Mercedes 240D 1981-1983 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: 240D Model Generation: W123 Series Model Years Covered: 1981, 1982, 1983 Codes Chassis Code: W123 👋 Introduction Market Position Vehicle Class: Compact Executive...

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Type: Car

Vendor:

Sku: 517280

Tags: 1981 1982 1983 240D Car Cars Mercedes Misc

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

Model Generation:

W123 Series

Model Years Covered:

1981, 1982, 1983

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Class:

Compact Executive / Mid-size Sedan and Wagon

Target Audience For Manual:

Mercedes-Benz owners, independent repair shops, classic car enthusiasts.

Competitive Analysis

Contemporary Competitors:

BMW 3 Series (E21/E30), Audi 80/90, Volvo 240 Series, Saab 900, Alfa Romeo Alfetta.

Key Features Of Vehicle

Diesel Engine Emphasis:

Known for exceptional fuel economy and durability, the 240D was a reliable workhorse.

Build Quality:

Typical Mercedes-Benz over-engineering, contributing to longevity and robust performance.

Design Philosophy:

Functional, durable, and conservative styling, emphasizing passenger comfort and safety.

Key Features Of Manual

Manual Value Proposition:

Essential resource for maintaining and repairing the robust W123 chassis, particularly the reliable diesel powertrain.

📋 Manual Details

Coverage Areas

Coverage Scope:

All Models, Engines, Trim Levels within the specified years

Page Count

Estimated Page Count:

Refer to specific edition, typically 500-800+ pages for comprehensive workshop manuals

Manual Type

Manual Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine System:

Detailed diagnosis, repair, and overhaul procedures for the OM616 diesel engine.

Fuel System:

Fuel injection pump (Bosch VE), injectors, glow plug system, fuel lines, filters.

Cooling System:

Radiator, thermostat, water pump, hoses, fan, coolant specifications.

Lubrication System:

Oil pump, oil filter, oil pan, lubrication passages, oil specifications.

Exhaust System:

Manifolds, pipes, muffler, catalytic converter (if applicable), mounting hardware.

Transmission Manual:

Repair, adjustment, and overhaul of the 4-speed and 5-speed manual transmissions.

Transmission Automatic:

Diagnosis and repair of the optional 3-speed automatic transmission (e.g., 722.1).

Drivetrain:

Clutch, driveshafts, universal joints, rear axle, differential.

Suspension Front:

Wishbones, ball joints, tie rods, steering knuckles, springs, shock absorbers.

Suspension Rear:

Trailing arms, semi-trailing arms, rear axle housing, shock absorbers, springs.

Steering System:

Steering box, steering column, steering linkage, power steering system (if equipped).

Brake System:

Front disc brakes, rear drum brakes, hydraulic system, master cylinder, brake fluid, parking brake.

Electrical System:

Battery, alternator, starter motor, ignition system (for gasoline models, not applicable to 240D), lighting, instrumentation, wiring diagrams.

Body And Chassis:

Body shell, doors, hood, trunk, interior trim, glass, seals, chassis components.

Heating And Ventilation:

HVAC system components, heater core, blower motor, controls, ventilation ducts.

Bodywork And Trim

Body And Interior:

Detailed instructions for removing and installing body panels, interior trim pieces, and dashboard components.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement (not applicable to 240D), brake adjustments.

Troubleshooting Diagnostics:

Systematic approaches to diagnose common and uncommon problems across all major vehicle systems.

Engine Repair:

Piston ring replacement, cylinder head service, valve adjustments, timing chain inspection and replacement.

Transmission Overhaul:

Complete disassembly, inspection, replacement of worn parts, and reassembly of manual and automatic transmissions.

Brake System Repair:

Brake pad/shoe replacement, caliper/wheel cylinder overhaul, brake line replacement, bleeding procedures.

Suspension And Steering Repair:

Replacement of ball joints, tie rod ends, control arm bushings, shock absorbers, and steering box adjustments.

Electrical Component Replacement:

Starter motor, alternator, battery, lighting fixtures, relays, switches.

Bodywork Repair:

Door alignment, panel replacement, rust repair techniques, glass installation.

Wiring Diagram Interpretation:

Detailed schematics for electrical systems, aiding in diagnosis and repair.

Technical Depth

Depth Of Information:

Comprehensive; covers routine maintenance to full engine and transmission rebuilds, including specialized tools and torque specifications.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable PDF for efficient information retrieval.

Print Quality

Printability:

Designed for printing, allowing users to create hard copies of specific sections or the entire manual.

Binding Type

Binding For Printed Version:

Not applicable for PDF download, but original manuals were typically bound for durability.

Paper Type

Paper Type For Printed Version:

Not applicable for PDF download, but original manuals used durable paper stock.

⚙️ Engine Specifications

Primary Engine

Engine Code:

OM616

Engine Type:

Inline-4 Cylinder, Naturally Aspirated Diesel

Displacement:

2.4 Liters (2399 cc)

Bore X Stroke:

87.0 mm x 92.4 mm

Compression Ratio:

21.5:1

Performance

Horsepower Net:

72 hp @ 4200 rpm (approx.)

Torque Net:

107 lb-ft @ 2400 rpm (approx.)

Fuel System

Fuel Delivery:

Bosch Inline Fuel Injection Pump (VE type)

Fuel Type:

Diesel

Engine Features

Valve Train:

Single Overhead Camshaft (SOHC), 2 valves per cylinder

Cooling Method:

Liquid-Cooled

Lubrication System:

Wet Sump

🔧 Transmission

Standard

Transmission Type Standard:

4-Speed Manual Transmission

Optional

Transmission Type Optional:

3-Speed Automatic Transmission (e.g., 722.1 series)

Features

Clutch Type:

Single Dry Plate (Manual Transmission)

Automatic Transmission Features:

Torque Converter Lock-up (on later models/variants)

📐 Dimensions

Exterior

Wheelbase:

2713 mm (106.8 inches)

Length:

4725 mm (186.0 inches)

Width:

1790 mm (70.5 inches)

Height:

1430 mm (56.3 inches)

Weights

Curb Weight:

Approx. 1370 kg (3020 lbs) depending on configuration

Gross Vehicle Weight Rating:

Approx. 1850 kg (4079 lbs)

🛡️ Safety Features

Ratings

Crash Test Standards Era:

Vehicles of this era were tested to different standards than modern vehicles. Focus was on occupant protection with known engineering principles.

Active Features

Braking System:

Front disc, rear drum with dual hydraulic circuits.

Steering Design:

Recirculating ball steering system, often with optional power assist.

Passive Features

Seatbelts:

Standard front seat belts, with optional rear seat belts.

Body Construction:

Reinforced passenger safety cell with crumple zones.

Windshield:

Laminated safety glass.

💡 Technology Features

Infotainment

Infotainment System:

Basic; typically includes an AM/FM radio, often with an 8-track player or cassette deck as an option. Analog gauges for instrumentation.

Driver Assistance

Driver Assistance Features:

Minimal by modern standards. Features like power steering (optional) and cruise control (optional) were the primary aids.

Connectivity

Connectivity Options:

None by modern definition; pre-dates widespread electronic connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000 - 7,500 miles (8,000 - 12,000 km) or annually.

Air Filter Replacement:

Every 15,000 - 20,000 miles (24,000 - 32,000 km).

Fuel Filter Replacement:

Every 10,000 - 15,000 miles (16,000 - 24,000 km) or as needed, critical for diesel systems.

Transmission Fluid Change Manual:

Recommended check every 30,000 miles (48,000 km), change as needed or at higher mileage intervals.

Transmission Fluid Change Automatic:

Typically every 20,000 - 30,000 miles (32,000 - 48,000 km), including torque converter flush.

Coolant Flush:

Every 2-3 years or 30,000 miles (48,000 km).

Fluid Specifications

Engine Oil Specification:

API CD or newer, SAE 15W-40 or 10W-40 diesel engine oil (refer to manual for specific ambient temperature recommendations).

Engine Oil Capacity:

Approx. 6.5 Liters (6.9 US Quarts) with filter change.

Transmission Fluid Type Manual:

GL-4 SAE 80W-90 or SAE 75W-90 gear oil.

Transmission Fluid Type Automatic:

MB Specification 236.2 (Dexron II equivalent).

Brake Fluid Type:

DOT 3 or DOT 4.

Coolant Type:

Ethylene Glycol based antifreeze, typically a 50/50 mix with distilled water. Consult manual for specific MB specification.

Known Issues

Diesel Injector Pump:

Potential for wear in the Bosch VE injection pump, requiring rebuild or replacement.

Glow Plug System:

Failure of glow plugs or associated relays can cause hard starting, especially in cold weather.

Rear Axle Seals:

Leaking axle shaft seals are a common wear item.

Vacuum Lines:

Aging and brittle vacuum lines can lead to issues with central locking, climate control, and engine performance.

Rust Perforation:

Common on older Mercedes-Benz models, particularly around wheel arches, sills, and the battery tray area.

Transmission Clunk:

Worn U-joints or differential mounts can cause clunking noises during acceleration or deceleration.

📚 Vehicle History

Brand Heritage

Mercedes Benz Legacy:

Renowned for engineering excellence, luxury, and durability since the late 19th century.

Model Evolution

W123 Development:

The W123 succeeded the W114/W115 and was a significant step forward in design and engineering, cementing Mercedes-Benz's reputation for robustness.

240D Positioning:

The 240D represented the entry-level diesel offering in the W123 lineup, prioritizing fuel efficiency and long-term reliability over outright performance.

Production

W123 Production Years:

1976-1985 (Sedan/Coupe), 1977-1985 (Estate/Wagon), 1979-1985 (Limousine)

Production Locations:

Primarily Sindelfingen, West Germany, with some assembly in other global locations.

🏆 Awards & Recognition

Recognitions

Vehicle Reputation:

The W123 series is widely regarded as one of the most durable and reliable Mercedes-Benz models ever produced, often referred to as 'tank-like'.

Model Longevity:

Many W123 models are still in regular service globally, testament to their robust engineering and the availability of good service documentation.