🏷️ Basic Information Identification Make: Mercedes-Benz Model: 240 D Model Code: W123 Years Covered: 1981, 1982, 1983 Codes Engine Code Primary: OM616 (inline 4-cylinder diesel) 👋 Introduction Market Position Target Audience: Mercedes-Benz owners, independent repair shops, classic car enthusiasts. Competitive Analysis Value Proposition: Provides in-depth technical information essential for maintaining and repairing the robust W123 chassis and its OM616 diesel engine, often surpassing generic repair guides in detail. Key Features Comprehensiveness: Covers all aspects of the vehicle's systems with a focus on practical repair and maintenance. Accuracy: Derived from official Mercedes-Benz technical documentation. 📋 Manual Details Coverage Areas Engine Mechanical: Complete disassembly, inspection, repair, and reassembly of engine components. Fuel System: Diesel injection system (Bosch), fuel pump, injectors, lines, and filters. Cooling System: Radiator, water pump, thermostat, hoses, and fan. Exhaust System: Exhaust manifold, catalytic converter (if applicable), muffler, and pipes. Ignition System: Glow plug system and diagnostics. Transmission Manual: Clutch, gearbox (4-speed or 5-speed manual), driveshafts. Transmission Automatic: Automatic transmission (e.g., 4-speed 722.1 or 722.3), torque converter, valve body. Suspension Front: Independent suspension, control arms, ball joints, springs, shock absorbers. Suspension Rear: Independent suspension, semi-trailing arms, springs, shock absorbers. Steering System: Steering box, linkages, power steering pump (if equipped). Brake System: Front disc brakes, rear drum brakes, master cylinder, calipers, wheel cylinders, parking brake. Electrical System: Battery, alternator, starter motor, wiring diagrams, lighting, fuses, relays. Bodywork And Chassis: Body panel repair, door mechanisms, window regulators, underbody protection. Heating And Ventilation: HVAC system, heater core, blower motor, air conditioning (if equipped). Interior Trim: Dashboard, seats, door panels, carpet replacement. Troubleshooting: Diagnostic procedures and common problem resolution for all systems. Page Count Estimated Pages: 500+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered All Systems: Covers all major mechanical, electrical, and body systems. Procedures Included Maintenance Procedures: Regular scheduled maintenance, oil changes, filter replacements, tune-ups. Repair Procedures: Step-by-step instructions for component repair and replacement. Rebuild Procedures: Detailed instructions for engine and transmission rebuilds. Diagnostic Procedures: Troubleshooting guides with symptom-based diagnosis. Specification Data: Torque specifications, clearances, fluid capacities, timing data. Technical Depth Depth: Comprehensive, covering everything from basic adjustments to complete overhauls. 📊 Manual Specifications File Format Searchable Text: Yes (if PDF is OCR'd) Printable: Yes Print Quality Illustrations: High-quality diagrams and schematics. Binding Type Binding: N/A (Digital format) Paper Type Paper Quality: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated Inline 4-Cylinder Diesel Engine Code: OM616.912 (typical for this era 240 D) Displacement: 2.4 Liters (2399 cc) Performance Horsepower Approx: 70-72 hp @ 4000 rpm Torque Approx: 100-103 lb-ft @ 2200 rpm Fuel System Injection System: Bosch Inline Injection Pump (e.g., PES 4M55/220) Injectors: Bosch Diesel Injectors Fuel Type Fuel Type: Diesel Fuel Cooling System Cooling Method: Liquid Cooling Lubrication Oil Capacity Approx: 7.5 Liters (with filter) Recommended Oil Viscosity: SAE 15W-40 Diesel (e.g., MB 228.1 specification) 🔧 Transmission Standard Type: 4-speed Manual (usually) Optional Type: 4-speed Automatic (e.g., 722.1 or 722.3) Features Clutch Type: Single dry plate clutch Fluid Specifications Manual Transmission Fluid: GL-4 Gear Oil (e.g., MB 235.0 specification, SAE 80W-90) Automatic Transmission Fluid: Dexron III equivalent (check manual for exact MB specification, e.g., MB 236.1) 📐 Dimensions Exterior Body Style: Sedan (Limousine) Wheelbase Approx: 2794 mm (110 inches) Overall Length Approx: 4725 mm (186 inches) Weights Curb Weight Approx: 1400 - 1500 kg (3086 - 3307 lbs) 🛡️ Safety Features Ratings Crash Test History: While official modern crash test ratings for this era are scarce, Mercedes-Benz W123 models were renowned for their robust build quality and safety features for their time. Active Features Braking: Front disc brakes, rear drum brakes with dual hydraulic circuits. Passive Features Chassis Design: Reinforced safety cage, crumple zones. Steering Column: Collapsible steering column. 💡 Technology Features Infotainment Audio System: Typically an AM/FM radio with cassette player, often a Becker unit. Driver Assistance Cruise Control: Optional on some models. Connectivity Connectivity Features: Limited by era; primarily mechanical and basic electrical systems. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 - 7,500 miles or 6 months (check specific manual recommendations). Fuel Filter Replacement: Every 15,000 - 20,000 miles. Air Filter Replacement: Every 15,000 - 20,000 miles. Valve Adjustment: Periodically, as specified in the manual (e.g., every 20,000-30,000 miles). Fluid Specifications Coolant Type: Ethylene Glycol based coolant (e.g., MB specification 325.0 or similar). Brake Fluid Type: DOT 3 or DOT 4. Known Issues Diesel Injection Pump Wear: Wear in injection pump components can lead to starting issues or rough running. Rust Corrosion: Common on older Mercedes-Benz models, particularly in wheel arches, sills, and around windows. Vacuum System Leaks: Vacuum leaks can affect central locking, door locks, and headlight leveling. Prechamber Glow Plugs: Failure of prechamber glow plugs can cause hard starting in cold weather. 📚 Vehicle History...