🏷️ Basic Information

Make:

Mercedes-Benz

Model:

450SEL

Chassis Code:

W116

Model Years Covered:

1973-1980

Engine Code:

M117

👋 Introduction

Positioning:

The Mercedes-Benz W116 represented the pinnacle of luxury and engineering for its era, establishing the S-Class as a benchmark for executive sedans worldwide. The 450SEL, with its V8 engine, was a flagship model.

Competitors:

Competed against other high-end luxury sedans of the period such as BMW's E23 7 Series, Jaguar XJ, and Cadillac Fleetwood.

Vehicle Highlight:

The W116 was known for its robust build quality, superior ride comfort, advanced safety features for its time (including optional ABS), and sophisticated engineering, setting a new standard for automotive luxury.

Value Proposition:

This comprehensive service manual is invaluable for owners and independent mechanics aiming to maintain, repair, and restore the iconic Mercedes-Benz W116 450SEL, ensuring its longevity and optimal performance.

📋 Manual Details

Primary Coverage:

Full Service, Repair, and Workshop Procedures

Region Specific Notes:

Covers specifications relevant to models sold in major global markets during the specified production years.

Estimated Pages:

Hundreds of pages (exact count not specified, but described as 'hundreds' and 'very detailed')

Type:

Factory Service Repair Workshop Manual

Language:

English

Format:

Downloadable PDF

📖 Manual Coverage

Engine:

Engine mechanical, lubrication, cooling, fuel injection (Bosch K-Jetronic), ignition, exhaust, emissions control, engine management.

Transmission:

Automatic transmission (e.g., 4-speed 4G-Tronic) service, repair, overhaul, adjustments, troubleshooting.

Drivetrain:

Driveshafts, universal joints, differential, axle shafts, wheel bearings.

Suspension:

Front and rear suspension components, springs, shock absorbers, control arms, bushings, steering linkage.

Brakes:

Hydraulic system, brake boosters, master cylinder, calipers, brake pads, discs, parking brake, bleeding procedures.

Steering:

Power steering system, steering gearbox, steering column, tie rods, adjustments.

Electrical:

Battery, charging system (alternator), starting system, lighting, ignition system, instrumentation, power windows, central locking, air conditioning electricals, wiring diagrams.

Body:

Body shell, doors, hoods, trunk, windows, seals, exterior trim, interior trim, HVAC system (including body integration).

HVAC:

Air conditioning system operation, service, refrigerant handling, climate control unit, blower motor, heater core.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, tune-ups, fluid level checks and changes.

Troubleshooting:

Diagnostic procedures for common and complex issues across all vehicle systems.

Repair:

Step-by-step repair instructions for component removal, installation, and rebuilding.

Disassembly Assembly:

Detailed exploded diagrams and instructions for component disassembly and reassembly.

Specifications:

Torque specifications, clearances, fluid capacities, and other critical technical data.

Engine Rebuild:

Includes procedures for engine disassembly, inspection, repair, and reassembly, detailing component specifications and tolerances.

Transmission Overhaul:

Detailed steps for the removal, disassembly, repair, and installation of the automatic transmission, including torque converter and related components.

Electrical Troubleshooting:

Includes comprehensive wiring diagrams and diagnostic flowcharts for troubleshooting electrical system faults.

Depth:

Comprehensive coverage from basic preventative maintenance to in-depth engine and transmission overhauls. Suitable for professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

Compatibility:

Compatible with Windows and MAC operating systems.

Accessibility:

Usable on unlimited computers and devices; no expiry or renewal fees.

Printing Capability:

Printable by the page or in its entirety.

Binding:

Not applicable (PDF download)

Paper Quality:

Not applicable (PDF download)

Diagram Quality:

Contains hundreds of pages with detailed photos and diagrams, including highly detailed exploded diagrams crucial for repair procedures.

⚙️ Engine Specifications

Engine Type:

SOHC V8

Displacement:

4.5 Liters (4520 cc)

Bore X Stroke:

92.0 mm x 85.0 mm

Compression Ratio:

8.0:1 (or similar depending on market variant)

Horsepower Net:

Approx. 220-230 hp (SAE net) at 5000 rpm (varies by market and specific year)

Torque Net:

Approx. 270-280 lb-ft (SAE net) at 3200 rpm (varies by market and specific year)

Fuel Injection:

Bosch K-Jetronic mechanical fuel injection

Fuel Type:

Unleaded gasoline (premium octane recommended)

Oil Capacity:

Approx. 8.0 US quarts (7.5 liters) with filter change (check manual for precise spec)

Coolant Capacity:

Approx. 12.0 US quarts (11.5 liters) (check manual for precise spec)

Ignition System:

Breakerless electronic ignition system

🔧 Transmission

Transmission Type:

4-speed automatic (e.g., 4G-Tronic)

Optional Transmission:

Manual transmission was not commonly offered or available on the 450SEL in most markets.

Transmission Fluid Type:

Dexron II (or equivalent specification)

Transmission Fluid Capacity:

Approx. 2.5-3.0 US quarts (2.4-2.8 liters) for fluid change (check manual for precise spec)

📐 Dimensions

Length:

Approx. 5030 mm (198.0 in)

Width:

Approx. 1800 mm (70.9 in)

Height:

Approx. 1480 mm (58.3 in)

Wheelbase:

Approx. 3070 mm (120.9 in)

Curb Weight:

Approx. 1700-1850 kg (3750-4080 lbs) (varies by equipment)

Gross Vehicle Weight Rating:

Approx. 2250 kg (4960 lbs) (check manual for precise spec)

🛡️ Safety Features

Crash Test Data:

While formal crash test ratings were less standardized during this period, the W116 was engineered with advanced safety structures, including a robust crumple zone design and reinforced passenger compartment, considered a leader in occupant safety for its time.

Active Safety Features:

Four-wheel disc brakes, optional Anti-lock Braking System (ABS) on later models, power steering.

Passive Safety Features:

Three-point seatbelts (front and rear), padded dashboard and interior surfaces, impact-absorbing steering column, reinforced A and B pillars.

💡 Technology Features

Infotainment System:

Basic for its era. Typically featured an AM/FM radio (often with power antenna), and basic climate controls. Cassette players became more common later in the production run.

Driver Assistance Features:

Optional Anti-lock Braking System (ABS), cruise control (on some models), and power adjustable seats.

Connectivity Features:

Limited by modern standards. Primarily mechanical and basic electrical systems. No integrated digital connectivity.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions and oil used. Consult the manual for specific recommendations.

Major Service Interval:

Major services including spark plug replacement, transmission fluid/filter change, and brake fluid flush typically recommended every 30,000-60,000 miles (48,000-96,000 km). Refer to manual for detailed schedule.

Engine Oil Type:

API SG or higher, SAE 10W-40 or 15W-50 recommended (depending on ambient temperature). Consult manual for precise API service classification and viscosity grade.

Coolant Type:

Ethylene glycol based antifreeze. Mixture of 50% antifreeze and 50% distilled water. Mercedes-Benz specification 302.0 (or equivalent).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Common Wear Items:

Fuel accumulator, injector seals, ignition components, vacuum hoses, suspension bushings, exhaust system, window regulators, door seals, and potential rust on common W116 areas (e.g., wheel wells, rockers).

Electrical Issues:

Degradation of wiring insulation over time, issues with the instrument cluster, door lock actuators, and climate control panel electronics.

Routine Checks:

Weekly: tire pressure, fluid levels (oil, coolant, brake, power steering, washer fluid). Monthly: check belts and hoses for wear.

📚 Vehicle History

Heritage Context:

Mercedes-Benz has a long-standing reputation for building durable, technologically advanced, and luxurious vehicles. The W116 continued this legacy, solidifying the S-Class as the benchmark for automotive excellence.

Generation Overview:

The W116 was the first generation to officially bear the 'S-Class' designation, marking a significant step in Mercedes-Benz's model lineup. It replaced the W108/W109 series and was succeeded by the W126 S-Class.

Powertrain Updates:

Early models featured the 4.5L V8, with a 3.5L V8 (350SEL) also available. Later models introduced fuel injection improvements and potential engine management updates.

Production Years:

1972-1980

Manufacturing Locations:

Primary manufacturing in Germany.

🏆 Awards & Recognition

Industry Recognition:

The W116 S-Class was widely praised by automotive journalists and industry experts for its engineering, build quality, and luxury, setting a high standard for luxury sedans and influencing future automotive design.

Consumer Ratings:

While specific contemporary ratings are less documented by modern standards, the W116 consistently received accolades for comfort, durability, and refinement, leading to strong resale values and a loyal following.