Model:
200D, 240D, 240TD, 300D, 300TD
Product Name:
Mercedes-Benz 200D 240D 240TD 300D 300TD 1976-1985 Service Repair Manual
Covered Years:
1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985
Chassis Codes:
W115 (partial updates), W123
Market Segment:
Mid-size luxury/executive sedans and wagons, renowned for durability and diesel efficiency.
Key Competitors:
BMW 5 Series, Audi 100, Volvo 240 Series, Peugeot 504/604
Vehicle Attributes:
Robust diesel engines, build quality, ride comfort, safety features for its era, long-term reliability.
Target Audience:
DIY mechanics, independent repair shops, classic Mercedes-Benz enthusiasts, owners seeking detailed maintenance and repair knowledge.
Primary Coverage:
Mechanical and Electrical Systems, Bodywork, Maintenance, Troubleshooting, Repair
Estimated Pages:
500-1000+ (typical for comprehensive factory-level manuals of this era)
Type:
Factory Service Manual / Workshop Manual
Language:
English (likely, common for international service manuals)
Format:
Digital Download (PDF)
Powertrain:
Engine (Diesel - OM615, OM616, OM617), Fuel System, Cooling System, Exhaust System
Drivetrain:
Transmission (Manual & Automatic), Clutch, Drive Shaft, Differential, Axles
Suspension Steering:
Front Suspension, Rear Suspension, Steering System, Wheel Alignment
Brakes:
Brake System (Disc & Drum), Parking Brake, ABS (if applicable on later models)
Electrical:
Battery, Charging System, Ignition System, Lighting System, Instrumentation, Wiring Diagrams
Body Chassis:
Body Structure, Doors, Windows, Interior Trim, Exterior Trim, Chassis Components
Maintenance:
Oil Change, Filter Replacement, Fluid Checks, Lubrication, Belt Adjustments
Repair:
Engine Rebuilds, Transmission Overhaul, Suspension Component Replacement, Brake Service, Electrical Component Diagnosis and Repair
Troubleshooting:
Diagnostic Charts, Symptom-Based Troubleshooting Guides, Fault Code Analysis (where applicable)
Specifications:
Torque Specifications, Clearances, Gaps, Fluid Capacities, Electrical Specifications
Depth:
Comprehensive: From basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures.
Digital Quality:
High-resolution scans or original digital files, ensuring readability of text and diagrams.
Searchability:
Likely text-searchable if created from OCR'd documents or original digital source.
Printability:
Designed for printing specific sections or the entire manual, with clear diagrams and text.
Digital Binding:
N/A (Digital Format)
Digital Paper Type:
N/A (Digital Format)
Engine Codes:
OM615 (2.0L), OM616 (2.4L), OM617 (3.0L)
Engine Type:
Inline-4 (200D, 240D), Inline-5 (300D)
Aspiration:
Naturally Aspirated Diesel
200D Power Output:
Approx. 55-65 hp (depending on specific market/year)
240D Power Output:
Approx. 62-72 hp (depending on specific market/year)
300D Power Output:
Approx. 70-80 hp (depending on specific market/year)
300Td Power Output:
Approx. 77-88 hp (depending on specific market/year, TD often implied turbo or wagon variant)
Fuel Delivery:
Bosch Inline Injection Pump
Glow Plugs:
Critical for cold starting; regular testing and replacement recommended.
Valve Adjustment:
Requires periodic adjustment to maintain performance and fuel efficiency.
Transmission Options:
4-speed Manual, 4-speed Automatic (often denoted '4G-Tronic' or similar)
Automatic Transmission:
Available on most models, providing smoother operation for touring.
Clutch Type:
Single Dry Plate (Manual Transmission)
Automatic Transmission Fluid:
MB Spec 236.1 (e.g., Dexron II compatible variants)
Manual Transmission Fluid:
GL-4 Gear Oil (e.g., SAE 80W-90)
Body Styles:
Sedan (W123), Wagon (S123 - 240TD, 300TD)
Wheelbase:
Approx. 2794 mm (110 inches) for W123 Sedan
Curb Weight:
Approx. 1400-1600 kg (3086-3527 lbs), varies by model and equipment.
Era Safety Standards:
Designed to high standards for its time, focusing on structural integrity and occupant protection.
Braking System:
Front Disc Brakes, Rear Drum Brakes. Some later models might have optional rear discs or ABS.
Construction:
Reinforced passenger safety cell, crumple zones, padded dashboard.
Seatbelts:
Standard front seatbelts; rear seatbelt provisions.
Audio System:
Factory AM/FM radio, often with cassette player option. Basic sound quality.
Cruise Control:
Optional on many models, providing highway comfort.
Auxiliary Inputs:
None (standard equipment for the era).
HVAC System:
Manual heating and ventilation, optional Air Conditioning (often belt-driven compressor).
Oil Change Interval:
Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months.
Fuel Filter Replacement:
Every 15,000-20,000 miles (24,000-32,000 km).
Air Filter Replacement:
Every 10,000-15,000 miles (16,000-24,000 km).
Engine Oil Type:
API CD or higher, SAE 10W-40 or 15W-40 diesel rated oil.
Coolant Type:
Ethylene Glycol based antifreeze, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4.
Common Problems:
Vacuum leaks (door locks, climate control), injector pump wear, early generation OM617 oil cooler leaks, rust (especially around wheel wells and undercarriage), idle speed instability.
Diesel Specific Issues:
Glow plug system reliability, injection pump calibration, valve seat wear on higher mileage engines.
Mercedes Benz Legacy:
Renowned for engineering excellence, durability, and pioneering diesel technology.
W123 Generation:
Successor to the W114/W115, the W123 platform solidified Mercedes-Benz's reputation for robust, reliable vehicles. The diesel variants were particularly popular for their economy and longevity.
Diesel Focus:
These models represent the peak of Mercedes-Benz's naturally aspirated diesel engines, known for their 'bulletproof' construction.
Production Period:
W123 generation produced from 1976 to 1986 (diesel models had overlapping lifespans).
