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Mercedes 350 SDL Turbo 1990-1991 Service Repair Manual
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🏷️ Basic Information Identification Make: Mercedes-Benz Model: 350 SDL Turbo Year: 1990-1991 Codes Chassis Code: W126 Engine Code: OM603.960 👋 Introduction Market Position Market Positioning: The Mercedes-Benz 350 SDL Turbo...
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🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
350 SDL Turbo
Year:
1990-1991
Codes
Chassis Code:
W126
Engine Code:
OM603.960
👋 Introduction
Market Position
Market Positioning:
The Mercedes-Benz 350 SDL Turbo was a flagship luxury diesel sedan known for its robust engineering, comfort, and fuel efficiency, appealing to executives and those seeking long-distance touring capabilities.
Competitive Analysis
Competitors:
Competed against other premium diesel sedans of the era, such as BMW's 7 Series diesel variants and other European luxury marques offering comparable diesel powertrains.
Key Features
Unique Selling Points:
Powerful yet efficient turbodiesel engine, signature Mercedes-Benz build quality, advanced safety features for its time (like ABS), and a spacious, luxurious interior.
Luxury Appointments:
Plush leather seating, wood trim, power-adjustable front seats, and ample rear legroom.
📋 Manual Details
Coverage Areas
Covered Systems:
• Engine (Diesel)
• Fuel System
• Cooling System
• Exhaust System
• Turbocharger System
• Transmission (Automatic)
• Drivetrain
• Suspension
• Steering System
• Brake System (ABS)
• Electrical System
• Climate Control
• Body and Chassis
• Interior Components
• Diagnostic Procedures
Wiring Diagrams:
Includes detailed electrical wiring diagrams for all vehicle systems.
Diagnostic Codes:
Covers diagnostic procedures and potential fault codes related to engine management, ABS, and other electronic systems.
Page Count
Page Count:
Highly Detailed (Exact count not provided, but described as comprehensive)
Manual Type
Manual Type:
Factory Service and Repair Manual
Language
Language:
English
Format
Format:
Likely Printed or Digital (PDF) - assuming typical for sales business
📖 Manual Coverage
Systems Covered
Engine Maintenance:
Detailed procedures for oil changes, filter replacements, valve adjustments, glow plug service, and component inspection.
Fuel System Repair:
In-depth coverage of injection pump removal/installation, injector testing, fuel filter replacement, and troubleshooting fuel delivery issues.
Cooling System Service:
Radiator, water pump, thermostat, coolant hoses, and fan clutch replacement and testing.
Turbocharger Diagnostics:
Turbocharger system checks, wastegate adjustment, intercooler inspection, and common failure diagnosis.
Transmission Overhaul:
Procedures for automatic transmission fluid and filter changes, valve body inspection, and complete rebuild steps.
Brake System Overhaul:
Brake pad and rotor replacement, caliper servicing, ABS system component testing, and bleeding procedures.
Electrical Troubleshooting:
Wiring diagrams, component testing, fuse/relay identification, and common electrical fault diagnosis.
Climate Control Repair:
Refrigerant system servicing, blower motor replacement, HVAC control module testing, and cabin filter replacement.
Body And Chassis Repair:
Panel alignment, door and window regulator service, bumper repair, and chassis component inspection.
Procedures Included
Diagnostic Procedures:
Comprehensive diagnostic trees, symptom-based troubleshooting, and fault code interpretation (if applicable).
Rebuilding Procedures:
Detailed instructions for engine, transmission, and major component rebuilds.
Routine Maintenance:
Scheduled maintenance tasks, fluid checks, and component inspections with recommended intervals.
Component Replacement:
Step-by-step guides for replacing virtually every serviceable component.
Technical Specifications:
Torque values, clearances, fluid capacities, and electrical resistance values.
Troubleshooting Guides:
Extensive troubleshooting sections based on symptoms, helping to pinpoint the root cause of problems.
Special Tool Requirements:
Identifies and explains the use of any specialized tools required for specific repairs or diagnostics.
Technical Depth
Depth Of Coverage:
Expert-level detail suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic fluid changes to complete engine and transmission overhauls.
📊 Manual Specifications
File Format
File Format Quality:
Likely searchable text for digital versions, high-resolution scans for PDFs. Assumed to be optimized for ease of use.
Print Quality
Print Quality:
High-quality paper, clear diagrams, and easy-to-read text if printed. (Assumption for quality sales)
Binding Type
Binding Type:
Likely perfect bound or spiral bound for ease of use in a workshop environment. (Assumption for quality sales)
Paper Type
Paper Type:
Durable, possibly coated paper to withstand workshop conditions. (Assumption for quality sales)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 6-Cylinder Turbodiesel
Engine Displacement:
3.5 Liters (3449 cc)
Bore X Stroke:
90.0 mm x 89.0 mm
Compression Ratio:
22.0:1
Horsepower:
Approx. 148 hp @ 4200 rpm (DIN)
Torque:
Approx. 273 lb-ft (370 Nm) @ 2400 rpm (DIN)
Engine Block Material:
Cast Iron
Cylinder Head Material:
Aluminum Alloy
Fuel System
Fuel Delivery:
Bosch inline mechanical injection pump with turbocharging and intercooling.
Fuel Type:
Diesel
Cooling System
Cooling Capacity:
Approx. 11.4 Liters (12.1 US Quarts)
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic (722.3 Series)
Transmission Fluid Type:
Mercedes-Benz Specification 236.1 (e.g., MB 3473 ATF)
Features
Transmission Features:
Lock-up torque converter for improved fuel efficiency at cruising speeds.
📐 Dimensions
Exterior
Length:
Approx. 5011 mm (197.3 in)
Width:
Approx. 1795 mm (70.7 in)
Height:
Approx. 1410 mm (55.5 in)
Wheelbase:
Approx. 2936 mm (115.6 in)
Weights
Curb Weight:
Approx. 1750 kg (3858 lbs)
Gross Vehicle Weight Rating:
Approx. 2200 kg (4850 lbs)
🛡️ Safety Features
Ratings
ABS Availability:
Standard
Active Features
Braking System:
Four-wheel disc brakes with ABS.
Passive Features
Airbags:
Driver's side airbag standard for 1990/1991 models. Passenger airbag optional or introduced later in the generation.
Seatbelts:
Three-point front and rear seatbelts with pre-tensioners for front occupants.
Chassis Construction:
Reinforced safety cell with crumple zones.
💡 Technology Features
Infotainment
Infotainment System:
Typically featured a premium audio system with AM/FM radio and cassette player. CD changers were an option on later models.
Climate Control Technology:
Automatic climate control (THERMATIC) was standard or optional, offering precise temperature regulation.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was a significant safety feature for its era.
Cruise Control:
Standard cruise control system for effortless highway driving.
Connectivity
Connectivity Features:
Limited by modern standards; focused on internal vehicle systems and optional telephone installations.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first, using synthetic diesel engine oil meeting MB 229.5 or equivalent.
Fuel Filter Replacement:
Recommended every 30,000 km (18,600 miles).
Air Filter Replacement:
Recommended every 30,000 km (18,600 miles) or as needed based on operating conditions.
Coolant Flush Interval:
Every 2-3 years or 40,000-60,000 km (25,000-37,000 miles).
Fluid Specifications
Engine Oil Specification:
API CD or higher, MB-Approval 228.1, 228.3, or 229.1 (or later appropriate spec for synthetic). Viscosity commonly 15W-40 or 5W-40 synthetic.
Coolant Type:
MB Specification 325.0 (Glycol-based coolant, typically a 50/50 mix with distilled water).
Brake Fluid Type:
DOT 4
Power Steering Fluid:
MB Specification 236.3 (e.g., Pentosin CHF 11 S or equivalent).
Differential Fluid:
API GL-5, SAE 80W-90.
Known Issues
Common Wear Items:
Engine mounts, suspension bushings, exhaust manifold gaskets, vacuum lines, and the SRS (Supplemental Restraint System) control unit can be prone to wear.
Diesel Specific Concerns:
Glow plug system reliability, injection pump seals, and potential injector issues can arise with age and mileage.
Electrical Gremlins:
The complex electrical system can sometimes develop issues related to wiring harnesses, relays, and control modules.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mercedes-Benz has a long-standing reputation for engineering excellence, safety, and luxury, particularly in its diesel offerings which were popular in Europe and gained traction in North America for their durability and economy.
Model Evolution
Model Lineage:
The 350 SDL Turbo is part of the W126 S-Class generation, known for its advanced technology and refined ride. The 'SDL' designation specifically indicated a long-wheelbase sedan with a diesel engine.
Production
Production Period:
The W126 S-Class was produced from 1979 to 1991. The 350 SDL Turbo variant was introduced later in this lifecycle.
Manufacturing Location:
Primarily Sindelfingen, Germany.
🏆 Awards & Recognition
Recognitions
Industry Recognition:
The W126 S-Class generation consistently received accolades for its engineering, comfort, and safety from automotive publications worldwide.
Ratings
Safety Ratings:
While formal crash test ratings like modern NHTSA or Euro NCAP were not as prevalent or standardized, Mercedes-Benz vehicles of this era were designed to exceptionally high safety standards, often exceeding contemporary requirements.