Engine Management:
Detailed diagnostics and repair for the OM617 turbocharged diesel engine, including fuel injection system, glow plug system, turbocharger, exhaust gas recirculation (EGR) where applicable.
Transmission Manual:
Repair and overhaul procedures for manual transmissions (4-speed and 5-speed options).
Transmission Automatic:
Service and repair for automatic transmissions (e.g., 3-speed 722.3, 4-speed 722.4), including adjustments and troubleshooting.
Suspension Steering:
Front and rear suspension components (independent front, semi-trailing arm rear), steering system (power steering), shock absorbers, springs, ball joints, tie rods.
Braking System:
Hydraulic brake system, including master cylinder, brake lines, calipers, brake pads, rotors, rear drum brakes, parking brake system.
Electrical System:
Comprehensive wiring diagrams, starter motor, alternator, battery system, lighting, ignition system (pre-glow), gauges, switches, fuses, relays.
Fuel System:
Diesel fuel injection pump (Bosch VE), injectors, fuel lines, fuel filters, lift pump, fuel tank, troubleshooting.
Cooling System:
Radiator, coolant hoses, thermostat, water pump, cooling fan, fan clutch, heater core, troubleshooting.
Exhaust System:
Exhaust manifold, catalytic converter (if equipped), muffler, tailpipe, hangers, troubleshooting.
Body Chassis:
Body panel removal and installation, door mechanisms, glass, seals, chassis lubrication, underbody.
HVAC System:
Heating, ventilation, and air conditioning (HVAC) system components, refrigerant charging, troubleshooting.
Scheduled Maintenance:
Detailed procedures for routine oil changes, filter replacements (oil, fuel, air), fluid checks and top-offs, tire rotation, brake inspection.
Engine Overhaul:
Complete engine rebuild procedures, including cylinder head removal and reconditioning, piston and connecting rod installation, crankshaft and bearing service, timing chain replacement.
Transmission Repair:
Step-by-step instructions for manual and automatic transmission disassembly, inspection, component replacement, and reassembly.
Brake System Repair:
Procedures for brake pad and rotor replacement, caliper overhaul, brake bleeding, master cylinder replacement, parking brake adjustment.
Suspension Component Replacement:
Ball joint replacement, tie rod end replacement, control arm bushing replacement, shock absorber and spring replacement.
Electrical Troubleshooting:
Diagnostic procedures for common electrical faults, using wiring diagrams to trace circuits, testing components like alternators, starters, and relays.
Fuel System Diagnostics:
Troubleshooting for starting issues, poor performance, and fuel leaks; procedures for injector testing, injection pump timing, and fuel filter replacement.
Turbocharger Service:
Inspection, installation, and troubleshooting of the turbocharger system, including boost pressure checks and intercooler (if equipped) servicing.
HVAC System Repair:
Refrigerant handling, compressor replacement, evaporator/condenser servicing, blower motor replacement, and system diagnostics.
Body Work Minor:
Procedures for minor body panel repairs, alignment, and replacement of trim pieces.
Depth:
Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds. Includes detailed torque specifications, diagnostic charts, and wiring diagrams.
Oil Change Interval:
Typically every 3,000-5,000 miles or 6 months for diesel engines, depending on driving conditions. Refer to manual for precise recommendation.
Fuel Filter Interval:
Recommended every 10,000-15,000 miles or annually, crucial for diesel engine health.
Air Filter Interval:
Recommended every 10,000-15,000 miles or as needed based on conditions.
Transmission Fluid Change Interval Auto:
Typically every 30,000-50,000 miles for automatic transmissions, though Mercedes-Benz's 'lifetime' fluid philosophy was emerging; manual specifies prudent intervals.
Engine Oil Capacity:
Approx. 7.5 liters (8 US quarts) with filter change.
Coolant Capacity:
Approx. 10 liters (10.6 US quarts) for the engine and radiator.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
MB 236.3 specification or equivalent ATF.
Known Issues Diesel:
Vacuum leaks affecting door locks and central locking, injector pump seals, timing chain wear (though generally robust), injector nozzle wear, potential overheating if cooling system is neglected, exhaust manifold cracks.
Known Issues General:
Rust (especially in wheel wells, rocker panels, and around windows), aging rubber hoses and seals, climate control unit issues, worn suspension bushings.
