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Mercedes 350 SD Turbo 1991 Service Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: 350 SD Turbo Year: 1991 Codes Chassis Code: W140 (S-Class) Engine Code: OM603.970 👋 Introduction Market Position Positioning: Luxury German sedan known for...
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Mercedes 350 SD Turbo 1991 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
350 SD Turbo
Year:
1991
Codes
Chassis Code:
W140 (S-Class)
Engine Code:
OM603.970
👋 Introduction
Market Position
Positioning:
Luxury German sedan known for its engineering prowess and comfort, targeting the executive market
Competitive Analysis
Competitors 1991:
BMW 7 Series (E32), Audi V8 Quattro, Lexus LS 400, Jaguar XJ
Key Features
Diesel Performance:
Torque-rich turbodiesel engine offering a blend of performance and efficiency for its class
Luxurious Appointments:
High-quality interior materials, advanced comfort features, and sophisticated design
Engineering Excellence:
Reputation for robust construction and advanced automotive technology
📋 Manual Details
Coverage Areas
General Coverage:
Comprehensive repair, maintenance, rebuilding, refurbishment, and restoration
Diagnostic Coverage:
All diagnostic and repair procedures in great detail
Page Count
Estimated Pages:
High (typically 1000+ pages for factory-level manuals)
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF), potentially printed
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (diesel, turbo), fuel injection, exhaust, cooling, lubrication, transmission (automatic)
Chassis:
Suspension (independent front/rear, self-leveling rear suspension), steering, brakes (ABS), wheels, tires
Electrical:
Wiring diagrams, lighting, ignition, charging system, starting system, instrumentation, comfort systems, power accessories
Body:
Body construction, exterior trim, interior trim, climate control, doors, windows, seats
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, inspections
Repair:
Engine overhauls, transmission repairs, brake system repairs, suspension component replacement, electrical component diagnosis and repair
Troubleshooting:
Diagnostic procedures, fault code interpretation (if applicable), common problem diagnosis
Technical Depth
Depth:
Factory-level, including detailed disassembly/assembly, specifications, tolerances, and torque values
📊 Manual Specifications
File Format
Digital Searchability:
High (if PDF with OCR)
Printable:
Yes (standard for service manuals)
Print Quality
Illustrations:
High quality, detailed diagrams and photographs
Text Clarity:
Excellent, professional typesetting
Binding Type
Binding:
N/A (for digital), or professional binding (for print)
Paper Type
Paper:
N/A (for digital), or high-quality, durable paper (for print)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 6-cylinder Turbocharged Diesel
Displacement:
3.5 Liters (3449 cc)
Bore X Stroke:
91.4 mm x 110.0 mm
Compression Ratio:
21.0:1
Performance
Horsepower Ps:
148-150 PS @ 4000 rpm (approximate)
Torque Lb Ft:
236-250 lb-ft @ 2400 rpm (approximate)
Fuel System
Injection System:
Bosch VE Rotary Injection Pump with Turbocharging
Fuel Type:
Diesel Fuel
Cooling
Cooling System:
Water-cooled, pressurized system
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic (4G-TRONIC)
Gear Ratios:
Detailed in manual (typical ratios for this era)
Features
Transmission Features:
Torque converter lock-up, electronic control (for later models, but likely hydraulic control in 1991)
📐 Dimensions
Exterior
Length Mm:
5113 mm (1991 model year W140)
Width Mm:
1886 mm (1991 model year W140)
Height Mm:
1484 mm (1991 model year W140)
Weights
Curb Weight Kg:
Approx. 1850-1950 kg
Gross Vehicle Weight Kg:
Approx. 2400 kg
🛡️ Safety Features
Ratings
Crash Safety Era Considerations:
Designed to 1990s safety standards, advanced for its time but not comparable to modern NCAP ratings
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Passive Features
Airbags:
Driver airbag standard, passenger airbag likely optional or introduced later in the W140 lifecycle
Seatbelts:
Pre-tensioning front seatbelts
Body Construction:
High-strength steel safety cage
💡 Technology Features
Infotainment
Audio System:
Premium Becker or Blaupunkt cassette-based audio systems, often with CD changer pre-wiring
Climate Control:
Automatic climate control with dual-zone capability
Driver Assistance
Cruise Control:
Standard cruise control
Parking Assistance:
Parking Assist System (PAS) - optional, typically rear parking sensors were not common in 1991
Connectivity
Connectivity Features:
Limited by 1991 standards; no integrated Bluetooth or smartphone connectivity
🔧 Maintenance
Service Intervals
Oil Change Interval Km:
Typically 7,500 - 10,000 km (or annually), consult manual for exact recommendations
Air Filter Replacement Km:
30,000 - 40,000 km (or as needed)
Fuel Filter Replacement Km:
20,000 - 30,000 km (crucial for diesel engines)
Coolant Change Interval Years:
Every 2-4 years
Fluid Specifications
Engine Oil Specification:
MB 229.1 or equivalent API CG-4/CF spec, SAE 10W-40 or 15W-40 (viscosity dependent on climate)
Engine Oil Capacity Liters:
Approx. 7.5 Liters
Transmission Fluid Type:
ATF DEXRON II/III or MB 236.6 specification
Coolant Type:
Mercedes-Benz Coolant/Antifreeze Concentrate (e.g., G05 or G48, mixed 50/50 with distilled water)
Known Issues
Diesel Specific Issues:
Glow plug system failure, injection pump issues, potential turbocharger wear, carbon buildup in intake manifold
General W140 Issues:
Vacuum system leaks (affecting door locks, HVAC), electrical gremlins, biodegradable wiring harness degradation (later models, but worth noting), suspension self-leveling issues
📚 Vehicle History
Brand Heritage
Mercedes Benz Reputation:
Long-standing reputation for engineering excellence, luxury, and durability
Model Evolution
W140 Introduction:
The W140 S-Class was introduced in 1991 as the successor to the W126 S-Class, representing a significant leap in size, technology, and luxury.
350 Sd Turbo Significance:
The 'SD' designation signified a 'Saugdiesel' (naturally aspirated diesel) initially, but the 'Turbo' suffix clearly denotes the turbodiesel variant, a move towards more powerful and efficient diesel engines for Mercedes-Benz luxury cars.
Production
Production Period W140:
1991-1998
Manufacturing Location:
Germany
🏆 Awards & Recognition
Recognitions
Luxury Sedan Awards:
While specific awards for the '350 SD Turbo' might be scarce, the W140 S-Class as a whole was consistently recognized as a benchmark in luxury, safety, and engineering by automotive publications worldwide upon its release.
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