🏷️ Basic Information Identification Make: Mercedes-Benz Model: 180d / 180Db / 180Dc Chassis Code: W120 (Sedan), W121 (Ponton, various models, including 180d variants) Engine Code Group: OM636 (diesel variants) Generation Production Era: Primarily 1950s - 1960s Codes Data Code Source: Workshop Manual Documentation 👋 Introduction Market Position Positioning: These models, particularly the diesel variants, represented Mercedes-Benz's entry into more economical and durable passenger car segments, often favored for their robust engineering and longevity. Competitive Analysis Competitors: Competed with other premium European and American manufacturers offering compact to mid-size sedans and estates, though the Mercedes diesel offered superior fuel economy and durability. Key Features Vehicle Highlights: Robust OM636 diesel engine known for longevity, comfortable ride, solid build quality, elegant styling characteristic of the era, and Mercedes-Benz's reputation for engineering excellence. Manual Purpose Manual Value Proposition: Essential for owners and independent workshops seeking to maintain, repair, and troubleshoot these classic Mercedes-Benz models, ensuring their continued operation and preserving their value. 📋 Manual Details Coverage Areas Vehicle Variants Covered: 180d, 180Db, 180Dc (all engine/trim variations within these designations) Page Count Estimated Pages: 500-800 (typical for comprehensive workshop manuals of this era) Manual Type Type: Workshop Repair Service Manual Language Primary Language: English (translated from original German) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: OM636 diesel engine: overhaul, diagnostics, fuel system (injection pump, injectors, glow plugs), lubrication system, cooling system, exhaust system Transmission: Manual transmission (4-speed, sometimes 5-speed options): disassembly, assembly, repair, clutch service Drivetrain: Rear-wheel drive: driveshaft, universal joints, differential, axle shafts Suspension: Front independent suspension (e.g., kingpins or ball joints depending on specific W120/W121 evolution), rear leaf springs: component inspection, replacement, alignment specifications Brakes: Hydraulic drum brakes (front and rear): master cylinder, wheel cylinders, brake shoes, brake drums, hydraulic lines, bleeding procedures Steering: Recirculating ball steering system: steering box, steering column, tie rods, linkage inspection and adjustment Electrical System: 12V DC system: battery, starter, alternator/generator, ignition system (if applicable for gasoline variants covered in broader manuals), lighting, gauges, wiring diagrams Bodywork Chassis: Body panel repair, structural integrity checks, door mechanisms, interior trim, glass replacement Heating Ventilation: Heater core service, fan operation, vent controls Procedures Included Maintenance: Lubrication schedules, oil changes, filter replacements, tune-up procedures, valve adjustments (if applicable), brake adjustments Troubleshooting: Diagnostic charts for common problems (engine no-start, poor performance, braking issues, electrical faults), symptom-based troubleshooting Repair: Step-by-step overhaul procedures for major components, component replacement instructions, specialized tool usage Diagnostics: Engine compression testing, fuel system pressure checks, electrical system testing using multimeters Technical Depth Depth: Comprehensive: Covers routine maintenance to complete engine and transmission rebuilds, including detailed component specifications and tolerances 📊 Manual Specifications File Format Quality: High-resolution PDF, typically scanned from original factory manuals, ensuring clarity of diagrams and text Searchability: Likely text-searchable PDF for quick information retrieval Print Quality Printability: Printable pages, allowing for physical copies for workshop use Binding Type Digital Binding: N/A (Digital PDF) Paper Type Digital Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code: OM636 (for diesel variants 180d, 180Db, 180Dc) Engine Type: Inline 4-cylinder Diesel Displacement: Approximately 1.8 liters (1767 cc) Bore X Stroke: Approximately 75 mm x 100 mm Compression Ratio: Typically around 20.5:1 to 21:1 Performance Horsepower Approx: 40-55 hp @ 3000-3500 rpm (depending on specific variant and tuning) Torque Approx: 90-110 Nm @ 1800-2000 rpm (depending on specific variant) Fuel System Injection System: Bosch inline injection pump with mechanical governor Glow Plug System: Pre-glow system for cold starts Cooling System Type: Water-cooled, thermostatically controlled Lubrication Oil Capacity Approx: 5.5 Liters (5.8 US quarts) 🔧 Transmission Standard Type: 4-speed manual transmission Optional Type: Some later models or specific variants might have offered a 5-speed manual or automatic transmission, though less common for the 180d designation. Features Clutch: Single dry plate clutch, hydraulically actuated Gear Ratios Typical Ratios: Manual transmission gear ratios vary but are optimized for torque delivery characteristic of diesel engines. Fluid Specification Manual Transmission Fluid: API GL-4, SAE 80W-90 gear oil (verify specific manual for exact spec) 📐 Dimensions Exterior Body Styles: 4-door Sedan (W120/W121), potentially Estate/Station Wagon variants (W121 variants like Universal) Wheelbase Approx: Approx. 2650 mm (for W120/W121 sedans) Length Approx: Approx. 4450 mm (for W120/W121 sedans) Width Approx: Approx. 1700 mm (for W120/W121 sedans) Height Approx: Approx. 1550 mm (for W120/W121 sedans) Weights Curb Weight Approx: Approx. 1200-1300 kg Gross Vehicle Weight Rating Approx: Approx. 1700-1800 kg Towing Capacity Approx: Not typically specified for these passenger models, but limited due to chassis strength. 🛡️ Safety Features Ratings Crash Test Data: No formal crash safety ratings (e.g., NHTSA, Euro NCAP) were available for vehicles of this era in the modern sense. Active Features Braking System: Hydraulic drum brakes (front and rear), dual-circuit system for redundancy. Steering System: Robust recirculating ball steering for stability. Passive Features Seat Belts: Optional or basic lap belts may...