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Mercedes 300D 2.5 Turbo 1990-1993 Repair Service Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: 300D 2.5 Turbo Chassis Code: W124 (E-Class) Production Years Covered: 1990, 1991, 1992, 1993 Codes Engine Code: OM602.912 👋 Introduction Market Position Segment:...
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Taper: Car
Distributeur:
UGS: 517288
Mercedes 300D 2.5 Turbo 1990-1993 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
300D 2.5 Turbo
Chassis Code:
W124 (E-Class)
Production Years Covered:
1990, 1991, 1992, 1993
Codes
Engine Code:
OM602.912
👋 Introduction
Market Position
Segment:
Mid-size Luxury Sedan/Coupe/Convertible/Wagon
Competitive Analysis
Competitors:
BMW 5 Series (E34), Audi 100/A6 (C3/C4), Volvo 240/740/940
Key Features
Durability:
Renowned for Mercedes-Benz's legendary build quality and long-term durability.
Diesel Performance:
The 2.5L turbo-diesel offered a compelling blend of torque, fuel economy, and respectable performance for its time.
Comfort And Refinement:
Exceptional ride comfort, quiet cabin, and premium interior appointments characteristic of the W124 chassis.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive Workshop Repair & Service
Page Count
Estimated Page Count:
Over 800 pages (typical for this era's comprehensive manuals)
Manual Type
Manual Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Cooling System, Exhaust System, Transmission (Automatic & Manual), Drivetrain, Clutch
Chassis:
Suspension (Front & Rear), Steering, Brakes (Hydraulic & Parking), Wheels & Tires
Electrical:
Engine Control Unit (ECU), Ignition System, Lighting, Instrumentation, Power Accessories, Audio System, Battery, Charging System, Starting System
Body:
Body Panels, Doors, Windows, Seats, Interior Trim, Exterior Trim, HVAC System, Sunroof
Procedures Included
Maintenance:
Scheduled Maintenance, Oil Change, Filter Replacement, Fluid Checks and Replenishment, Belt Replacement, Spark Plug Replacement (where applicable)
Diagnostics:
Troubleshooting Guides, Symptom-Based Diagnosis, Diagnostic Trouble Codes (DTCs), Electrical Schematics for diagnosis
Repair:
Component Removal and Installation, Engine Overhaul, Transmission Rebuild, Brake System Service, Suspension Component Replacement, Electrical Component Repair
Specifications:
Torque Values, Clearances, Timing Procedures, Fluid Capacities, Component Dimensions
Technical Depth
Depth:
Detailed, professional level covering complete overhaul and advanced diagnostics.
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, text-searchable PDF for easy navigation and printing.
Print Quality
Printable Pages:
Designed for clear printing of individual pages or sections.
Binding Type
Binding Recommendation:
Digital format, recommended for viewing on computer, tablet, or printing for workshop use.
Paper Type
Recommended Print Paper:
Standard printer paper is suitable for printed copies.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-5 Cylinder, Turbocharged Diesel
Displacement:
2.5 Liters (2497 cc)
Performance
Horsepower:
Approx. 126 hp @ 4,000 rpm
Torque:
Approx. 201 lb-ft (273 Nm) @ 2,400 rpm
Fuel System
Injection System:
Bosch VE Rotary Injection Pump with Turbocharger and Intercooler
Fuel Type:
Diesel Fuel
Maintenance
Glow Plugs:
Crucial for cold starts; detailed replacement procedure included in manual.
Technical Details
Compression Ratio:
19.0:1 (typical)
Bore X Stroke:
87.0 mm x 84.0 mm (typical)
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic (722.4) standard on most models, 5-Speed Manual (G50) available
Optional
Optional Transmission:
5-Speed Manual Transmission
Features
Automatic Features:
Selectable modes (e.g., Economy/Sport) in some variants, torque converter lock-up.
Fluid Specifications
Automatic Transmission Fluid:
MB Spec 236.2, 236.6, or 236.7 (refer to manual for specific year/model)
Manual Transmission Fluid:
MB Spec 235.0 (e.g., SAE 80W-90 gear oil, refer to manual)
📐 Dimensions
Exterior
Body Styles:
Sedan (W124.030), Coupe (C124.030), Convertible (A124.030), Wagon (S124.030)
Wheelbase:
Approx. 2800 mm (Sedan)
Weights
Curb Weight:
Approx. 3,300 - 3,600 lbs (1500 - 1630 kg), varies by body style and equipment
🛡️ Safety Features
Ratings
Crash Safety Era:
Designed to meet safety standards of the late 1980s/early 1990s.
Active Features
Brakes:
Front: Ventilated Discs, Rear: Solid Discs. ABS (Anti-lock Braking System) standard.
Traction Control:
Optional ASR (Acceleration Slip Regulation) available on some models.
Passive Features
Airbags:
Driver's side airbag standard from 1991/1992 onwards (check specific VIN).
Body Structure:
Reinforced safety cell, crumple zones, side-impact protection beams.
💡 Technology Features
Infotainment
Audio System:
Factory premium audio system, often with cassette player. Manual covers basic diagnostics and speaker replacement.
Driver Assistance
Cruise Control:
Standard cruise control system, details on operation and troubleshooting included.
Connectivity
Power Accessories:
Power windows, power mirrors, central locking. Manual covers electrical diagrams and repair for these systems.
Hvac
Climate Control:
Automatic climate control (ACC) or manual HVAC system. Manual provides service and repair for blower motor, control modules, actuators, and refrigerant system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 - 5,000 miles or annually (diesel specific, refer to manual for exact intervals and oil type).
Fuel Filter Interval:
Recommended every 15,000 - 30,000 miles (crucial for diesel systems).
Air Filter Interval:
Check every 15,000 miles, replace as needed (typically 30,000 miles).
Transmission Fluid Interval:
Recommended every 30,000 - 50,000 miles for automatic transmissions.
Fluid Specifications
Engine Oil Capacity:
Approx. 7.5 Liters (7.9 US Quarts) with filter change. Recommended oil: MB Spec 229.1 or 229.5 (API CD/CF or higher diesel specification for this era, consult manual).
Coolant Capacity:
Approx. 9.5 Liters (10 US Quarts). Recommended coolant: MB Spec 325.0 (Glysantin G05 or equivalent).
Brake Fluid Type:
DOT 4
Known Issues
Diesel Specific Concerns:
Glow plug issues, injector problems, turbocharger wear, vacuum line degradation, exhaust manifold cracks, diesel fuel gelling in extreme cold.
General W124 Concerns:
Headlight switch failures, evaporator core leaks (HVAC), window regulator issues, vacuum door lock failures, rust in typical W124 areas (wheel wells, jacking points).
Manual Utility For Issues:
The manual provides detailed diagnostic procedures and repair steps for all common and uncommon issues.
📚 Vehicle History
Brand Heritage
Mercedes Diesel Legacy:
Mercedes-Benz has a long and distinguished history in diesel engine development, known for reliability and longevity.
Model Evolution
W124 Era:
The 300D 2.5 Turbo is part of the highly regarded W124 E-Class generation, produced from 1984 to 1995, known for its engineering excellence and build quality.
Production
Manufacturing Location:
Germany
🏆 Awards & Recognition
Recognitions
W124 Reputation:
The W124 generation is widely considered one of the best-built Mercedes-Benz vehicles ever produced, lauded for its engineering, durability, and safety.
Ratings
Consumer Reports Era:
Consistently received high reliability ratings from publications like Consumer Reports during its production years.
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