Engine:
Detailed coverage of all gasoline (M114, M115) and diesel (OM601, OM602, OM615, OM616) engines, including overhaul, timing, fuel injection systems, lubrication, cooling, and exhaust.
Transmission:
Manual and automatic transmission service, repair, overhaul, clutch, and drive shaft components.
Brakes:
Hydraulic brake system (front discs, rear drums), parking brake, brake fluid, master cylinder, wheel cylinders, calipers, and ABS if applicable to later variants.
Suspension:
Front independent suspension (double wishbone), rear semi-trailing arm suspension, shock absorbers, springs, ball joints, bushings, and steering components.
Electrical:
Complete electrical system, wiring diagrams, ignition system, starting system, charging system (alternator/generator), lighting, instrumentation, fuses, relays, and accessories.
Body:
Body shell construction, door mechanisms, window regulators, trim, bumpers, glass replacement, interior components, and underbody protection.
HVAC:
Heating system, ventilation, and optional air conditioning system diagnosis and repair.
Maintenance:
Routine maintenance schedules, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, tune-ups, and belt adjustments.
Repair:
Detailed step-by-step repair procedures for all major mechanical and electrical components, including engine rebuilds, transmission overhaul, brake caliper replacement, suspension arm replacement, and electrical component diagnostics.
Troubleshooting:
Diagnostic charts and troubleshooting guides for common and uncommon problems, helping to identify causes and solutions.
Diagnostics:
Procedures for diagnosing faults in the engine, fuel, ignition, electrical, and mechanical systems.
Adjustments:
Precise specifications and procedures for adjusting valve clearances, ignition timing, carburetor settings, idle speed, and clutch pedal free play.
Fuel System Repair:
Detailed procedures for carburetor overhaul and adjustment, fuel pump replacement, fuel line repair, and fuel tank cleaning/servicing.
Ignition System Diagnosis:
Step-by-step troubleshooting for ignition timing, distributor, coil, spark plugs, and wiring for reliable starting and running.
Cooling System Maintenance:
Radiator, water pump, thermostat, hoses, and fan clutch inspection, replacement, and coolant flush procedures.
Steering And Suspension Alignment:
Specifications and procedures for wheel alignment, tie rod end replacement, ball joint inspection, and bushing replacement.
Electrical Component Replacement:
Guides for replacing starter motors, alternators, voltage regulators, wiper motors, headlights, and dashboard instruments.
Depth Level:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, suitable for professional mechanics and experienced DIY enthusiasts.
Engine Rebuild:
Includes detailed specifications for bore, hone, piston ring gap, bearing clearances, and torque sequences for complete engine overhauls.
Transmission Rebuild:
Procedures for disassembling, inspecting, and reassembling manual and automatic transmissions, including gear replacement and seal installation.
Bodywork Repair:
Information on body panel alignment, rust repair techniques, and interior trim component removal/installation.
Wiring Diagrams:
Full vehicle wiring schematics for all major electrical systems, crucial for diagnosis and repair.
Gasoline Options:
M114: 2.3L inline-6 (114.980), M115: 2.0L inline-4 (115.912, 115.914), 2.3L inline-4 (115.917)
Diesel Options:
OM601: 2.0L inline-4 diesel (W115 variant), OM615: 2.2L inline-4 diesel (60 hp), OM616: 2.4L inline-4 diesel (65 hp), later OM615.940 2.0L and OM616.912 2.2L diesel engines.
Horsepower Range:
Approx. 90 hp (2.0L diesel) to 140 hp (2.5L gasoline).
Torque Range:
Approx. 120 lb-ft (2.0L diesel) to 150 lb-ft (2.5L gasoline).
Gasoline Induction:
Carburetor (e.g., Solex, Zenith) for most models; fuel injection (Bosch D-Jetronic or similar) on some later or higher-performance variants.
Diesel Injection:
Bosch inline injection pump.
Block Material:
Cast Iron
Head Material:
Aluminum Alloy
Type:
Water Cooled, Thermostatic Control
Oil Change Interval:
Typically every 5,000 - 8,000 km (3,000 - 5,000 miles) or 6-12 months, depending on driving conditions and oil used.
Tune Up Interval:
Spark plugs, ignition points, and condenser every 10,000 - 20,000 km (6,000 - 12,000 miles). Valve adjustment as per manual (e.g., 15,000 - 25,000 km).
Engine Oil:
API SF/SG or equivalent. Viscosity: 10W-40, 15W-40, or 20W-50 depending on climate. (Consult manual for precise MB specs).
Coolant:
Ethylene glycol based antifreeze/coolant. 50/50 mix with distilled water recommended. Capacity varies by engine (approx. 6-8 liters).
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Transmission Fluid Auto:
Dexron II or equivalent automatic transmission fluid (ATF).
Transmission Fluid Manual:
GL-4 Hypoid gear oil, SAE 80W-90.
Differential Fluid:
GL-5 Hypoid gear oil, SAE 80W-90.
Common Problems:
Rust (particularly wheel arches, sills, underbody), aging rubber components (bushings, hoses, mounts), vacuum leaks, carburetor issues, fuel system deterioration (especially with ethanol in fuel), potential overheating if cooling system is neglected, wear in suspension and steering components.