🏷️ Basic Information

Make:

Mercedes-Benz

Models Covered:

280 S, 280 SE, 300 SD, 450 SE, 450 SEL

Production Years Covered:

1973-1980

Chassis Codes:

W116 (Series)

👋 Introduction

Positioning:

This manual targets owners and independent workshops seeking professional-grade repair and maintenance information for a classic Mercedes-Benz luxury sedan, enabling them to perform tasks typically handled by dealership service centers.

Target Audience:

Enthusiasts, classic car owners, and independent mechanics who value meticulous detail and factory-accurate information for maintaining and repairing these iconic Mercedes-Benz vehicles.

Value Proposition:

Offers a cost-effective alternative to dealership labor for repairs and maintenance, empowering owners with the same detailed information professionals use. The digital format provides immediate access and convenience.

Features:

Includes detailed substeps, critical notes/cautions, numbered instructions, bold figure numbers for easy illustration matching, detailed illustrations/photos, enlarged inset views for parts identification, and a user-friendly table of contents.

📋 Manual Details

Primary Coverage:

Workshop Repair and Service

Scope:

All Models, Engines, Trim, and Transmission Types within the specified years.

Estimated Pages:

Hundreds (specific number not provided, but described as 'hundreds of pages')

Type:

Workshop Service Manual / Repair Manual

Language:

English

Format:

PDF Download

Delivery Method:

Instant Download

📖 Manual Coverage

Powertrain:

Engine Service/Repair, Transmission Service/Repair, Fuel Injection/Fuel System, Cooling System, Exhaust System, Emission Control System

Chassis And Suspension:

Suspension, Steering, Brake System, Differential/Drive Axle

Electrical And Electronics:

Electrical System, Wiring Diagrams, Engine Control System, Heater/Air Conditioning, Interior Electrical Components

Body And Interior:

Chassis/Body, Interior, Restraint System (Seatbelts), Bodywork, Trim

Fuel System Details:

Detailed information on fuel pumps, injectors, fuel lines, fuel filters, and fuel pressure regulators for both gasoline and diesel variants.

Cooling System Details:

Radiator, water pump, thermostat, hoses, fan clutch, and coolant flow paths.

Exhaust System Details:

Exhaust manifolds, catalytic converters (if applicable by market), mufflers, and pipe routing.

Chassis And Body Details:

Frame construction, body panel alignment, door mechanisms, window regulators, sunroof operation (if equipped), sound deadening, and underbody protection.

Restraint System Details:

Seatbelt operation, adjustment, and replacement procedures. Airbags were not standard on these models.

Maintenance:

General Maintenance, Periodic Lubrication, Fluid Changes, Filter Replacements

Repair And Rebuild:

Detailed substeps for repair procedures, Disassembly, Assembly, Reinstallation

Diagnostics And Troubleshooting:

Troubleshooting, Diagnostic Procedures, Electrical System Diagnosis

Engine Repair Procedures:

Engine overhaul, cylinder head removal/installation, piston and connecting rod service, crankshaft service, timing chain/belt replacement (if applicable).

Transmission Repair Procedures:

Automatic transmission disassembly, inspection, repair, and reassembly. Manual transmission overhaul (if applicable).

Brake System Repair:

Brake caliper service, brake pad/shoe replacement, rotor/drum machining or replacement, brake line repair, master cylinder service, ABS system troubleshooting (if equipped).

Electrical System Diagnostics:

Troubleshooting common electrical faults, starter motor, alternator, battery system, lighting systems, ignition system diagnostics, fuel injection system wiring.

Suspension Repair:

Shock absorber replacement, spring inspection and replacement, ball joint and tie rod end service, bushing replacement, alignment procedures.

Steering System Repair:

Power steering pump service, steering gearbox inspection and repair, steering linkage components.

Depth:

Professional-level, comprehensive detail including diagnostics, repair, and maintenance; equivalent to factory service manuals used by technicians.

Diagnostic Tools:

The manual implicitly guides the use of standard automotive tools and potentially specialized diagnostic equipment used by professional technicians for the era.

Illustrations And Diagrams:

Features detailed illustrations, drawings, and photos, including enlarged insets, to guide users through repair procedures, crucial for complex Mercedes-Benz systems of this era.

Completeness Statement:

Described as 'COMPLETE and INTACT as should be without any MISSING/CORRUPT part or pages,' mirroring the information found in local service/repair shops.

📊 Manual Specifications

Format:

PDF

Requirements:

Adobe PDF Reader, WinZip

Printability:

Full Printable

Zoom Functionality:

Zoom IN/OUT enabled

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

280 S/Se:

M110 Inline-6 (2.8L DOHC)

300 Sd:

OM617 Inline-5 Diesel (3.0L SOHC Turbocharged)

450 Se/Sel:

M117 V8 (4.5L SOHC)

280 S/Se (Approximate):

158-180 hp / 177-188 lb-ft torque (depending on market and fuel injection system)

300 Sd (Approximate):

115-125 hp / 170-185 lb-ft torque

450 Se/Sel (Approximate):

180-200 hp / 238-254 lb-ft torque

Turbo Diesel Characteristics:

The OM617 engine in the 300 SD is renowned for its durability and exceptional fuel efficiency, offering strong low-end torque characteristic of diesel engines of the period.

280 S/Se:

Bosch L-Jetronic or D-Jetronic Fuel Injection (depending on year and market)

300 Sd:

Bosch Inline Injection Pump (Diesel)

450 Se/Sel:

Bosch D-Jetronic or L-Jetronic Fuel Injection (depending on year and market)

🔧 Transmission

Transmission Options:

Typically a 4-speed automatic transmission (e.g., 4G-Tronic) was standard on most models, with some markets and specific models offering a 4-speed or 5-speed manual transmission.

Manual Transmission Availability:

Availability of manual transmissions varied by market and specific model designation. The 450 models were predominantly automatic.

Automatic Features:

Torque converter lock-up, hydraulic control, and possibly different driving modes (e.g., 'S' for Standard, 'E' for Economy).

📐 Dimensions

Wheelbase:

2850 mm (112.2 in) for SE/SEL models; 2795 mm (110.0 in) for S models.

Length:

Approx. 4970-5050 mm (195.7-198.8 in) depending on model variant.

Curb Weight:

Approx. 1700-1850 kg (3748-4079 lbs) depending on engine and options.

🛡️ Safety Features

Historical Safety Standards:

While formal crash test ratings as we know them today were not as prevalent, the W116 chassis was engineered with significant safety considerations for its era, including a robust body structure.

Braking System:

Four-wheel disc brakes (ventilated front discs) were standard across most models. Early models may have had less sophisticated ABS, but later models incorporated anti-lock braking systems.

Occupant Protection:

Reinforced safety cage, energy-absorbing steering column, padded interior surfaces, and three-point seatbelts (often with automatic reel).

💡 Technology Features

Audio System:

Original systems typically featured AM/FM radio, often with an optional cassette player. Modern replacements or upgrades are common.

ABS:

Anti-lock Braking System (ABS) was an available option and became more common in later production years of the W116.

Connectivity Features:

No modern connectivity features like Bluetooth or USB were present in the original design. These would be aftermarket additions.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000-7,500 miles or 6-12 months, depending on driving conditions and oil specification. The manual will provide precise intervals.

Transmission Fluid Change:

Recommended at 30,000-50,000 mile intervals, or as specified by the manual for optimal transmission longevity.

Spark Plug Replacement:

Intervals vary by engine type; typically 20,000-30,000 miles for gasoline engines. Diesel engines do not use spark plugs.

Timing Belt Or Chain:

M110 and M117 engines use a timing chain, which generally does not require periodic replacement but should be inspected for wear and proper tension. The OM617 uses a timing chain as well.

Engine Oil:

Refer to manual for specific viscosity grade (e.g., 10W-40 or 20W-50) and API service classification. MB approval may be required for optimal performance.

Transmission Fluid:

Dexron-III (or equivalent) automatic transmission fluid is commonly used, but the manual will specify the exact type and capacity for each transmission variant.

Coolant:

A 50/50 mix of ethylene glycol antifreeze and distilled water. Specific Mercedes-Benz approved coolant types should be referenced in the manual.

Power Steering Fluid:

Specific hydraulic fluid type as per Mercedes-Benz recommendations for the W116 steering system. Manual will specify exact type and capacity.

Brake Fluid:

DOT 3 or DOT 4 brake fluid, depending on system requirements. Manual will specify the correct type and bleeding procedures.

Common Problems:

Vacuum leaks affecting central locking and climate control, fuel injection system issues (especially D-Jetronic), aging rubber hoses and seals, potential corrosion on body panels, and Mercedes-specific diesel injection pump maintenance for the OM617.

Preventative Maintenance:

Regular inspection and replacement of vacuum lines, fuel filters, air filters, and all rubber components are crucial for maintaining optimal performance and preventing costly repairs.

Engine Mounts:

Hydraulic engine mounts can degrade over time, leading to increased vibration and noise.

Climate Control Vacuum System:

A common point of failure due to age and brittle vacuum lines, affecting HVAC system operation and central locking.

📚 Vehicle History

Mercedes Benz Legacy:

Mercedes-Benz has a long-standing reputation for engineering excellence, luxury, and safety, established through decades of innovation in automotive technology.

W116 Introduction:

The W116 chassis, introduced in 1972, was the first generation to be officially designated as the S-Class. It represented a significant advancement in luxury, comfort, and engineering for Mercedes-Benz sedans.

Engine Introductions:

The 300 SD introduced the W116 to the North American market as a diesel variant, offering superior fuel economy. The 2.8L and 4.5L gasoline engines provided a balance of performance and refinement.

Production Period:

1972-1979 (with overlap into 1980 for some markets and models). Total W116 production was approximately 473,000 units.