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Mercedes Benz W124 1990-1995 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: W124 Model Generation: Second Generation (Facelifted) Production Years Covered: 1990-1995 Codes Chassis Code: W124 Internal Project Code: Project 124 👋 Introduction Market Position...
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Mercedes Benz W124 1990-1995 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
W124
Model Generation:
Second Generation (Facelifted)
Production Years Covered:
1990-1995
Codes
Chassis Code:
W124
Internal Project Code:
Project 124
👋 Introduction
Market Position
Historical Reputation:
The Mercedes-Benz W124 is renowned for its exceptional build quality, durability, and engineering excellence, often considered one of the last 'over-engineered' Mercedes-Benz models.
Competitive Analysis
Segment:
Executive Sedan/Coupe/Wagon/Cabriolet
Key Competitors:
BMW E34 5 Series, Audi V8 Quattro, Lexus LS400 (for flagship models).
Key Features
Design Philosophy:
Emphasis on robust construction, comfort, safety, and long-term reliability.
Manual Advantage:
Provides access to factory-level technical knowledge, empowering owners and independent mechanics to perform accurate repairs and maintenance, thereby preserving the vehicle's integrity and value.
📋 Manual Details
Coverage Areas
Primary Coverage:
All mechanical, electrical, and body repair and maintenance procedures for W124 models from 1990-1995.
Page Count
Estimated Page Count:
Hundreds (exact count not specified, but stated as comprehensive)
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
Digital Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, repair, tuning, and troubleshooting for gasoline and diesel variants.
Engine Management:
Fuel injection systems (KE-Jetronic, HFM), ignition systems, emissions control systems, and electronic control unit (ECU) diagnostics.
Transmission:
Manual and automatic transmission overhaul, repair, adjustments, and fluid specifications.
Drivetrain:
Driveshaft, differential, axle shafts, and wheel bearing service.
Suspension:
Front and rear suspension components, shock absorbers, springs, bushings, and alignment procedures.
Steering:
Power steering system, steering gear, linkages, and column repair.
Brakes:
Brake system components, hydraulic lines, ABS system troubleshooting and repair, disc and drum brake service.
Electrical System:
Wiring diagrams, battery, charging system, starter, lighting, power accessories, and fuse/relay identification.
Climate Control:
Air conditioning system servicing, heater core replacement, and climate control unit diagnostics.
Body And Interior:
Body panel repair, door mechanisms, window regulators, seat adjustments, trim removal, and restoration.
Safety Systems:
Seat belt mechanisms, airbag system (if applicable for late models), and passive safety features.
Procedures Included
Preventative Maintenance:
Scheduled maintenance, oil changes, filter replacements, tune-ups, and fluid level checks.
Diagnostic Procedures:
Systematic troubleshooting guides, fault code interpretation, and component testing.
Repair Instructions:
Step-by-step instructions for component removal, installation, and adjustment.
Overhaul Procedures:
Detailed instructions for complete engine and transmission rebuilds.
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems.
Torque Specifications:
Precise torque values for all fasteners and critical components.
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine/transmission overhauls and advanced electrical diagnostics.
Diagrams:
Hundreds of detailed photos and exploded diagrams illustrating procedures and component relationships.
Tool Requirements:
Includes specifications of special tools and equipment required for specific tasks.
📊 Manual Specifications
File Format
Compatibility:
Fully compatible with Windows and MAC operating systems.
Searchability:
Likely searchable due to PDF format, allowing quick access to information.
Print Quality
Printable:
Printable pages, either individual or the entire manual.
Binding Type
Digital Binding:
N/A (Digital download)
Paper Type
Digital Paper:
N/A (Digital format)
Licensing
Licensing Model:
Lifetime access, no expiry dates, no renewal fees, usable on multiple devices.
⚙️ Engine Specifications
Primary Engine
Engine Options:
Wide range including M102 (2.0L/2.3L I4), M103 (2.6L/3.0L I6), M104 (2.8L/3.2L I6), M111 (2.2L/2.3L I4 - later models), OM601 (2.0L Diesel I4), OM602 (2.5L/2.9L Diesel I5), OM603 (3.0L Diesel I6).
Performance
Power Output Range:
Approximately 94 hp (Diesel) to 275 hp (500E).
Torque Range:
Approximately 125 lb-ft (Diesel) to 354 lb-ft (500E).
Fuel System
Fuel Delivery Gasoline:
Mechanical fuel injection (KE-Jetronic) and later electronically controlled fuel injection (HFM - Hot Film Metering).
Fuel Delivery Diesel:
Indirect injection with Bosch inline or rotary injection pumps.
Engine Oil
Recommended Oil Viscosity:
Varies by engine and climate. Commonly 10W-40, 15W-40, or 10W-30 (e.g., MB-Approval 229.1 or 229.3 compliant synthetic oils often recommended for later models and longevity).
Oil Capacity:
Typically 5.5 to 7.5 liters depending on engine variant.
🔧 Transmission
Standard
Manual Transmission Variants:
4-speed and 5-speed manual transmissions were available on many models.
Optional
Automatic Transmission Variants:
4-speed (e.g., 722.4) and 5-speed (e.g., 722.5/722.6) automatic transmissions were common, with the 5-speed being a significant improvement.
Features
Automatic Transmission Features:
Some models featured a 'Sport/Economy' mode selector on the automatic transmission.
Fluid Specifications
Automatic Transmission Fluid Type:
Mercon/Dexron II or III compatible ATF (e.g., MB-Approval 236.1 or 236.2, depending on transmission variant). Specific checks are crucial.
📐 Dimensions
Exterior
Body Styles:
Sedan (Saloon), Coupe, Estate (T-model/Wagon), Convertible (A124).
Wheelbase Sedan:
2800 mm (110.2 inches)
Weights
Curb Weight Range:
Approximately 1400 kg to 1800 kg depending on body style and engine.
🛡️ Safety Features
Ratings
Historical Safety Focus:
W124 chassis incorporated advanced safety features for its era, including a very robust safety cell and crumple zones.
Active Features
ABS:
Anti-lock Braking System (ABS) was standard on many models from 1990 onwards, with a Bosch 2.0, 3.0, or 4.0 system depending on year and model.
Passive Features
Airbags:
Driver's airbag became optional and then standard on many models in the later part of the production run (from around 1991/1992 onwards).
Seatbelts:
Pyrotechnically tensioned front seatbelts were introduced on some models in this period.
💡 Technology Features
Infotainment
Audio Systems:
Factory fitted Becker or Blaupunkt radios with optional CD changers. Basic cassette players were common.
Driver Assistance
Cruise Control:
Often available as an option, providing basic speed regulation.
Connectivity
Telephony:
Some late models offered factory-installed car phone options.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000-15,000 km (6,000-9,000 miles) or 12 months, depending on engine oil type and driving conditions. Consult specific manual for exact intervals.
Transmission Fluid Interval:
Automatic transmission fluid and filter typically recommended for replacement every 40,000-60,000 km (25,000-37,000 miles).
Spark Plug Replacement:
Varies by plug type; platinum or iridium plugs can extend intervals significantly (e.g., 100,000 km).
Fluid Specifications
Coolant Type:
Glycol-based antifreeze with corrosion inhibitors. MB-Approval 325.0 or 325.3 (e.g., BASF Glysantin G48 or similar).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (MB-Approval 331.0 or 332.0). Always flush and replace every 2 years.
Known Issues
Wiring Harness:
Degradation of the engine wiring harness insulation (cracking, brittleness) is a common issue on W124s due to age and material composition.
Headliner:
Sagging headliner fabric is prevalent due to the adhesive failing over time.
Rust:
While generally well-built, areas prone to rust include wheel arches, rear quarter panels, sills, and around windows.
O-Ring Leaks:
Leaking engine oil cooler 'O'-rings and rear main crankshaft seal can be points of oil leakage.
Vacuum Lines:
Cracked or split vacuum lines can affect climate control, central locking, and engine idle.
📚 Vehicle History
Brand Heritage
Mercedes Benz Legacy:
The W124 lineage is a direct continuation of Mercedes-Benz's commitment to building durable, reliable, and sophisticated luxury vehicles.
Model Evolution
Facelift:
The 1990-1995 models represent the facelifted W124, featuring revised front and rear styling, updated interior trim, and new engine options (notably the M111 and M104 engines).
Production
Production Period:
Original W124 production ran from 1984 to 1997 (with the W210 E-Class arriving in 1995, overlapping production).
Notable Variants:
The high-performance '500E' (later E500) and 'E60 AMG' variants are legendary models within the W124 family.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
Widely praised by automotive journalists and critics upon release for its engineering, safety, and comfort. Often cited as a benchmark in its class.
Ratings
Reliability Perception:
Holds a strong reputation for long-term reliability and durability, often achieving high mileage with proper maintenance.
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