagnosis, level sensor calibration — a notorious W220 failure point |
| OM613 / OM628 Diesel Engine | Injection pump service, turbocharger inspection, glow plug replacement, timing chain procedures |
| Electrical / ABC / ESP | Wiring diagrams, ABS/ESP module diagnosis, SBC brake system fault procedures, connector pinouts |
| Transmission | 5-speed automatic fluid service, valve body removal, shift adaptation reset, torque converter replacement |
Format & Delivery
PDF. Instant download; lifetime re-downloads.
Frequently Asked Questions
Why does the W220 AIRMATIC suspension fail, and does this manual cover the repair?
The W220-generation S Class is well known for AIRMATIC air suspension failures, typically caused by cracked air strut bladders or a worn compressor. This manual includes full AIRMATIC diagnostics, strut replacement torque specs, compressor testing procedures, and level sensor recalibration steps so you can address the root cause rather than just clearing fault codes.
What is the difference between the S320CDI and S400CDI covered here?
The S320CDI uses the OM613 3.2-liter inline-six turbodiesel producing approximately 197 hp, while the S400CDI is powered by the larger OM628 4.0-liter V8 turbodiesel rated around 250 hp with significantly higher torque. Both share the W220 platform and 5-speed automatic, and this manual covers unique specifications, torque values, and service intervals for each engine independently.
Are wiring diagrams and SBC brake system schematics included?
Yes. The electrical section contains full wiring diagrams for the W220 architecture including engine management, transmission control, the Sensotronic Brake Control (SBC) system, ESP, climate control, and comfort electronics. Connector pinouts, wire color codes, ground locations, and scan-tool diagnostic connector information are all documented.
What format is the manual?
This manual is delivered as a PDF file. After purchase you receive an instant download link — no waiting for physical shipping. The searchable PDF works on Windows, Mac, tablet, or smartphone with any standard PDF reader, and you can print individual pages or full sections for bench use.
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