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Mercedes Benz W116 450 SEL 1973-1980 Repair Service Manual

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This manual covers the 450 SEL, chassis code W116, produced from 1973 to 1980. The W116 was the inaugural model designated as an S-Class, signifying its position as a benchmark...
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Type: Car
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Sku: 69993
Mercedes Benz W116 450 SEL 1973-1980 Repair Service ManualMercedes Benz W116 450 SEL 1973-1980 Repair Service ManualMercedes Benz W116 450 SEL 1973-1980 Repair Service ManualMercedes Benz W116 450 SEL 1973-1980 Repair Service Manual
This manual covers the 450 SEL, chassis code W116, produced from 1973 to 1980. The W116 was the inaugural model designated as an S-Class, signifying its position as a benchmark in executive sedan engineering. Featuring a robust V8 SOHC 4.5-liter engine paired with an automatic transmission, the 450 SEL was engineered for comfort, performance, and durability. Its long-wheelbase configuration provided exceptional interior space, reflecting a renowned commitment to luxury and advanced technology for its time, including features like automatic climate control and four-wheel disc brakes. This comprehensive workshop repair service manual is designed for W116 450 SEL owners and independent repair professionals. It provides in-depth coverage of all engine variants, transmission types, and trim levels across the 1973, 1974, 1976-1980 model years. The manual details general maintenance, periodic lubrication, disassembly and assembly procedures, and cleaning/reinstallation techniques. It includes extensive troubleshooting guides, advanced diagnostic procedures, and hundreds of illustrations and wiring diagrams for all major vehicle systems, including the engine, transmission, brakes, electrical, suspension, steering, cooling, fuel injection, and climate control.
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
450 SEL
Chassis Code:
W116
Production Years:
1973-1980
Generation
Generation Code:
First Generation W116
👋 Introduction
Market Position
Target Audience:
Mercedes-Benz W116 450 SEL owners and independent repair shops seeking comprehensive technical information.
Competitive Analysis
Value Proposition:
Provides factory-level repair data, enabling significant cost savings on maintenance and repairs compared to dealership services.
Key Features
Authenticity:
Original Mercedes-Benz workshop manual used by local service/repair shops.
Completeness:
Complete and intact, with no missing or corrupt parts/pages.
User Friendliness:
Easy-to-follow directions, numbered instructions, and bold figure numbers for quick reference.
Digital Advantage:
Convenience of digital format for easy searching, printing specific sections, and staying clean.
📋 Manual Details
Coverage Areas
Covered Years:
1973, 1974, 1976, 1977, 1978, 1979, 1980
Covered Models:
All W116 450 SEL models
Covered Engines:
All engine variants for the 450 SEL
Covered Transmissions:
All transmission types for the 450 SEL
Covered Trims:
All trim levels for the 450 SEL
Page Count
Estimated Page Count:
Hundreds of pages (typical for a comprehensive workshop manual)
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Service And Repair:
Detailed procedures for engine overhaul, component replacement, tuning, and diagnostics.
Transmission Service And Repair:
Comprehensive coverage of automatic transmission removal, installation, repair, and adjustment.
Brake System:
Maintenance, repair, and diagnostics for hydraulic and pneumatic brake systems, including ABS if applicable to late models.
Electrical System:
Detailed diagnostics and repair procedures for all electrical components, including wiring diagrams.
Suspension:
Service and repair of front and rear suspension systems, including shock absorbers, springs, and control arms.
Steering:
Maintenance and repair of the power steering system, steering column, and steering linkages.
Cooling System:
Radiator, fan, water pump, and thermostat service, including flush and refill procedures.
Fuel Injection Fuel System:
Detailed information on the Bosch K-Jetronic fuel injection system, including fuel pump, injectors, and pressure regulators.
Emission System:
Information on emission control components and troubleshooting.
Heater Air Conditioning:
Service and repair of HVAC systems, including refrigerant handling and component replacement.
Engine Control System:
Diagnostics and repair of the engine management unit and associated sensors.
Chassis Body:
Body repair, panel replacement, and chassis maintenance.
Restraint System:
Information on seatbelts and associated components.
Interior:
Trim removal and installation, upholstery, and interior component service.
Differential Drive Axle:
Service and maintenance of the rear axle and differential.
Procedures Included
General Maintenance:
Routine checks, fluid changes, filter replacements, and lubrication.
Troubleshooting:
Systematic diagnosis of common and uncommon problems with step-by-step guides.
Periodic Lubrication:
Detailed lubrication points and schedules.
Disassembly Assembly:
Step-by-step instructions for removing and reassembling vehicle components.
Cleaning Reinstalling:
Procedures for cleaning parts before reassembly and proper installation techniques.
Technical Depth
Depth Of Coverage:
Complete professional-level repair and maintenance information, identical to factory service manuals.
Diagnostic Capabilities:
Advanced diagnostic procedures for all major vehicle systems.
Illustrations Diagrams:
Hundreds of detailed illustrations, drawings, photos, and wiring diagrams.
📊 Manual Specifications
File Format
Format:
PDF
Accessibility Features:
Zoom IN/OUT functionality
Print Quality
Printability:
Full Printable
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Delivery
Delivery Method:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader, WinZip
Compatibility:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Type:
V8 SOHC (M117)
Displacement:
4.5 Liters (4520 cc)
Performance
Horsepower Approx:
230 hp @ 5000 rpm (varies by market and year)
Torque Approx:
380 Nm (280 lb-ft) @ 3000 rpm (varies by market and year)
Fuel System
Fuel Delivery:
Bosch K-Jetronic (CIS) Fuel Injection
Recommended Fuel:
Unleaded Gasoline (Octane rating varies by market, consult manual for specifics)
Cooling System
Coolant Capacity:
Approximately 12.5 Liters (13.2 US Quarts)
🔧 Transmission
Standard
Type:
3-speed Automatic (3HP22)
Optional
Type:
4-speed Automatic (e.g., 4G-Tronic, introduced later in the W116 production run for some models)
Features
Fluid Type:
Dexron-III (or equivalent ATF, consult manual for exact specification)
📐 Dimensions
Exterior
Length:
Approx. 5085 mm (199.8 in)
Width:
Approx. 1830 mm (72.0 in)
Height:
Approx. 1430 mm (56.3 in)
Weights
Curb Weight Approx:
Approx. 1800 kg (3968 lbs)
🛡️ Safety Features
Ratings
Safety Standards:
Designed to meet 1970s automotive safety standards.
Active Features
Brakes:
Four-wheel disc brakes (ventilated front)
Passive Features
Structure:
Reinforced body structure, crumple zones.
Restraints:
Three-point seat belts (front and rear).
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM radio with cassette player (or optional multi-speaker systems).
Driver Assistance
Cruise Control:
Standard on many models.
Climate Control:
Automatic climate control system with vacuum-actuated actuators.
Connectivity
Connectivity Features:
Limited to period-appropriate features; no modern digital connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000-15,000 km (6,000-9,000 miles) or 12 months, refer to specific manual for exact intervals.
Transmission Fluid Change:
Recommended at 40,000-80,000 km (25,000-50,000 miles), depending on driving conditions.
Fluid Specifications
Engine Oil Specification:
Refer to manual for specific API service classification and viscosity grade (e.g., 10W-40, 15W-40, or synthetic equivalents based on climate).
Coolant Specification:
Mercedes-Benz approved antifreeze/coolant concentrate (e.g., G05 or equivalent, mixed with distilled water).
Brake Fluid Specification:
DOT 4 Brake Fluid (typically).
Known Issues
Common Wear Items:
Rubber hoses and bushings prone to aging, vacuum lines for climate control, fuel distributor diaphragm, ignition components.
Potential Problems:
Fuel injection system adjustments, climate control system leaks, window regulator mechanisms, rust on body panels in certain climates.
📚 Vehicle History
Brand Heritage
Manufacturer Legacy:
Mercedes-Benz is renowned for its engineering excellence, luxury, and safety innovations since its inception.
Model Evolution
W116 Significance:
The W116 was the first Mercedes-Benz model to be officially designated an 'S-Class' (Sonderklasse - Special Class), setting a new standard for executive sedans.
450 Sel Positioning:
The 450 SEL was the long-wheelbase version, offering enhanced rear passenger space and luxury.
Production
Production Period:
1972-1980
Manufacturing Plant:
Various Mercedes-Benz plants (primarily Sindelfingen, Germany)
🏆 Awards & Recognition
Recognitions
General Reputation:
The W116 S-Class established Mercedes-Benz as a leader in automotive luxury, safety, and engineering during its era.
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