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Mercedes 300 D Turbo 1986-1987 Service Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: 300D Turbo Generation: W124 (First Generation) Chassis Code: W124 Codes Engine Code Family: OM603 👋 Introduction Market Position Vehicle Segment: Mid-size Luxury Sedan...
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UGS: 375030
Mercedes 300 D Turbo 1986-1987 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
300D Turbo
Generation:
W124 (First Generation)
Chassis Code:
W124
Codes
Engine Code Family:
OM603
👋 Introduction
Market Position
Vehicle Segment:
Mid-size Luxury Sedan (E-Class)
Target Audience:
Discerning buyers seeking durability, comfort, and refined diesel performance
Competitive Analysis
Key Competitors:
BMW 5 Series Diesel, Audi 100/200 Diesel, Volvo 240/740 Diesel
Key Features
Vehicle Attributes:
Exceptional build quality, robust diesel engine, comfortable ride, advanced engineering for its era
Manual Value Proposition
Benefit To Owner:
Empowers owners and technicians to accurately diagnose and repair the vehicle, ensuring longevity and optimal performance
📋 Manual Details
Coverage Areas
Years Covered:
1986, 1987
Models Covered:
300D Turbo Sedan (W124.133)
Page Count
Estimated Pages:
Refer to actual manual content, typically 500+ pages for comprehensive coverage
Manual Type
Type:
Service Repair Manual
Language
Language:
English
Format
Digital Format:
PDF / WINRAR
📖 Manual Coverage
Systems Covered
Powertrain:
Engine Mechanical, Fuel System, Lubrication System, Cooling System, Turbocharging System
Transmission:
Manual Transmission, Automatic Transmission (4-Speed 722.4), Transfer Case (if applicable to specific model variant)
Drivetrain:
Driveshaft, Axles, Differential
Suspension Steering:
Front Suspension, Rear Suspension, Steering System, Level Control (if equipped)
Brakes:
Brake System Hydraulics, Parking Brake, ABS (Anti-lock Braking System - if equipped)
Electrical:
Engine Electrical, Ignition System, Lighting, Instrumentation, Power Accessories, Fuses, Relays
Body Chassis:
Body Structure, Doors, Hood, Trunk, Glass, Body Seals, Interior Trim, Noise Insulation
Climate Control:
Heating, Ventilation, Air Conditioning (HVAC), Climate Control Systems
Safety Features:
Seat Belts, Airbags (if equipped), Locking Mechanisms
Procedures Included
Routine Maintenance:
Oil and Filter Changes, Fluid Level Checks and Top-offs, Air Filter Replacement, Fuel Filter Replacement, Belt Inspection and Adjustment, Spark Plug Service, Coolant Flush and Replacement
Troubleshooting:
Diagnostic Procedures for Engine Performance, Electrical Faults, and Component Failures
Component Repair:
Engine Overhaul, Transmission Repair, Brake System Overhaul, Suspension Component Replacement, Steering System Repair
Disassembly Assembly:
Detailed steps for removing and installing major components and sub-assemblies
Inspection:
Visual inspections of components, lines, hoses, body structure, and fluid conditions
Adjustments:
Valve Clearance Adjustment, Idle Speed Adjustment, Injection Timing Adjustment, Parking Brake Adjustment
Technical Depth
Level:
Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts
Detail Level:
Includes torque specifications, diagnostic charts, component diagrams, and step-by-step repair instructions
📊 Manual Specifications
File Format
Digital Delivery:
Instant Download
Compatibility:
Win95/98/ME/XP/vista/7/8/Linux/MAC, iOS, Android
Print Quality
Digital Resolution:
High-resolution for clear viewing and printing
Binding Type
Digital Format:
N/A (Digital Download)
Paper Type
Digital Format:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 6-Cylinder Turbocharged Diesel
Displacement:
2.996 cc (3.0 Liters)
Bore X Stroke:
87.0 mm x 84.0 mm
Compression Ratio:
22.0:1
Fuel Delivery:
Bosch Inline Fuel Injection Pump with Turbocharger
Performance
Horsepower:
125 hp @ 4,300 rpm (approx.)
Torque:
228 lb-ft @ 2,400 rpm (approx.)
Fuel System
Injection System:
Mechanical Diesel Injection
Fuel Type:
Diesel Fuel
🔧 Transmission
Standard
Type:
4-Speed Automatic (722.4)
Optional
Type:
5-Speed Manual Transmission (Less Common)
Features
Automatic Transmission Characteristics:
Smooth shifting, robust design, often referred to as 'bulletproof'
📐 Dimensions
Exterior
Wheelbase:
110.1 inches (2799 mm)
Length:
188.0 inches (4775 mm)
Width:
69.4 inches (1763 mm)
Height:
55.5 inches (1410 mm)
Weights
Curb Weight:
Approx. 3,400 - 3,600 lbs (1542 - 1633 kg)
🛡️ Safety Features
Ratings
Era Specific Ratings:
As per contemporary testing standards, known for robust construction.
Active Features
ABS:
Optional Anti-lock Braking System (ABS)
Passive Features
Construction:
Reinforced safety cage, crumple zones
Restraints:
Three-point seat belts, optional driver's side airbag
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM cassette stereo systems, often with optional premium sound.
Driver Assistance
ABS:
Available ABS system on later models.
Connectivity
Original Features:
Focus on mechanical and electrical reliability rather than advanced electronic connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 7,500 miles or 6-12 months, consult specific manual for exact recommendation.
Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on driving conditions.
Fuel Filter Replacement:
Every 15,000 - 25,000 miles.
Coolant Replacement:
Every 30,000 - 50,000 miles or 2-3 years.
Fluid Specifications
Engine Oil:
API CD or higher; SAE 15W-40 or 10W-40 diesel engine oil recommended. Consult manual for precise viscosity based on climate.
Transmission Fluid Automatic:
MB 236.1 (ATF Dexron II or equivalent)
Transmission Fluid Manual:
MB 235.1 (GL-4 Gear Oil)
Brake Fluid:
DOT 3 or DOT 4
Power Steering Fluid:
MB 236.3 (ATF Dexron II or equivalent)
Coolant:
Glysantin G48 (or equivalent silicate-free antifreeze) mixed 50/50 with distilled water.
Known Issues
Common Wear Items:
Vacuum lines, suspension bushings, glow plugs, fuel injector seals, transmission control pressure regulator
Diesel Specific Concerns:
Maintenance of injection pump timing, fuel system cleanliness, glow plug system reliability
📚 Vehicle History
Brand Heritage
Mercedes Benz Legacy:
Pioneering diesel technology, engineering excellence, and luxury vehicle manufacturing.
Model Evolution
W124 Introduction:
Introduced in 1984 (as W124), the 300D Turbo variant became available later, representing a significant advancement in diesel performance and refinement for Mercedes-Benz.
Production
Manufacturing Location:
Germany
Production Period:
W124 platform produced from 1984 to 1997. 300D Turbo specifically relevant for the earlier years of this generation.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
The W124 platform as a whole was renowned for its build quality and engineering, often cited as one of the best-built cars of its era by automotive journalists and owners alike.
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