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Mercedes-Benz 450SEL1973-1980 Factory Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: 450SEL Product Name: Mercedes-Benz 450SEL 1973-1980 Factory Workshop Service Repair Manual Codes Chassis Code: W116 Engine Code: M117 👋 Introduction Market Position Positioning:...
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Mercedes-Benz 450SEL1973-1980 Factory Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
450SEL
Product Name:
Mercedes-Benz 450SEL 1973-1980 Factory Workshop Service Repair Manual
Codes
Chassis Code:
W116
Engine Code:
M117
👋 Introduction
Market Position
Positioning:
Premium luxury sedan, representing the pinnacle of Mercedes-Benz engineering and comfort in its era.
Competitive Analysis
Competitors:
BMW E12 5 Series, Jaguar XJ6 Series II, Cadillac Eldorado, Lincoln Continental Mark IV/V
Key Features
Vehicle Highlights:
Spacious interior, advanced (for its time) safety features, powerful V8 engine, refined ride quality, extensive use of sound deadening.
Manual Value Proposition
Value:
Provides access to the same factory-level information used by authorized technicians, enabling accurate and efficient maintenance and repair for enthusiasts and owners.
📋 Manual Details
Coverage Areas
Years Covered:
1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980
Page Count
Estimated Page Count:
Extensive (Specific count not provided, but described as covering 'every service and repair imaginable')
Manual Type
Type:
Factory Workshop Service Repair Manual
Language
Language:
English (Assumed based on product description context)
Format
Digital Format:
HTML/Flash menu with PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Transmission, Fuel System, Exhaust System
Chassis:
Suspension, Steering, Brakes, Drivetrain, Wheels and Tires
Electrical:
Ignition System, Charging System, Starting System, Lighting, Instruments, HVAC Electrical, Power Accessories
Bodywork:
Exterior Trim, Interior Trim, Seats, Doors, Glass, Body Panels, Paint
Miscellaneous:
HVAC System, Body Control Modules (if applicable for later years), Emissions Control Systems
Procedures Included
Maintenance:
Oil changes, fluid flushes, filter replacements, tune-ups, lubrication
Diagnostics:
Troubleshooting common issues, fault code interpretation (if applicable), diagnostic procedures for all systems
Repair:
Engine rebuilds, transmission overhauls, brake system repair, suspension component replacement, electrical system repairs, body panel repair, interior component repair
Special Procedures:
Component removal and installation, calibration procedures, alignment specifications
Technical Depth
Depth:
Comprehensive: From basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and specifications.
📊 Manual Specifications
File Format
Format:
HTML/Flash menu with PDF
Compatibility:
Windows (95/98/ME/XP/Vista/win7), Linux, MAC
Print Quality
Quality:
High (Typical of factory manuals, designed for clarity and detail)
Binding Type
Binding:
Digital (Downloadable file)
Paper Type
Paper Type:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
V8, SOHC
Displacement:
4.5 Liters (4520 cc)
Bore X Stroke:
92.0 mm x 84.0 mm
Compression Ratio:
8.0:1 (typical)
Horsepower Gross:
Approx. 220-230 hp (depending on market and emissions regulations)
Torque Gross:
Approx. 270-280 lb-ft (depending on market and emissions regulations)
Fuel System
Injection System:
Bosch K-Jetronic (CIS - Continuous Injection System)
Fuel Type:
Unleaded gasoline (minimum 91 octane recommended)
Lubrication
Oil Capacity Quarts:
7.7 quarts (7.3 liters) with filter change (refer to manual for exact specification)
Recommended Oil Viscosity:
SAE 10W-40 or 20W-50 (depending on climate, refer to manual)
Cooling System
Coolant Capacity Quarts:
Approx. 10.5 quarts (10 liters) (refer to manual)
Coolant Type:
Ethylene glycol based coolant (50/50 mix with distilled water)
🔧 Transmission
Standard
Transmission Type:
3-speed Automatic (TorqueFlite variant by Mercedes-Benz)
Transmission Model:
300 Automatic (often referred to by internal Mercedes designation)
Optional
Optional Transmission:
None offered for 450SEL in this generation.
Features
Features:
Hydraulic torque converter, planetary gear sets, electronic/vacuum modulator for shift control.
Fluid
Transmission Fluid Type:
Dexron II (or equivalent approved fluid, refer to manual)
Transmission Fluid Capacity Quarts:
Approx. 3.3 quarts (3.1 liters) for torque converter refill, higher for complete overhaul (refer to manual).
📐 Dimensions
Exterior
Wheelbase Inches:
116.7 inches (2965 mm)
Overall Length Inches:
199.6 inches (5070 mm)
Overall Width Inches:
70.5 inches (1790 mm)
Overall Height Inches:
57.3 inches (1455 mm)
Weights
Curb Weight Lbs:
Approx. 3900 - 4200 lbs (1770 - 1905 kg) depending on equipment.
Gross Vehicle Weight Rating Lbs:
Approx. 4800 - 5000 lbs (2177 - 2268 kg) (refer to vehicle plate or manual).
🛡️ Safety Features
Ratings
Crash Test Data:
No standardized crash test ratings like NHTSA exist for vehicles of this era. However, Mercedes-Benz was a leader in passive safety design for its time.
Active Features
Braking System:
Power-assisted hydraulic disc brakes front and rear, ABS (Anti-lock Braking System) became available on later models within this range (e.g., from 1978 onwards).
Steering System:
Power recirculating ball steering.
Passive Features
Occupant Protection:
Reinforced safety cage, impact-absorbing steering column, padded dashboard and interior surfaces, three-point seatbelts (front standard, rear optional or standard depending on market/year).
Lighting:
Halogen headlights, integrated fog lamps (often optional or part of European spec).
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM radio with cassette player. Optional upgraded sound systems may have been available.
Speakers:
Typically 4-6 speakers depending on configuration.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) available on later models (e.g., from 1978 onwards). Not standard on all vehicles in this range.
Connectivity
Connectivity Features:
None in the modern sense (no Bluetooth, USB, etc.).
Comfort Features
Climate Control:
Automatic climate control (Thermatic) was a key feature, offering sophisticated temperature regulation for its time.
Power Accessories:
Power windows, power door locks, power antenna, power adjustable seats (optional).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 - 5,000 miles or 6-12 months, whichever comes first (refer to manual for precise interval and oil type).
Filter Replacement:
Oil filter with every oil change. Air filter and fuel filter typically every 15,000 - 30,000 miles or as specified.
Tune Up Interval:
Spark plugs every 30,000 - 50,000 miles. Ignition points (if applicable) and timing adjustments as needed.
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for specific type and change interval).
Power Steering Fluid Type:
Dexron II (or equivalent approved fluid, refer to manual).
Known Issues
Common Wear Items:
Fuel distributor (K-Jetronic), fuel pump, vacuum lines (perishing), distributor cap and rotor, spark plug wires, exhaust system, window regulators, climate control system components.
Electrical Gremlins:
Can be prone to minor electrical issues due to age of wiring and components, especially related to power accessories and ignition/fuel management.
Structural Concerns:
Rust is a common concern on older Mercedes-Benz vehicles, particularly around wheel arches, door bottoms, and chassis components. Proper undercoating and maintenance are crucial.
📚 Vehicle History
Brand Heritage
Heritage:
Mercedes-Benz has a long-standing reputation for engineering excellence, safety, and luxury dating back to the late 19th century.
Model Evolution
Generation:
W116: First generation of the S-Class sedan, replacing the W108/W109 series.
Introduction Year:
1972 (for the 1973 model year).
Key Changes During Production:
Engine options diversified, ABS introduced on later models, minor styling updates, increased focus on emissions and fuel efficiency.
Production
Production Years:
1972-1980
Manufacturing Locations:
Germany (primarily Sindelfingen)
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
The W116 generation was highly acclaimed for its safety, ride comfort, and build quality, setting new benchmarks for luxury sedans. Often cited as the first true S-Class.
Ratings
Reliability Perception:
Generally perceived as a very robust and well-engineered vehicle, though maintenance is critical due to its complexity and age. Specialized knowledge is often required for optimal upkeep.
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