Basic Information Identification Make: Mercedes-Benz Model: 240D Chassis Code: W115 Model Years Covered: 1974, 1975, 1976 Introduction Market Position Target Audience: Mercedes-Benz 240D owners, independent repair shops, DIY enthusiasts, classic Mercedes-Benz collectors. Value Proposition: Provides access to the same authoritative repair information used by authorized Mercedes-Benz technicians. Competitive Analysis Comparison To Other Manuals: Superior to generic repair guides due to factory specificity and comprehensive coverage; offers a more in-depth resource than owner's manuals. Key Features Authenticity: Genuine Mercedes-Benz factory publication, ensuring accuracy and completeness. Breadth Of Coverage: Covers virtually every system and component of the vehicle for maintenance and repair. Ease Of Use: Digital format with menu-driven navigation and searchable PDFs enhances user experience. Manual Details Coverage Areas Manual Type: Factory Workshop Service Repair Manual Language: English Format: HTML/Flash menu with PDF files Digital Format Compatibility: Windows (95, 98, ME, XP, Vista, 7), Linux, MAC Manual Coverage Systems Covered Engine General: Complete overhaul and repair procedures for the OM616 diesel engine. Engine Mechanical: Engine block, cylinder head, pistons, connecting rods, crankshaft, camshaft, valve train, timing belt/chain, lubrication system, cooling system. Engine Fuel System: Diesel injection pump (Bosch VE type), injectors, fuel lines, glow plug system, fuel filters, fuel tank and pump. Transmission: Repair and overhaul of manual and automatic transmissions (if applicable for the model years), clutch, driveshafts. Brakes: Hydraulic system, brake discs, brake pads, brake calipers, wheel cylinders, master cylinder, parking brake, bleeding procedures. Suspension: Front and rear suspension components, shock absorbers, springs, control arms, ball joints, bushings, steering linkage. Steering: Steering gearbox, steering column, tie rods, steering linkage, power steering system (if equipped). Electrical System: Battery, alternator, starter motor, ignition system (less emphasis on gasoline engines as it's a diesel), lighting, wiring diagrams, fuses, relays, dashboard instruments. Body And Interior: Body panels, doors, windows, interior trim, seats, dashboard, HVAC system, upholstery, exterior trim, bumpers. HVAC: Heating, ventilation, and air conditioning system components, controls, refrigerant system (if applicable). Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, fuel, air), fluid checks and top-offs, tire rotation, battery maintenance. Major Repairs: Engine rebuilding, transmission overhaul, brake system overhauls, suspension component replacement, steering system repair. Diagnostics: Troubleshooting guides for common issues, diagnostic procedures for engine performance, electrical faults, and mechanical problems. Adjustments: Valve adjustments, idle speed adjustments, timing adjustments, brake adjustments. Bodywork: Panel replacement, rust repair, glass replacement, trim installation. Technical Depth Depth Level: Comprehensive, covering everything from basic preventative maintenance to complete vehicle rebuilds and advanced diagnostics. Diagnostic Charts: Includes detailed diagnostic charts and flowcharts for troubleshooting various systems. Torque Specifications: Provides specific torque values for all critical fasteners throughout the vehicle. Wiring Diagrams: Detailed electrical wiring diagrams for all major systems. Special Tools: Identifies and describes required special tools for specific repair procedures. Manual Specifications File Format File Type: HTML/Flash menu with PDF embedded files Searchability: PDF files are likely searchable if optically character recognized (OCR), menu provides navigation. Printability: PDF files are printable for physical reference. Print Quality Resolution: Dependent on the original scan quality of the factory manual; typically high resolution for factory documents. Clarity: Professional clarity, including diagrams, illustrations, and text. Binding Type Binding: N/A (Digital Product) Paper Type Paper Quality: N/A (Digital Product) Engine Specifications Primary Engine Engine Code: OM616 Engine Type: Inline 4-cylinder, naturally aspirated diesel Displacement: 2.4 Liters (2399 cc) Performance Horsepower: Approximately 68-72 hp (depending on specific market and tuning) Torque: Approximately 100-103 lb-ft (depending on specific market and tuning) Fuel System Injection System: Bosch inline mechanical injection pump (VE type) Fuel Type: Diesel fuel Cooling System Cooling Medium: Engine coolant (typically a 50/50 mix of ethylene glycol and water) Lubrication System Oil Type Specification: API CD or ACEA B3 specification diesel engine oil (e.g., SAE 15W-40 or 10W-40 depending on climate) Transmission Standard Transmission Type: 4-speed manual transmission Optional Transmission Type: 4-speed automatic transmission (optional) Features Clutch Type: Single dry plate, hydraulically operated clutch (for manual) Automatic Transmission Fluid: Dexron II or equivalent automatic transmission fluid (for automatic) Dimensions Exterior Wheelbase: Approx. 2750 mm (108.3 inches) Length: Approx. 4700 mm (185.0 inches) Width: Approx. 1750 mm (68.9 inches) Height: Approx. 1420 mm (55.9 inches) Weights Curb Weight: Approx. 1400-1500 kg (3086-3307 lbs) Wheels And Tires Standard Wheel Size: 14-inch or 15-inch steel wheels Standard Tire Size: 175 SR 14 or 185 SR 14 Bolt Pattern: 5 x 112 mm Safety Features Ratings Crash Test Information: Modern crash test ratings are not directly applicable to vehicles of this era. However, Mercedes-Benz's reputation for build quality and safety was strong during this period. Active Features Braking System: Front disc brakes, rear drum brakes. Power assisted. Passive Features Seat Belts: Standard front seat belts, rear lap belts (three-point belts may have been optional or standard on later models). Body Structure: Reinforced safety cage, crumple zones (advanced for its time). Steering Column: Collapsible steering column designed...