Mercedes Benz 300 sdl 1986 Service Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: 300 SDL Year: 1986 Body Style: W124 Sedan Codes Chassis Code: W124.131 👋 Introduction Market Position Vehicle Segment: Luxury Mid-Size Sedan with a...

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Taper: Car

Distributeur:

UGS: 491734

Mots clés: 1986 300 sdl Car Cars Mercedes Mercedes Benz Misc

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

300 SDL

Year:

Body Style:

W124 Sedan

Codes

Chassis Code:

W124.131

👋 Introduction

Market Position

Vehicle Segment:

Luxury Mid-Size Sedan with a focus on diesel efficiency and long-distance touring.

Target Audience:

Affluent consumers seeking reliability, comfort, and superior engineering, often used for executive transport or extended travel.

Competitive Analysis

Key Competitors 1986:

BMW 5 Series (e.g., 524td), Audi 100/200 TDI (though less common), Cadillac DeVille diesel variants.

Key Features

Performance Attributes:

Strong torque delivery from the turbodiesel engine, renowned Mercedes-Benz ride comfort and handling.

Engineering Philosophy:

Built to last, with an emphasis on robust construction, advanced (for the time) engineering, and driver comfort.

Manual Value Proposition

Utility For Owners:

Empowers owners and independent mechanics with the knowledge to perform complex repairs and maintenance, extending the vehicle's lifespan and preserving its value.

📋 Manual Details

Coverage Areas

Diagnostic Procedures:

Comprehensive diagnostic flowcharts and troubleshooting guides for all major systems.

Repair Procedures:

Detailed step-by-step repair instructions for mechanical, electrical, and body components.

Maintenance Schedules:

Factory-recommended maintenance intervals and procedures for various mileage and time-based services.

Specifications Data:

Extensive technical specifications, including torque values, clearances, fluid capacities, and component dimensions.

Wiring Diagrams:

Detailed electrical wiring diagrams for all vehicle circuits, including component location and color coding.

Page Count

Estimated Pages:

Approximately 800-1000 pages (typical for a comprehensive factory service manual of this era).

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Digital Format:

Likely PDF (Printable, Searchable)

📖 Manual Coverage

Systems Covered

Engine:

OM603.960 3.0L Inline-6 Turbo Diesel: Engine mechanical, fuel injection system (Bosch VE), lubrication, cooling, emissions control.

Transmission:

4-speed Automatic Transmission (4G-TRONIC): Overhaul, diagnostics, fluid service, control systems.

Brakes:

Hydraulic Brakes with ABS (Anti-lock Braking System): Component description, bleeding procedures, ABS sensor diagnostics, brake pad/rotor replacement.

Suspension:

Independent Front Suspension (Double Wishbone), Multi-link Rear Suspension: Component replacement, alignment specifications, shock absorber/strut service.

Steering:

Power Steering System: Component inspection, leak diagnosis, fluid replacement, steering column service.

Electrical:

Starting System, Charging System, Lighting, Instrumentation, Power Accessories (windows, locks, seats), Climate Control, Cruise Control, Radio/Audio System.

Body:

Body Panel Repair, Door Mechanism Service, Glass Replacement, Trim Components, Body Sealing.

HVAC:

Automatic Climate Control System: Component testing, refrigerant handling (R-12), blower motor, evaporator/heater core service.

Procedures Included

Scheduled Maintenance:

Oil and filter changes, air filter replacement, fuel filter replacement, coolant flush, transmission fluid service, brake fluid flush.

Engine Overhaul:

Piston/ring replacement, cylinder head removal/installation, camshaft service, valve adjustments (if applicable), crankshaft bearing inspection.

Fuel System Repair:

Fuel injector testing/replacement, fuel pump diagnosis, glow plug system service, injection pump timing and adjustment (requires specialized tools).

Transmission Repair:

Valve body diagnosis, clutch pack replacement, torque converter service, sealing ring replacement.

Brake System Repair:

Brake caliper rebuilding, master cylinder replacement, brake line repair/replacement, ABS hydraulic unit diagnostics.

Electrical Troubleshooting:

Component testing using multimeters, tracing electrical faults, diagnosing starter/alternator issues, power window/lock mechanism repair.

HVAC Repair:

Leak detection and repair in the refrigerant system, compressor replacement, blower motor resistor testing, control module diagnosis.

Technical Depth

Depth Level:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds. Suitable for professional technicians and advanced DIY enthusiasts.

Diagnostic Capability:

Detailed symptom-based troubleshooting guides, likely including oscilloscope wave-form examples for critical electronic components (e.g., fuel injection control).

Special Tool Requirements:

Identification of specialized Mercedes-Benz tools required for certain procedures (e.g., injection pump timing tools, pressure gauges).

📊 Manual Specifications

File Format

Digital Format Details:

Searchable text, ability to print specific sections or the entire manual, high-resolution diagrams and illustrations.

Print Quality

Illustration Quality:

Clear, detailed line drawings, schematics, and photographic illustrations.

Binding Type

Physical Manual Binding:

Likely perfect bound or spiral bound for ease of use on a workbench (if a physical version is described).

Paper Type

Physical Manual Paper:

Durable, high-quality paper stock suitable for workshop environments.

⚙️ Engine Specifications

Primary Engine

Engine Code:

OM603.960

Engine Type:

Inline 6-cylinder, turbocharged diesel

Displacement:

3.0 Liters (2999 cc)

Bore X Stroke:

87.0 mm x 84.0 mm

Compression Ratio:

21.0:1

Performance

Horsepower Net Bhp:

148 bhp @ 4400 rpm

Torque Net Lb Ft:

221 lb-ft @ 2400 rpm

Fuel System

Fuel Injection Type:

Bosch VE (Variable Endurance) mechanical inline injection pump with direct injection

Fuel Type:

Diesel Fuel (ASTM D975 Grade 1-D or 2-D recommended)

Glow Plug System:

Pre-chamber glow plug system with automatic timing, typically 6 glow plugs.

🔧 Transmission

Standard

Transmission Type:

4-speed Automatic (4G-TRONIC)

Gear Ratios:

1st: 3.68, 2nd: 2.41, 3rd: 1.41, 4th: 1.00, Reverse: 4.18

Transmission Fluid Type:

MB Specification 236.7 (e.g., MB-Approval 000 040 0004)

Features

Driving Modes:

Standard (S) and Economy (E) modes, selected via a shift quadrant button.

📐 Dimensions

Exterior

Length:

191.7 inches (4870 mm)

Width:

69.7 inches (1770 mm)

Height:

55.1 inches (1400 mm)

Wheelbase:

110.2 inches (2800 mm)

Weights

Curb Weight:

Approximately 3600-3800 lbs (1630-1725 kg)

Gross Vehicle Weight Rating:

Approximately 4600 lbs (2087 kg)

Cargo

Trunk Volume:

Approximately 16.0 cubic feet (0.45 cubic meters)

🛡️ Safety Features

Ratings

Crash Test Standard Era:

NHTSA/IIHS data from the mid-1980s may be limited compared to modern standards. Focus on passive safety features designed at the time.

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Not available on this model.

Passive Features

Airbags:

Driver's airbag (standard from late 1986/early 1987 model year onwards in some markets, optional prior). Passenger airbag not available.

Seat Belts:

3-point front seatbelts with pretensioners, 3-point rear seatbelts.

Body Construction:

Reinforced safety cell, crumple zones front and rear, side impact beams.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM cassette stereo, often with premium sound system options, power antenna.

Driver Assistance

Cruise Control:

Standard vacuum or electronically controlled cruise control.

Parking Assistance:

No parking sensors or rearview cameras. Relies on driver awareness and mirror visibility.

Connectivity

External Connectivity:

No integrated Bluetooth or USB. Aftermarket head unit installations are common for modern connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 - 7,500 miles or 6-12 months, depending on driving conditions. Refer to manual for specific recommendations.

Fuel Filter Replacement:

Every 15,000 - 30,000 miles. Crucial for diesel engine health.

Air Filter Replacement:

Every 15,000 - 30,000 miles or as needed based on driving environment.

Transmission Service:

Every 30,000 - 40,000 miles (fluid and filter change).

Coolant Flush:

Every 2-3 years or 30,000 miles.

Fluid Specifications

Engine Oil Type:

API CD or CE rated, SAE 15W-40 or 10W-30 diesel engine oil. Consult manual for precise viscosity based on ambient temperature.

Engine Oil Capacity:

Approximately 7.5 liters (7.9 US quarts) with filter change.

Coolant Type:

Mercedes-Benz specified coolant (e.g., MB 325.0, typically a 50/50 mix of ethylene glycol and distilled water).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Known Issues

Diesel Specific Concerns:

Glow plug issues, injector pump calibration, turbocharger wear, potential for head gasket failure under extreme heat or improper maintenance, fuel line leaks (old rubber hoses).

Electrical Common Failures:

Wiring harness degradation (especially under battery tray and firewall), vacuum line leaks affecting climate control and central locking, headlight switch failures.

Suspension Wear:

Ball joint wear, control arm bushings, rear axle mount bushings (known as 'subframe mounts' or 'dog bones') can degrade, leading to clunking and poor handling.

Climate Control Problems:

Vacuum leaks in the HVAC control system, failing blower motor resistors, refrigerant leaks (R-12).

Rust Prone Areas:

Fender wells, rocker panels, around the sunroof, and trunk lid edges are common areas for rust due to age and environmental exposure.

📚 Vehicle History

Brand Heritage

Mercedes Benz Legacy:

Established reputation for engineering excellence, durability, and luxury since the early 20th century.

Model Evolution

W124 Development:

The W124 chassis (1985-1995) was designed for superior durability, aerodynamics, and safety, setting new benchmarks for the automotive industry.

300Sdl Introduction:

The 300 SDL was introduced as a long-wheelbase variant of the W124, offering enhanced rear passenger legroom and an executive focus, powered by Mercedes-Benz's robust turbodiesel engines.

Production

Production Years:

W124 chassis produced from 1985 to 1995. The 300 SDL variant was primarily offered in North America for the 1986-1987 model years.

Manufacturing Location:

Sindelfingen, West Germany

🏆 Awards & Recognition

Recognitions

Chassis Recognition:

The W124 chassis was widely acclaimed by automotive journalists for its build quality and engineering, often referred to as one of the best-built Mercedes-Benz models ever.

Ratings

Long Term Durability:

Consistently ranked high in consumer satisfaction surveys for reliability and longevity, particularly the diesel models.