🏷️ Basic Information

Make:

Mercedes-Benz

Model:

200D

Model Code:

W123 (specific sub-models like 200 D)

Chassis Code:

W123

Generation Designation:

First Generation W123

Engine Code Family:

OM615 (for 2.0L Diesel)

👋 Introduction

Positioning:

The Mercedes-Benz W123 series, particularly the 200D, was positioned as a robust, reliable, and durable executive sedan known for its exceptional build quality and longevity, especially favored in markets valuing fuel efficiency and low running costs.

Competitors:

Competed with other European executive sedans like BMW's 5 Series (E12/E28), Audi 100, and Volvo 240 series. The 200D's diesel engine offered superior fuel economy compared to many gasoline counterparts.

Vehicle Highlights:

Exceptional build quality, renowned durability, spacious and comfortable interior, strong diesel engine reputation, and classic Mercedes-Benz styling.

Value For Owner:

Essential resource for owners seeking to maintain, repair, or restore their W123 200D, enabling cost-effective DIY maintenance and ensuring proper repair procedures are followed.

📋 Manual Details

Coverage Years:

1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985

Covered Models:

Mercedes-Benz 200D (W123 Series Sedans, Coupes, Estates, and Long Wheelbase Variants)

Estimated Page Count:

Approximately 800-1200 pages (typical for comprehensive service manuals of this era, actual may vary based on specific publisher and edition)

Manual Type:

Service and Repair Manual

Content Focus:

Comprehensive diagnostics, repair, maintenance, and overhaul procedures.

Language:

English

Format:

PDF Download (as indicated by 'Pdf Download')

📖 Manual Coverage

Engine Mechanical:

Complete overhaul, cylinder head, pistons, crankshaft, camshaft, timing, lubrication system, cooling system.

Engine Fuel System:

Injection pump (Bosch VE), injectors, fuel lines, glow plug system, fuel filter replacement.

Transmission Manual:

Clutch, gearbox overhaul, shifting mechanisms, fluid changes, driveshafts.

Transmission Automatic:

Overhaul of automatic transmission, hydraulic control, fluid changes, adjustments (if applicable to 200D variants).

Brakes:

Hydraulic system, master cylinder, wheel cylinders, brake calipers, brake pads/shoes, parking brake, bleeding procedures, ABS (if equipped on later models).

Steering:

Power steering system, steering box, tie rods, steering column, alignment specifications.

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, wheel bearing replacement, alignment.

Electrical System:

Battery, starter, alternator, ignition system (for gasoline variants, less relevant for 200D but general electrical coverage), lighting, wipers, horn, fuses, relays.

Body And Chassis:

Body panel repair, door mechanisms, interior trim, glass replacement, rust prevention, chassis lubrication.

HVAC:

Heating system, ventilation, air conditioning (if factory fitted), refrigerant charging, component replacement.

Preventative Maintenance:

Scheduled maintenance checks, oil changes, filter replacements, fluid top-offs, belt inspections, spark plug checks (for gasoline). Diesel specific: glow plug testing, fuel filter replacement.

Troubleshooting Diagnostics:

Systematic diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, electrical wiring diagrams with diagnostic paths.

Repair Overhaul:

Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major systems.

Special Tools:

Identification and usage instructions for specialized tools required for specific repair procedures.

Torque Specifications:

Detailed torque values for critical fasteners across all systems.

Depth Level:

Comprehensive (from basic fluid changes to full engine and transmission rebuilds).

Diagnostic Capability:

Advanced diagnostic procedures, including component testing and electrical circuit analysis.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable, allowing for quick location of specific information.

Print Quality:

Generally good to very good for digital scans of original factory manuals, including clear diagrams and schematics.

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

Naturally Aspirated Inline-4 Cylinder Diesel

Engine Code:

OM615.940 (typically)

Displacement:

1988 cc (2.0 Liters)

Bore X Stroke:

87.0 mm x 84.0 mm

Compression Ratio:

21.0:1 (approximate)

Horsepower Hp:

55-60 hp (approximate, varies by market and specific variant)

Torque Lb Ft:

81-85 lb-ft (approximate, varies by market and specific variant)

Fuel Injection:

Bosch VE (Variable Speed) Rotary Injection Pump, Indirect Injection

Fuel Type:

Diesel Fuel

Coolant Capacity:

Approximately 8.0 - 9.0 Liters (check specific manual for exact)

Oil Capacity Liters:

Approximately 6.0 - 6.5 Liters (with filter, check manual)

Recommended Oil Viscosity:

API CD or CE rated Diesel Oil, SAE 15W-40 or 10W-30 depending on climate (refer to manual for precise recommendations)

Glow Plug Type:

Pre-combustion chamber glow plugs, typically requiring a 5-15 second heat-up time.

🔧 Transmission

Standard Transmission Type:

4-Speed Manual Transmission

Optional Transmission Type:

4-Speed Automatic Transmission (often referred to as 'Hydrak ' or later 722.1/722.2 series)

Clutch Type:

Single dry plate diaphragm clutch (manual)

Manual Transmission Fluid Type:

GL-4 Hypoid Gear Oil, SAE 80W/90 (check manual for specific MB specification, e.g., MB 235.0)

Automatic Transmission Fluid Type:

Dexron II or equivalent (MB specification 236.3 or similar, check manual)

📐 Dimensions

Length Mm:

4725 mm (Sedan)

Width Mm:

1785 mm (Sedan)

Height Mm:

1430 mm (Sedan)

Wheelbase Mm:

2795 mm (Sedan)

Curb Weight Kg:

Approximately 1300-1400 kg (depending on equipment and body style)

Gross Vehicle Weight Rating Kg:

Approximately 1800-1900 kg

Trunk Capacity Liters:

Approximately 560 Liters (Sedan)

Standard Tire Size:

175 HR 14 or 185/70 HR 14 (check specific model variant)

Wheel Bolt Pattern:

5 x 112 mm

Wheel Offset:

ET 30 - ET 41 (typical for W123, consult manual for exact)

🛡️ Safety Features

Safety Standards:

Designed to meet rigorous European safety standards of the era, featuring crumple zones and a reinforced passenger cell.

Active Safety Features:

Four-wheel disc brakes (front vented), power-assisted steering, independent suspension for stable handling.

Passive Safety Features:

Reinforced safety cage, laminated windscreen, padded dashboard, collapsible steering column, seat belts (front 3-point, rear lap belts typically).

💡 Technology Features

Original Infotainment:

Basic AM/FM radio, often with cassette player option. Limited digital integration of course.

Driver Assistance Features:

Limited by modern standards; primarily focused on robust mechanical systems. Features like power steering and disc brakes were considered advanced for the time.

Connectivity Features:

None in the modern sense. The focus was on mechanical reliability and driver control.

🔧 Maintenance

Oil And Filter Change:

Every 5,000 - 7,500 km or annually (refer to manual for specific mileage and time recommendations).

Fuel Filter Replacement:

Every 10,000 - 15,000 km (crucial for diesel reliability).

Air Filter Replacement:

Every 10,000 - 15,000 km, or as needed based on inspection.

Coolant Flush And Refill:

Every 2-3 years or as specified.

Valve Adjustment:

Periodic adjustment recommended, typically every 20,000 - 40,000 km (solid lifters).

Transmission Fluid Change:

Manual: Every 40,000 - 60,000 km. Automatic: Typically every 20,000 - 40,000 km (check filter replacement also).

Brake Fluid Type:

DOT 3 or DOT 4 (check manual for specific MB recommendation).

Power Steering Fluid:

MB Specification 236.3 or equivalent ATF (check manual).

Common Wear Items:

Suspension bushings, ball joints, tie rod ends, fuel injection pump seals, vacuum lines, glow plug issues, rust in common areas (wheel arches, door bottoms, jacking points).

Diesel Specific Concerns:

Injector pump wear, glow plug reliability, potential for fuel gelling in extreme cold if untreated fuel is used.

📚 Vehicle History

Mercedes Benz Legacy:

Mercedes-Benz has a long-standing reputation for engineering excellence, safety, and durability, established in the early 20th century.

W123 Development:

The W123 series, launched in 1975, was developed as a successor to the highly successful W114/W115 series, aiming for even greater refinement, safety, and durability. It was available in sedan, coupe, estate (T-model), and long-wheelbase versions.

200D Significance:

The 200D represented the entry-level diesel model, prioritizing fuel economy and long-term reliability, making it a popular choice for taxi fleets and economical personal transportation.

Production Period:

1976-1985 for the 200D model within the W123 range.

Manufacturing Sites:

Primarily manufactured in Germany, with some assembly in other global locations.

🏆 Awards & Recognition

Model Accolades:

The W123 series was widely recognized for its durability and reliability, often cited in automotive reviews as a benchmark for build quality. It was also popular in motorsports endurance events and as a durable everyday vehicle.