Mercedes 408 Service Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: 408 Codes Chassis Code: VB3 Engine Code Prefix: OM615 👋 Introduction Market Position Segment: Light Commercial Vehicle (LCV) / Van Target Audience: Businesses,...

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

Codes

Chassis Code:

Engine Code Prefix:

OM615

👋 Introduction

Market Position

Segment:

Light Commercial Vehicle (LCV) / Van

Target Audience:

Businesses, tradespeople, and fleet operators requiring reliable and robust transportation.

Competitive Analysis

Competitors:

Ford Transit, Volkswagen Transporter, Fiat Ducato, Renault Master (during its production era).

Key Features

Durability:

Renowned for Mercedes-Benz build quality and long-term durability.

Versatility:

Available in various body styles (panel van, chassis cab) catering to diverse needs.

Powertrain Options:

Primarily diesel engines, offering fuel efficiency and torque for hauling.

📋 Manual Details

Coverage Areas

Diagnostic Procedures:

Comprehensive diagnostic procedures for all major vehicle systems.

Repair Instructions:

Step-by-step repair instructions for mechanical, electrical, and body components.

Maintenance Schedules:

Detailed maintenance schedules and recommended service intervals.

Troubleshooting Guides:

Extensive troubleshooting guides for common and uncommon issues.

Wiring Diagrams:

Complete electrical wiring diagrams for all vehicle circuits.

Component Locations:

Diagrams illustrating the location of key components.

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

All aspects of engine operation, overhaul, and diagnostics (including diesel injection).

Transmission:

Manual transmission service, repair, and adjustment.

Drivetrain:

Clutch, driveshafts, differential, and axle service.

Suspension:

Front and rear suspension systems, shock absorbers, springs, and alignment.

Steering:

Steering gear, linkage, and power steering system (if applicable).

Brakes:

Hydraulic brake system, disc and drum brake service, parking brake.

Electrical:

Battery, starting system, charging system, ignition system, lighting, instrumentation, and accessories.

Fuel System:

Fuel tank, lines, filters, and diesel injection pump/injector service.

Cooling System:

Radiator, thermostat, water pump, and coolant specifications.

Exhaust System:

Muffler, catalytic converter (if applicable), and pipe replacement.

Body And Chassis:

Body panel repair, interior trim, door mechanisms, and chassis components.

Procedures Included

Preventive Maintenance:

Oil changes, filter replacements, fluid checks, belt inspections, and lubrication points.

Engine Rebuild:

Complete engine disassembly, cleaning, inspection, and reassembly procedures.

Transmission Overhaul:

Detailed steps for transmission disassembly, repair, and reassembly.

Brake System Repair:

Brake pad/shoe replacement, caliper/wheel cylinder service, and brake bleeding.

Electrical Component Replacement:

Instructions for replacing alternators, starters, ignition coils, sensors, etc.

Diagnostic Troubleshooting:

Systematic approach to diagnosing issues based on symptoms and fault codes.

Body Panel Alignment:

Procedures for adjusting doors, hoods, and fenders for proper fit.

Fluid Flush And Replacement:

Correct procedures for replacing coolant, brake fluid, transmission fluid, etc.

Technical Depth

Depth:

Expert-level detail suitable for professional mechanics and advanced DIY enthusiasts.

Diagnostic Tools:

Reference to specific tools and diagnostic equipment where applicable.

Torque Specifications:

Precise torque values for all critical fasteners.

Clearances And Tolerances:

Detailed specifications for component clearances and wear tolerances.

📊 Manual Specifications

File Format

Type:

Searchability:

Text-searchable for quick information retrieval.

Printability:

Printable pages for workshop use.

Print Quality

Image Resolution:

High-resolution images and diagrams.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Description:

Naturally aspirated indirect injection diesel engines.

Displacement Liters:

2.3L (2304 cc)

Configuration:

Inline 4-cylinder

Fuel Type:

Diesel

Horsepower Approx:

60-70 HP (depending on specific variant)

Torque Approx:

120-135 Nm (depending on specific variant)

Performance

Emissions Standards:

Pre-Euro emissions standards.

Fuel System

Injection Type:

Indirect Injection (IDI) with Bosch or similar injection pump.

Fuel Filter:

Spin-on diesel fuel filter, typically replaced at service intervals.

Glow Plugs:

Essential for cold starting, with specific replacement procedures.

🔧 Transmission

Standard

Type:

4-speed Manual Transmission

Optional

Type:

5-speed Manual Transmission (available on later models or specific configurations).

Features

Clutch:

Single dry plate clutch, hydraulic actuation.

Fluid Type:

GL-4 Gear Oil (e.g., SAE 75W-90 or SAE 80W-90, specific OEM recommendation preferred).

📐 Dimensions

Exterior

Length Mm Approx:

4600-5000

Width Mm Approx:

1900-2000

Height Mm Approx:

1900-2200

Weights

Gvwr Kg Approx:

2800-3500

Curb Weight Kg Approx:

1800-2000

🛡️ Safety Features

Ratings

Crash Test Data:

Limited public crash test data available due to vehicle classification and era; focus on inherent Mercedes-Benz engineering standards.

Active Features

Brakes:

Hydraulic dual-circuit braking system, front discs, rear drums.

Steering Assist:

Optional power steering on some variants.

Passive Features

Seatbelts:

Three-point seatbelts in the front, lap belts for passengers.

Structural Integrity:

Robust body-on-frame or unibody construction typical of the era, designed for commercial duty.

💡 Technology Features

Infotainment

Radio:

Basic AM/FM radio, often with cassette player as an option.

Speakers:

Typically 2-4 basic speakers.

Driver Assistance

Anti-lock Braking System (ABS) was an optional feature on later models.

Power Steering:

Optional on many variants, significantly improving low-speed maneuverability.

Connectivity

Bluetooth:

Not available in original factory specification; aftermarket upgrades are common.

🔧 Maintenance

Service Intervals

Oil Change:

Every 5,000 - 10,000 km or annually, whichever comes first (check manual for specific recommendation).

Fuel Filter Replacement:

Every 15,000 - 30,000 km.

Air Filter Replacement:

Every 10,000 - 20,000 km or as needed based on operating conditions.

Coolant Flush:

Every 2-3 years or 40,000-60,000 km.

Fluid Specifications

Engine Oil:

API CD or higher, SAE 15W-40 Diesel Engine Oil is common (verify specific grade).

Coolant:

Ethylene glycol based coolant (e.g., G48 or equivalent) mixed 50/50 with distilled water.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Known Issues

Rust Corrosion:

Common in older vehicles, particularly wheel arches, sills, and door bottoms. Requires regular inspection and treatment.

Diesel Injection System:

Potential wear in injection pumps and injectors, requiring specialized servicing. Glow plug reliability can vary.

Suspension Wear:

Ball joints, bushings, and shock absorbers can wear over time, affecting ride and handling.

Electrical Contact Issues:

Corrosion on electrical connectors can lead to intermittent faults in lighting and accessories.

📚 Vehicle History

Brand Heritage

Heritage:

Mercedes-Benz, a pioneer in automotive engineering, established a reputation for robust commercial vehicles long before the 408.

Model Evolution

Generation Timeline:

Part of the Mercedes-Benz TN (Transporter) platform which evolved through various iterations, including the T1 series.

Production

Production Period:

Late 1970s to early 1990s.

Manufacturing Locations:

Primarily Germany.

🏆 Awards & Recognition

Recognitions

Reputation:

Recognized for its workhorse reliability and longevity in commercial applications.

Ratings

Tuv Approval:

Many units were subject to stringent German TUV inspections, indicating a baseline of quality.

Certifications

Commercial Vehicle Standards:

Built to meet demanding commercial vehicle operational standards of its era.