🏷️ Basic Information Identification Make: Mercedes-Benz Model: 300 SD Chassis Code: W116 Model Years Covered: 1978, 1979, 1980 Codes Engine Code: OM617 (Inline-5 Diesel) 👋 Introduction Market Position Target Audience: Mercedes-Benz W116 300 SD owners, DIY enthusiasts, professional mechanics Competitive Analysis Manual Origin: Actual Genuine Factory Manuals (not 3rd party) Key Features User Experience: Easy to use, guides through procedures, print-on-demand convenience Cost Savings: Potential to save significant labor costs compared to professional shop rates Content Quality: High resolution, detailed illustrations, diagrams, and specifications 📋 Manual Details Coverage Areas Scope: Complete factory service and repair Page Count Estimated Pages: Hundreds (precise number not specified, but described as 'complete') Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Service: Engine repair, troubleshooting, fuel injection, emission system, engine control system Transmission Service: Transmission service and repair Brake System: Complete brake system service and repair Electrical System: Wiring diagrams, electrical system diagnostics and repair Suspension And Steering: Suspension, steering, axle, differential/drive systems Cooling And Fuel: Cooling system, fuel injection/fuel system Chassis And Body: Chassis and body repair, interior, heater/air conditioning, restraint system Procedures Included Maintenance: General maintenance, periodic lubrication, troubleshooting Repair: Step-by-step repair procedures for all covered systems Diagnostics: Advanced troubleshooting guide for problem diagnosis and correction Technical Depth Depth: Professional technician level, covering rebuilds and full restoration 📊 Manual Specifications File Format File Type: PDF Accessibility: Searchable and printable Print Quality Printability: Printable without restriction (individual pages or entire manual) Binding Type Binding Method: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download - printable on any paper) Software Requirements Reader Requirement: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Type: Inline 5-cylinder Turbocharged Diesel Engine Code: OM617.950 (or similar variant for the 300 SD) Performance Horsepower Est: ~115-125 hp (Varies slightly by specific market and year) Torque Est: ~230-250 Nm (Varies slightly by specific market and year) Fuel System Injection System: Bosch Inline Injection Pump with Diesel Particulate Filter (DPF) not applicable for this era, but advanced injection control for its time. Fuel Type: Diesel Fuel Cooling System Coolant Capacity Est: Approx. 9-10 liters (Specifics in manual) 🔧 Transmission Standard Transmission Type: 4-speed Automatic Transmission Optional Manual Option: No manual transmission option typically available for the 300 SD model in these years. Features Transmission Fluid Type: MB Spec 236.1 Automatic Transmission Fluid (ATF) - e.g., Mobil ATF 220 or equivalent 📐 Dimensions Exterior Wheelbase: 2850 mm (112.2 inches) Length: 4995 mm (196.7 inches) Width: 1790 mm (70.5 inches) Height: 1480 mm (58.3 inches) Weights Curb Weight Est: 1700-1850 kg (3750-4080 lbs) - Varies by equipment Gross Vehicle Weight Rating Est: Approx. 2200 kg (4850 lbs) 🛡️ Safety Features Ratings Crash Test Data: Modern crash test data is not directly comparable to vehicles of this era, but the W116 was known for its robust construction and safety features for its time. Active Features Braking System: Four-wheel disc brakes, power-assisted Passive Features Body Structure: Reinforced safety cage, crumple zones Restraint System: Seat belts (three-point front, lap rear - typically) 💡 Technology Features Infotainment Audio System: Factory fitted AM/FM radio, often with cassette player. Upgrades common. Driver Assistance Cruise Control: Standard cruise control (often vacuum-operated or early electronic). Connectivity Early Features: Central locking, power windows, power steering, automatic climate control (optional or standard depending on trim). Electrical Components Lighting: Halogen headlights with manual leveling adjustment. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000 miles (8,000 km) or 6 months, whichever comes first (check manual for precise intervals). Air Filter Replacement: Annually or every 10,000-15,000 miles (16,000-24,000 km), or as per manual recommendations. Fuel Filter Replacement: Every 15,000-20,000 miles (24,000-32,000 km) or as per manual. Crucial for diesel engines. Fluid Specifications Engine Oil Spec: API CD or higher for diesel engines, SAE 15W-40 or 10W-30 depending on climate (Specific MB spec required - consult manual). Coolant Spec: Ethylene glycol based antifreeze with corrosion inhibitors. MB Spec 325.0 or similar. Known Issues Diesel Engine Reliability: OM617 engines are renowned for their durability. Common issues can include injector pump wear, glow plug system faults, and potential vacuum line leaks affecting various systems. Climate Control: Aging R12 refrigerant systems and vacuum-actuated climate controls can be complex to diagnose and repair. Suspension Wear: Ball joints, tie rods, and bushings are common wear items due to age and mileage. Body Rust: Rust can be a significant concern on W116 models, particularly around wheel arches, rocker panels, and the subframes. 📚 Vehicle History Brand Heritage Mercedes Benz Legacy: Long history of engineering excellence, luxury, and durability Model Evolution W116 Introduction: The W116 was Mercedes-Benz's flagship luxury sedan from 1972 to 1980, replacing the W108/W109 chassis and preceding the W126 S-Class. 300 Sd Significance: The 300 SD was the first diesel-powered S-Class model offered in the North...