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Mercedes 300 E 4MATIC 1990-1993 Service Repair Manual

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Basic Information Identification Make: Mercedes-Benz Model: 300 E Trim: 4MATIC Model Years: 1990-1993 Codes Chassis Code: W124 Engine Code: M103.980 Introduction Market Position Positioning: The Mercedes-Benz 300 E 4MATIC (W124...
Typ: Cars
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Art.-Nr: 423024
Stichworte: Mercedes Misc
Mercedes 300 E 4MATIC 1990-1993 Service Repair Manual
Basic Information
Identification
Make: Mercedes-Benz
Model: 300 E
Trim: 4MATIC
Model Years: 1990-1993
Codes
Chassis Code: W124
Engine Code: M103.980
Introduction
Market Position
Positioning: The Mercedes-Benz 300 E 4MATIC (W124 chassis) represented the pinnacle of engineering and luxury in its segment during the late 1980s and early 1990s. It was positioned as a premium, technologically advanced, and durable sedan offering refined performance and exceptional build quality.
Competitive Analysis
Competitors: Competed with other luxury sedans of the era, including BMW 5-Series, Audi V8 Quattro, and higher-end models from Jaguar and Lexus.
Key Features
Salient Features: Permanent four-wheel drive (4MATIC), robust inline-6 engine, legendary W124 chassis durability, sophisticated build, and comfortable ride.
Manual Details
Coverage Areas
Coverage: Comprehensive service, repair, and maintenance
Page Count
Page Count: Estimated 1500+ pages (typical for full workshop manuals of this era)
Manual Type
Manual Type: Factory-authorized Service/Repair Manual
Language
Language: English
Format
Format: Digital (PDF), often searchable
Manual Coverage
Systems Covered
Engine Systems: Engine mechanical (M103 3.0L inline-6), fuel injection (Bosch KE-Jetronic/CIS-E), ignition, cooling, lubrication, exhaust
Transmission Systems: 4-speed automatic transmission (722.4) operation, diagnosis, and repair; 4MATIC all-wheel drive system
Drivetrain Systems: Front and rear differentials, driveshafts, CV joints, 4MATIC system components
Suspension Steering: Front and rear suspension components, shocks, springs, control arms, bushings, steering gear, power steering system
Brake Systems: Hydraulic brake system, ABS (Anti-lock Braking System), front and rear brake assembly, parking brake
Electrical Systems: Complete wiring diagrams, component testing, battery, alternator, starter, lighting, fuses, relays, instrumentation, control modules
Body Chassis: Body panels, doors, windows, locks, convertible top mechanisms (if applicable to specific sub-models not mentioned), frame structure, seals
HVAC Systems: Heating, ventilation, and air conditioning (HVAC) system diagnosis and repair
Procedures Included
Maintenance Procedures: Scheduled maintenance intervals, oil changes, filter replacements, spark plug service, coolant flushes, belt replacements
Diagnostic Procedures: Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs) and their interpretation
Repair Procedures: Step-by-step instructions for component removal, installation, overhaul, and rebuilding
Rebuilding Procedures: Detailed instructions for engine, transmission, and differential rebuilding
Adjustment Procedures: Valve adjustments, timing adjustments, idle speed adjustments
Installation Procedures: Installation of accessories, replacement parts
Technical Depth
Depth: Factory-level diagnostic and repair procedures, including torque specifications, tolerances, and special tool requirements
Manual Specifications
File Format
File Format Details: Digital PDF, typically with text search functionality for easy navigation
Print Quality
Print Quality: High-resolution scans of original factory manuals, ensuring clarity of diagrams and text
Binding Type
Binding Type: Not applicable for digital format; if printed, likely a robust comb or perfect binding
Paper Type
Paper Type: Not applicable for digital format; original manuals used durable paper stock suitable for workshop environments
Engine Specifications
Primary Engine
Engine Type: Naturally Aspirated Inline 6-Cylinder
Displacement: 2.96 L (180.7 cu in)
Bore X Stroke: 89.9 mm x 78.6 mm (3.54 in x 3.09 in)
Compression Ratio: 9.2:1
Valve Train: SOHC (Single Overhead Camshaft), 2 valves per cylinder
Performance
Horsepower: 188 hp @ 5700 rpm (approx.)
Torque: 195 lb-ft @ 4400 rpm (approx.)
Fuel System
Fuel Injection System: Bosch KE-Jetronic (CIS-E) Electronic Fuel Injection
Fuel Type: Unleaded Premium Gasoline (91 Octane or higher recommended)
Lubrication
Oil Type: API SG, SAE 15W-40 or 10W-30 (depending on climate)
Cooling
Coolant Type: Mercedes-Benz Approved Antifreeze/Coolant (e.g., G48)
Transmission
Standard
Transmission Type: 4-speed Automatic Transmission (722.4)
Optional
Optional Transmission: None (Automatic was standard for 4MATIC models)
Features
Drive System: 4MATIC Permanent All-Wheel Drive System
Transmission Fluid Type: Dexron III or equivalent (MB 236.1 specification)
Transmission Fluid Capacity: Approx. 7.0 - 8.0 liters (depending on torque converter drain)
Dimensions
Exterior
Length: 4740 mm (186.6 in)
Width: 1740 mm (68.5 in)
Height: 1420 mm (55.9 in)
Wheelbase: 2800 mm (110.2 in)
Weights
Curb Weight: Approx. 1600-1700 kg (3527-3748 lbs) depending on options
Safety Features
Ratings
NHTSA Rating: No specific NHTSA ratings for this era, but considered exceptionally safe for its time due to robust structure.
Active Features
ABS: Standard Anti-lock Braking System (ABS)
Passive Features
Airbags: Driver-side airbag (standard from late 1990 onwards, optional earlier)
Seatbelts: Front seatbelt pre-tensioners
Construction: Reinforced passenger compartment, crumple zones
Technology Features
Infotainment
Infotainment Features: Factory-installed radio/cassette player, optional CD changer, manual climate control or optional automatic climate control (ACC).
Driver Assistance
Assistance Features: ABS (Anti-lock Braking System), Cruise Control (optional/standard depending on market/trim).
Connectivity
Connectivity Features: Limited by modern standards; basic analog systems.
Maintenance
Service Intervals
Oil Change Interval: Every 10,000 km (6,200 miles) or 12 months, whichever comes first
Air Filter Interval: Every 30,000 km (18,600 miles) or 24 months
Fuel Filter Interval: Every 40,000 km (24,800 miles) or 24 months
Spark Plug Interval: Every 50,000 km (31,000 miles) or 36 months (for standard plugs)
Coolant Flush Interval: Every 2-3 years
Transmission Service Interval: Every 50,000-80,000 km (30,000-50,000 miles) or 4-5 years, depending on driving conditions.
Fluid Specifications
Engine Oil Capacity: Approx. 7.5 liters (7.9 US quarts)
Coolant Capacity: Approx. 10.5 liters (11.1 US quarts)
Brake Fluid Type: DOT 3 or DOT 4
Known Issues
Common Problems: Head gasket leaks, oil cooler seal leaks, distributor O-ring leaks, fuel distributor issues (KE-Jetronic), ABS sensor failures, vacuum hose deterioration, climate control panel failures, window regulator issues.
4Matic Specific Issues: Potential wear in the transfer case and front differential, issues with the hydraulic actuation system for the 4MATIC clutch.
Vehicle History
Brand Heritage
Heritage: Mercedes-Benz has a long-standing reputation for engineering excellence, safety, and durability, dating back to the invention of the automobile. The W124 generation is particularly revered for its build quality and longevity.
Model Evolution
W124 Introduction: The W124 E-Class was introduced in 1984, and the 300 E 4MATIC variant was launched in 1987, featuring the permanent all-wheel-drive system developed in conjunction with Steyr-Puch.
W124 Facelift: A significant facelift occurred in 1993, introducing updated styling and the new E-Class naming convention. The 1990-1993 models represent the pre-facelift styling.
Production
Production Period: W124 production ran from 1984 to 1995, with the 300 E 4MATIC being a key part of the lineup during its production lifespan.
Awards & Recognition
Recognitions
Industry Recognition: The W124 chassis, in general, received widespread acclaim for its build quality, engineering, and durability, often cited as one of Mercedes-Benz's best-built cars. While specific awards for the 300 E 4MATIC might not be individually documented, the model benefited from the overall positive reputation of the W124 line.
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