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Mercedes 300D Turbo 1982-1987 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: 300D Turbo Model Code: W124 (specifically the 300D Turbo variants) Generation Generation: First generation of the E-Class sedan, known internally as the W124...
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Mercedes 300D Turbo 1982-1987 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
300D Turbo
Model Code:
W124 (specifically the 300D Turbo variants)
Generation
Generation:
First generation of the E-Class sedan, known internally as the W124 series.
Codes
Engine Code:
OM603.960 (3.0L Turbocharged Diesel)
👋 Introduction
Market Position
Market Position:
The Mercedes-Benz 300D Turbo (W124) was positioned as a reliable, durable, and technologically advanced luxury diesel sedan. It appealed to buyers seeking fuel efficiency, long-term ownership value, and the prestige of the Mercedes-Benz brand.
Competitive Analysis
Competitors:
Competed primarily against other European luxury sedans, although its diesel powertrain offered a unique selling proposition. Key competitors in the broader luxury segment included BMW (e.g., 524td), Audi, and Jaguar. Its diesel focus set it apart in many markets.
Key Features
Key Features Vehicle:
Robust turbocharged OM603 diesel engine, advanced independent suspension, refined ride quality, high build quality, excellent safety features for its era, aerodynamic design, and long-term durability.
Key Features Manual:
Provides factory-level technical data, detailed diagnostic procedures, and comprehensive repair instructions, essential for maintaining and restoring these classic vehicles.
📋 Manual Details
Coverage Areas
Years Covered:
1982, 1983, 1984, 1985, 1986, 1987
Page Count
Page Count:
Likely over 1000 pages, typical for comprehensive factory-level workshop manuals.
Manual Type
Manual Type:
Service Repair Workshop Manual
Language
Language:
English (Assumed based on typical market for such manuals)
Format
Format:
Digital (PDF) is most common for aftermarket sales, but original might be printed.
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (3.0L Turbo Diesel OM603.960), fuel injection system, turbocharger, exhaust system, cooling system, lubrication system, engine mechanicals (assembly/disassembly).
Transmission:
Automatic Transmission (e.g., 722.3 4-speed), clutch (if manual option existed, though less common for this specific diesel), driveshaft, differential.
Chassis:
Suspension (front and rear), steering system (power steering), braking system (hydraulic, ABS if equipped), wheel alignment.
Electrical System:
Wiring diagrams, charging system (alternator), starting system (starter), lighting, ignition (glow plugs), instrumentation, power accessories (windows, locks, etc.), fuse and relay locations.
Body And Interior:
Body panels, doors, windows, seats, HVAC system, interior trim, body sealing, corrosion protection.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug/glow plug replacement, belt inspections and tensioning.
Component Overhaul:
Engine rebuild, transmission overhaul, brake caliper rebuilding, power steering pump replacement.
Diagnostic Procedures:
Troubleshooting guides for common symptoms, fuel system diagnostics, electrical system testing, emissions system checks.
Component Replacement:
Step-by-step instructions for replacing major components like alternators, starters, radiators, fuel pumps, etc.
Special Tools:
Identification and usage of specialized Mercedes-Benz tools required for certain repairs.
Technical Depth
Technical Depth:
Comprehensive, factory-level detail. Covers everything from basic maintenance to full engine and transmission rebuilds, including torque specifications, clearances, and diagnostic flowcharts.
📊 Manual Specifications
File Format
File Format Quality:
Likely high-resolution scans or original digital files for clarity. Searchable text is highly desirable for digital formats.
Print Quality
Print Quality:
If printed, expect professional binding with durable pages designed for workshop use. High-quality paper to withstand grease and dirt.
Binding Type
Binding Type:
If printed: Spiral-bound or perfect-bound for easy page laying and durability. If digital: Searchable PDF.
Paper Type
Paper Type:
If printed: Heavy-duty, coated paper to resist wear and tear in a workshop environment. Likely a matte finish to reduce glare.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 6-cylinder, turbocharged, naturally aspirated diesel
Displacement:
2,999 cc (3.0 Liters)
Bore X Stroke:
87.0 mm x 84.0 mm
Compression Ratio:
21.0:1
Horsepower Net:
Approx. 125 hp @ 4,000 rpm (Varies slightly by market/year)
Torque Net:
Approx. 181 lb-ft (245 Nm) @ 2,400 rpm (Varies slightly by market/year)
Performance
0-60 Mph:
Approx. 12-13 seconds (depending on transmission and configuration)
Top Speed:
Approx. 115-120 mph (185-193 km/h)
Fuel System
Fuel System Type:
Bosch inline mechanical fuel injection system with turbocharger
Fuel Type:
Diesel fuel
Lubrication
Oil Capacity With Filter:
7.5 Liters (8 US Quarts)
Cooling
Coolant Capacity:
Approx. 9.0 Liters (9.5 US Quarts)
🔧 Transmission
Standard
Standard Transmission Type:
4-speed Automatic Transmission (Model 722.3)
Optional
Optional Transmission Type:
5-speed Manual Transmission (less common on the 300D Turbo models, but available in some markets/configurations)
Features
Transmission Features:
Lock-up torque converter in top gear for improved efficiency and reduced heat. Hydraulic control system.
Fluid Spec
Automatic Transmission Fluid Spec:
MB 236.1 (e.g., Dexron II compatible, but specifically MB approved is recommended)
Fluid Capacity
Automatic Transmission Fluid Capacity:
Approx. 7.5 Liters (requires refill during torque converter drain/fill)
📐 Dimensions
Exterior
Length:
Approx. 188.1 inches (4778 mm)
Width:
Approx. 69.1 inches (1755 mm)
Height:
Approx. 55.5 inches (1410 mm)
Wheelbase:
Approx. 109.5 inches (2780 mm)
Weights
Curb Weight:
Approx. 3,350 lbs (1520 kg)
Gross Vehicle Weight Rating:
Approx. 4,450 lbs (2020 kg)
Cargo
Cargo Volume:
Approx. 16 cu ft (453 Liters)
Wheels Tires
Standard Tire Size:
195/65R15 (may vary by market and wheel option)
Wheel Bolt Pattern:
5x112 mm
Wheel Offset:
ET37 (typical for 15-inch wheels)
🛡️ Safety Features
Ratings
Era Safety Standards:
Designed to meet or exceed stringent safety standards of its time, including crumple zones and reinforced passenger compartment.
Active Features
Active Safety Features:
Four-wheel disc brakes, power-assisted steering, optional Anti-lock Braking System (ABS) on later models.
Passive Features
Passive Safety Features:
Energy-absorbing steering column, dual-circuit hydraulic braking system, reinforced B-pillars, impact-absorbing interior materials.
💡 Technology Features
Infotainment
Infotainment System:
Basic for its era: AM/FM radio, cassette player (often optional or dealer-installed), analog gauges for speed, RPM, fuel, oil pressure, coolant temperature. No digital displays or navigation.
Driver Assistance
Driver Assistance Features:
Optional ABS, power steering. No advanced electronic driver-assistance systems like traction control or stability control.
Connectivity
Connectivity Features:
Limited to basic antenna for radio. No Bluetooth or USB connectivity. Central locking and power accessories were considered advanced features.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-10,000 miles (8,000-16,000 km) or annually, whichever comes first, depending on driving conditions and oil used. The manual will provide specific recommendations.
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on operating environment. Manual specifies exact intervals.
Fuel Filter Replacement:
Typically every 15,000-30,000 miles (24,000-48,000 km). Crucial for diesel engines. Manual will detail specific intervals.
Transmission Service:
Fluid and filter change recommended every 30,000-60,000 miles (48,000-96,000 km). Manual provides specific intervals and procedures.
Fluid Specifications
Engine Oil Spec:
API CD or CE rated diesel engine oil, SAE 15W-40 or 10W-40 depending on climate. Refer to manual for precise MB approval specifications.
Coolant Spec:
Ethylene glycol based coolant meeting MB 325.0 specification (typically a 50/50 mix with distilled water).
Known Issues
Known Issues Diesel:
Injector pump issues, glow plug failures, vacuum leaks in the intake manifold, turbocharger wear, vacuum-actuated systems (e.g., central locking), potential for injector nozzle clogging, early signs of diesel particulate buildup.
Known Issues Chassis:
Ball joint wear, subframe mount deterioration, differential mounts, wheel bearing noise, potential for wiring harness degradation (insulation cracking).
Known Issues Electrical:
Instrument cluster issues, antenna motor failure, early ABS sensor failures, aging wiring insulation.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mercedes-Benz has a long-standing reputation for engineering excellence, luxury, and durability, particularly in diesel technology.
Model Evolution
Model Evolution W124:
The W124 was a significant evolution from the W123, featuring more advanced aerodynamics, a more sophisticated multi-link rear suspension, and increased emphasis on safety and driver comfort. The 300D Turbo represented Mercedes' push for more powerful and efficient diesel engines.
Production
Production Years W124:
1984-1995 (sedan/coupe/wagon), with the 300D Turbo variants primarily in the earlier years of this range.
Manufacturing Location:
Primarily Germany (Sindelfingen, Bremen, etc.), with some assembly in other global locations.
🏆 Awards & Recognition
Recognitions
Vehicle Awards Era:
While specific awards for the 300D Turbo might not be prominent, the W124 chassis as a whole was highly regarded for its engineering, build quality, and durability, often featuring in 'best cars' lists for their respective segments. It was a benchmark for its time.
Ratings
Typical Reliability Reputation:
Generally considered extremely reliable and durable, especially the powertrain, when properly maintained. Often praised for longevity and low ownership costs over long distances due to fuel efficiency.
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