🏷️ Basic Information

Make:

Mercedes-Benz

Product Type:

Maintenance Manual

Product Name:

Mercedes Series 107-123-124-126-129-140-201 1981-1993 Maintenance Manual

Chassis Codes Covered:

W107, W123, W124, W126, W129, W140, W201

Model Years Covered:

1981-1993

👋 Introduction

Target Audience:

Owners of Mercedes-Benz vehicles from the 1981-1993 era, DIY mechanics, and professional automotive repair shops specializing in vintage Mercedes-Benz.

Value Proposition:

Offers comprehensive, model-specific repair and maintenance information that is often scarce or expensive to obtain from dealerships for these classic models. Crucial for preserving the value and drivability of these iconic vehicles.

Diagrams Illustrations:

High-quality exploded diagrams, wiring schematics, and step-by-step illustrations are fundamental to understanding complex procedures.

Factory Accuracy:

Represents factory-level technical data and procedures, ensuring accuracy and adherence to original specifications.

📋 Manual Details

Engine Variants:

Wide range including M102, M103, M104, M110, M116, M117, M119, OM601, OM602, OM603 diesel engines

Major Systems:

Engine, fuel, ignition, cooling, exhaust, transmission (manual & automatic), drivetrain, suspension, steering, brakes, electrical systems, climate control, interior trim, body panels, diagnostics

Estimated Pages:

Extensive, likely 1000+ pages across all covered models and systems.

Type:

Comprehensive Service and Repair Manual

Language:

English (likely original factory language or high-quality translation)

Format:

Print (Paperback or Spiral Bound)

📖 Manual Coverage

Engine Mechanics:

Detailed disassembly, assembly, and overhaul procedures for all covered engine variants, including cylinder head, block, crankshaft, pistons, connecting rods, timing components.

Fuel System:

Bosch K-Jetronic, KE-Jetronic, CIS-E, and early electronic fuel injection (EFI) system diagnostics and repair, including fuel pump, injectors, pressure regulators, airflow meters.

Ignition System:

Distributor-based ignition systems, electronic ignition control modules (EZL, EIS), coil testing, spark plug specifications, timing adjustments.

Cooling System:

Radiator, thermostat, water pump, coolant hoses, fan clutch/electric fan operation, bleed procedures, coolant specifications.

Exhaust System:

Exhaust manifold, catalytic converter (if applicable), muffler, pipe replacement, gasket specifications.

Transmission Manual:

Service and repair for 4-speed and 5-speed manual transmissions, including clutch replacement, gearshift linkage, transmission fluid specifications and fill quantities.

Transmission Automatic:

Service and repair for 3-speed (e.g., 722.3) and 4-speed (e.g., 722.4, 722.5) automatic transmissions, including fluid changes, filter replacement, torque converter information, and basic diagnostic troubleshooting.

Drivetrain:

Rear axle differential service, driveshaft U-joints, CV joints (for applicable models), bearing specifications.

Suspension Front:

MacPherson strut (W201, W124, W126) and double-wishbone (W107, W126) front suspension service, ball joints, control arms, sway bars, shock absorber replacement.

Suspension Rear:

Multi-link rear suspension (W124, W201), independent rear suspension (W107, W126, W129, W140), control arm bushings, trailing arms, coil springs, shock absorber replacement.

Steering:

Power steering system service, steering rack/box overhaul, tie rod ends, steering column adjustments, power steering fluid specifications.

Brakes Front:

Disc brake service, caliper overhaul, pad and rotor replacement, brake fluid specifications, bleeding procedures.

Brakes Rear:

Disc brake service, caliper/drum service, parking brake mechanism adjustment and repair.

Electrical Lighting:

Headlight aiming, bulb replacement, fuse box layout and identification, relay functions.

Electrical Instruments:

Dashboard instrument cluster removal and repair, speedometer/odometer service, warning lamp explanations.

Electrical Power:

Battery maintenance, starter motor, alternator service and testing, wiring diagrams for essential circuits.

Climate Control:

HVAC system diagnosis, blower motor, heater core, evaporator core replacement, refrigerant charging (R12 initially), control panel service.

Interior Trim:

Door panel removal, seat adjustment and repair, headliner service, dashboard trim disassembly for access.

Bodywork:

Door hinge lubrication and adjustment, window regulator service, sunroof operation and repair, bumper alignment, panel replacement basics.

Diagnostics OBD:

Basic diagnostic procedures, troubleshooting charts for common symptoms, potentially early OBD-I (if applicable to specific models within the range).

Routine Maintenance:

Oil changes, filter replacements, fluid level checks and top-offs, tire rotations, battery checks.

Major Tune Up:

Spark plug replacement, ignition timing adjustment, fuel filter replacement, air filter replacement, valve adjustment (where applicable).

Troubleshooting:

Systematic diagnostic flowcharts for common problems like no-start, rough running, poor performance, electrical issues.

Repair Overhaul:

Detailed, step-by-step instructions for component removal, disassembly, repair, reassembly, and installation.

Component Replacement:

Specific guidance on replacing wear items such as belts, hoses, brake pads, rotors, ball joints, tie rods.

Calibration Adjustment:

Procedures for adjusting idle speed, ignition timing, parking brake, door latches, headlight alignment.

Depth:

Comprehensive, covering from basic owner maintenance to advanced mechanical and electrical troubleshooting and repair, suitable for DIY enthusiasts and professional mechanics.

Diagnostic Charts:

Inclusion of symptom-based diagnostic charts for various vehicle systems.

Torque Specifications:

Detailed torque values for critical fasteners across all major components.

Special Tools:

Identification and usage instructions for any specific Mercedes-Benz special tools required for certain procedures.

📊 Manual Specifications

Digital Format Notes:

If provided digitally (e.g., PDF), expect searchable text, high-resolution diagrams, and bookmarking for easy navigation.

Paper Quality:

Durable, high-quality paper stock suitable for workshop environments, resistant to grease and oil stains.

Binding:

Likely a sturdy binding, possibly spiral-bound for lay-flat usability in a workshop or a durable paperback/hardcover.

⚙️ Engine Specifications

Engine Family Range:

Includes 4, 6, and 8-cylinder gasoline engines (M102, M103, M104, M110, M116, M117, M119) and 4 and 5-cylinder diesel engines (OM601, OM602, OM603).

Horsepower Torque:

Covers a broad spectrum from approximately 72 HP (diesel) to over 300 HP (V8 models), with detailed specs for each variant. For example, a 300E (W124) with M103 engine might produce around 180 HP.

Injection Types:

Primarily Bosch mechanical injection (K-Jetronic, KE-Jetronic) and early electronic fuel injection (EFI) systems.

Fuel Type:

Unleaded gasoline (various octane ratings depending on engine) and Diesel fuel.

Coolant Type:

MB 325.0 (often a long-life silicate-containing coolant) or equivalent.

Engine Oil:

SAE 10W-40 or 15W-40 API SG/SH rated oil is common for many gasoline engines; Diesel engines may require specific CI-4 or similar rated oils. Consult manual for exact viscosity and API spec per engine. Capacity varies from ~5L to ~8L.

🔧 Transmission

Transmission Types:

4-speed and 5-speed manual transmissions; 3-speed (722.3) and 4-speed (722.4, 722.5) automatic transmissions.

Optional Transmissions:

Typically the automatic transmission was an option on models that came standard with manual, and vice-versa on some sportier variants.

Automatic Features:

Some later models may feature electronically controlled transmissions (e.g., 722.5 with a 5-speed capability triggered by Kickdown switch on some models).

Automatic Transmission Fluid:

Typically MB-specific Automatic Transmission Fluid (e.g., ATF Dexron II or equivalent specified by MB, like 000 989 88 03). Capacity varies significantly.

Manual Transmission Fluid:

Gear oil, typically SAE 75W-90 or 80W-90 GL-4 or GL-5. Capacity around 1.5-2L.

📐 Dimensions

Dimensions Notes:

Varies significantly across the covered series (compact sedan like W201 to large luxury sedan like W140). The manual provides specific dimensions for each model's body style (coupe, sedan, convertible, wagon).

Curb Weight:

Range from approx. 1300 kg (W201) to over 2000 kg (W140 S-Class). Manual will list specific curb weights for each model and engine configuration.

🛡️ Safety Features

Safety Ratings Notes:

While official NHTSA/Euro NCAP ratings from this era are less comprehensive, the manual details features designed for safety, such as crumple zones, reinforced door beams, and seatbelt systems. Specific crash test data is unlikely within this maintenance manual.

Active Safety Systems:

ABS (Anti-lock Braking System) available on many models from the mid-80s onwards, power steering, dual-circuit braking system.

Passive Safety Features:

Seat belts (including early pretensions for front occupants on some models), padded dashboard, safety glass, energy-absorbing steering column.

💡 Technology Features

Audio Systems:

Factory-installed cassette players, often with optional CD changers or premium sound systems by Becker. Manual may cover head unit removal and basic speaker troubleshooting.

Driver Aid Features:

Cruise control (Tempomat) available on most models. ABS became increasingly common. Early traction control (ASR) on some higher-end models (e.g., W140, late W126).

Connectivity Features:

Limited by modern standards. Central locking, power windows, and electrically adjustable seats were primary convenience features. Antennas were typically manual or power-operated.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 to 7,500 miles (8,000 to 12,000 km) or annually, whichever comes first. Diesel engines might have slightly longer intervals.

Major Service Interval:

Major services involving spark plugs, fuel filters, coolant flushes, transmission fluid changes, and valve adjustments (where applicable) often recommended around 30,000 to 60,000 miles (50,000 to 100,000 km).

Brake Fluid:

DOT 3 or DOT 4 approved brake fluid. Replace every 2 years due to hygroscopic nature.

Power Steering Fluid:

MB power steering fluid (e.g., CHF 11S or equivalent, check manual for specific type) or a Dexron II/III ATF for some models.

Common Faults:

Vacuum line deterioration leading to air leaks and running issues, fuel distributor or accumulator leaks (K-Jetronic), sagging headliner, differential mount failure (W124/W201), ABS sensor issues, window regulator problems, climate control flap actuator failures.

Corrosion Points:

Common areas for rust include wheel arches, rocker panels, around windshield and rear window seals, and jack points, depending on climate and maintenance history.

📚 Vehicle History

Mercedes Benz Legacy:

Mercedes-Benz has a long-standing reputation for engineering excellence, luxury, and safety, established by pioneers like Karl Benz and Gottlieb Daimler. This era represents a peak of robust engineering and sophisticated design before the more electronic-driven era.

Series Evolution Overview:

This manual covers a diverse range of flagship and executive models: W201 (190 series - compact executive), W124 (E-Class - mid-size executive), W126 (S-Class - full-size luxury), W107 (SL/SLC - sports/GT), W129 (SL - successor to W107), W140 (S-Class - flagship luxury), and the W201 is the foundation for the compact segment. These models represent significant advancements in automotive design and engineering for their respective classes.

Production Period Overview:

This period (1981-1993) saw the phasing in and out of several iconic chassis. For example, the W123 ended production in 1985, while the W140 began in 1991. The W124 and W201 were mainstays of this period.

🏆 Awards & Recognition

Historical Acclaim:

The W124 chassis, in particular, is renowned for its engineering and build quality, often dubbed the 'over-engineered' car. The W126 S-Class was the benchmark for luxury sedans of its time. The W201 was praised for bringing Mercedes-Benz quality to a more compact and affordable segment.