Mercedes-Benz Model 126 Service & Repair Manual 1981-1991

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: W126 S-Class Model Variants: 300SD, 300SDL, 300 SE, 300 SEL, 350 SD, 350 SDL, 380 SE, 380 SEL, 380 SEC, 420 SEL, 500 SEL, 500 SEC, 560 SEL, 560 SEC Production Years Covered: 1981-1991 Codes Chassis Code: W126 👋 Introduction Market Position Positioning: The Mercedes-Benz W126 S-Class, produced from 1979 to 1991, represented the pinnacle of luxury, engineering, and safety for its era. This manual covers the later production years and key variants, including the diesel models (SD/SDL) and the potent V8 and V12 (though V12 is not explicitly listed but often associated with this generation's later models like the 560SEL, it's important to note the manual covers the listed models) AMG variants. Target Audience: Owners of 1981-1991 Mercedes-Benz W126 S-Class models seeking to perform maintenance, repairs, or diagnostics themselves, or professional mechanics needing a comprehensive reference. Competitive Analysis Competitors: Competed against other high-end luxury sedans and coupes of its time, such as the BMW 7 Series (E23/E32), Audi V8 Quattro, Jaguar XJ, and Cadillac Fleetwood. The W126 was renowned for its build quality, durability, and advanced features. Key Features Manual Highlights: Comprehensive coverage of diverse engine options (diesel and gasoline), detailed troubleshooting guides, extensive wiring diagrams, and step-by-step repair procedures with illustrations. This is the same information utilized by authorized Mercedes-Benz service centers. 📋 Manual Details Coverage Areas Covered Models And Years: 300 SD (1981-1985), 300 SDL (1986-1987), 300 SE (1988-1991), 300 SEL (1988-1991), 350 SD (1991), 350 SDL (1990-1991), 380 SE (1984-1985), 380 SEL (1981-1983), 380 SEC (1982-1983), 420 SEL (1986-1991), 500 SEL (1984-1985), 500 SEC (1984-1985), 560 SEL (1986-1991), 560 SEC (1986-1991) Page Count Total Pages: Over 5,000 pages Manual Type Type: Workshop Service and Repair Manual Language Language: English Format Format: PDF (also compatible with HTML/SWF) Compatibility: Compatible with all PC-based Windows operating systems, Mac, and Linux. 📖 Manual Coverage Systems Covered All Major Systems: Engine Mechanical, Engine Control System, Cooling System, Fuel System, Emission Control Systems, Exhaust System, Ignition System, Starting System, Charging System, Clutch System, Manual Transmission, Automatic Transmission, Drive Shaft, Drive Axle, Suspension System (Front & Rear), Steering System, Brake System, Wheels & Tires, Electrical System, Body & Chassis, Climate Control, Safety Systems (SRS, ABS where applicable), Interior & Exterior Trim, Maintenance, Troubleshooting. Engine Mechanical Details: Cylinder head removal and installation, valve train servicing, piston and connecting rod installation, crankshaft installation, timing chain/belt replacement, lubrication system components (oil pump, filter, oil cooler). Engine Control System: Diagnosis and repair of fuel injection systems (K-Jetronic/KE-Jetronic), ignition timing, idle speed control, emission control components (EGR, Lambda sensors), engine sensors (crankshaft position, camshaft position, throttle position, coolant temperature). Transmission And Drivetrain: Automatic transmission servicing (fluid change, filter replacement, valve body adjustments), torque converter removal and installation, drive shaft maintenance, universal joint replacement, rear axle and differential service. Suspension And Steering: Front and rear suspension component replacement (shocks, struts, control arms, ball joints, bushings), steering gear diagnosis and repair, power steering pump and hose replacement, wheel alignment procedures. Brake System Repair: Brake pad and rotor replacement, caliper servicing, brake line replacement, master cylinder and brake booster testing and replacement, ABS system troubleshooting and component replacement. Electrical System Wiring Diagrams: Detailed wiring diagrams for all electrical systems including lighting, starting, charging, instrument cluster, power accessories, climate control, and safety systems. Troubleshooting electrical faults using wiring schematics. Climate Control System: Diagnosis and repair of HVAC systems, including blower motor, evaporator, condenser, refrigerant lines, climate control panel operation, and vacuum actuators for air distribution. Fuel System Maintenance: Fuel pump testing, fuel injector servicing, fuel pressure regulator testing, fuel tank cleaning and inspection, charcoal canister system (emission control). Lighting And Instrumentation: Headlight aiming, bulb replacement, instrument cluster repair, warning light diagnosis, gauge calibration. Procedures Included Repair And Maintenance: Complete disassembly and reassembly instructions, detailed repair procedures, step-by-step diagnostics, routine maintenance, fluid changes, component replacement, electrical system troubleshooting, wiring diagrams, body repair, chassis adjustments, emission control adjustments. Tune Up Procedures: Spark plug replacement, ignition timing adjustment, fuel filter replacement, air filter replacement, fuel system cleaning, distributor maintenance (where applicable). Troubleshooting Guides: Systematic troubleshooting steps for common drivability issues, electrical problems, HVAC malfunctions, and suspension/brake noise. Body And Interior Repair: Door panel removal, seat repair, headliner replacement, body panel alignment, rust repair techniques, glass replacement, bumper repair. Diagnostic Procedures: Fault code reading (where applicable for electronic systems), voltage drop testing, pressure testing, vacuum testing, and component resistance checks. Technical Depth Depth Of Coverage: Comprehensive, covering everything from basic fluid checks and filter replacements to major engine rebuilds, transmission overhauls, and complex electrical diagnostics. Designed for both DIY enthusiasts and professional mechanics. Specific Rebuild Procedures: Detailed instructions for engine internal component rebuilding, transmission overhauls, differential rebuilds, and steering box rebuilding. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable PDF, allowing users to quickly find specific...

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Tipo: Car

Proveedor:

SKU: 290842

Colecciones: ALL

Disponibilidad: En stock

Etiquetas: 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 Car Engines Mercedes Mercedes Benz Model 126

Variantes de producto

Descripción

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

W126 S-Class

Model Variants:

300SD, 300SDL, 300 SE, 300 SEL, 350 SD, 350 SDL, 380 SE, 380 SEL, 380 SEC, 420 SEL, 500 SEL, 500 SEC, 560 SEL, 560 SEC

Production Years Covered:

1981-1991

Codes

Chassis Code:

👋 Introduction

Market Position

Positioning:

The Mercedes-Benz W126 S-Class, produced from 1979 to 1991, represented the pinnacle of luxury, engineering, and safety for its era. This manual covers the later production years and key variants, including the diesel models (SD/SDL) and the potent V8 and V12 (though V12 is not explicitly listed but often associated with this generation's later models like the 560SEL, it's important to note the manual covers the listed models) AMG variants.

Target Audience:

Owners of 1981-1991 Mercedes-Benz W126 S-Class models seeking to perform maintenance, repairs, or diagnostics themselves, or professional mechanics needing a comprehensive reference.

Competitive Analysis

Competitors:

Competed against other high-end luxury sedans and coupes of its time, such as the BMW 7 Series (E23/E32), Audi V8 Quattro, Jaguar XJ, and Cadillac Fleetwood. The W126 was renowned for its build quality, durability, and advanced features.

Key Features

Manual Highlights:

Comprehensive coverage of diverse engine options (diesel and gasoline), detailed troubleshooting guides, extensive wiring diagrams, and step-by-step repair procedures with illustrations. This is the same information utilized by authorized Mercedes-Benz service centers.

📋 Manual Details

Coverage Areas

Covered Models And Years:

300 SD (1981-1985), 300 SDL (1986-1987), 300 SE (1988-1991), 300 SEL (1988-1991), 350 SD (1991), 350 SDL (1990-1991), 380 SE (1984-1985), 380 SEL (1981-1983), 380 SEC (1982-1983), 420 SEL (1986-1991), 500 SEL (1984-1985), 500 SEC (1984-1985), 560 SEL (1986-1991), 560 SEC (1986-1991)

Page Count

Total Pages:

Over 5,000 pages

Manual Type

Type:

Workshop Service and Repair Manual

Language

Language:

English

Format

Format:

PDF (also compatible with HTML/SWF)

Compatibility:

Compatible with all PC-based Windows operating systems, Mac, and Linux.

📖 Manual Coverage

Systems Covered

All Major Systems:

Engine Mechanical, Engine Control System, Cooling System, Fuel System, Emission Control Systems, Exhaust System, Ignition System, Starting System, Charging System, Clutch System, Manual Transmission, Automatic Transmission, Drive Shaft, Drive Axle, Suspension System (Front & Rear), Steering System, Brake System, Wheels & Tires, Electrical System, Body & Chassis, Climate Control, Safety Systems (SRS, ABS where applicable), Interior & Exterior Trim, Maintenance, Troubleshooting.

Engine Mechanical Details:

Cylinder head removal and installation, valve train servicing, piston and connecting rod installation, crankshaft installation, timing chain/belt replacement, lubrication system components (oil pump, filter, oil cooler).

Engine Control System:

Diagnosis and repair of fuel injection systems (K-Jetronic/KE-Jetronic), ignition timing, idle speed control, emission control components (EGR, Lambda sensors), engine sensors (crankshaft position, camshaft position, throttle position, coolant temperature).

Transmission And Drivetrain:

Automatic transmission servicing (fluid change, filter replacement, valve body adjustments), torque converter removal and installation, drive shaft maintenance, universal joint replacement, rear axle and differential service.

Suspension And Steering:

Front and rear suspension component replacement (shocks, struts, control arms, ball joints, bushings), steering gear diagnosis and repair, power steering pump and hose replacement, wheel alignment procedures.

Brake System Repair:

Brake pad and rotor replacement, caliper servicing, brake line replacement, master cylinder and brake booster testing and replacement, ABS system troubleshooting and component replacement.

Electrical System Wiring Diagrams:

Detailed wiring diagrams for all electrical systems including lighting, starting, charging, instrument cluster, power accessories, climate control, and safety systems. Troubleshooting electrical faults using wiring schematics.

Climate Control System:

Diagnosis and repair of HVAC systems, including blower motor, evaporator, condenser, refrigerant lines, climate control panel operation, and vacuum actuators for air distribution.

Fuel System Maintenance:

Fuel pump testing, fuel injector servicing, fuel pressure regulator testing, fuel tank cleaning and inspection, charcoal canister system (emission control).

Lighting And Instrumentation:

Headlight aiming, bulb replacement, instrument cluster repair, warning light diagnosis, gauge calibration.

Procedures Included

Repair And Maintenance:

Complete disassembly and reassembly instructions, detailed repair procedures, step-by-step diagnostics, routine maintenance, fluid changes, component replacement, electrical system troubleshooting, wiring diagrams, body repair, chassis adjustments, emission control adjustments.

Tune Up Procedures:

Spark plug replacement, ignition timing adjustment, fuel filter replacement, air filter replacement, fuel system cleaning, distributor maintenance (where applicable).

Troubleshooting Guides:

Systematic troubleshooting steps for common drivability issues, electrical problems, HVAC malfunctions, and suspension/brake noise.

Body And Interior Repair:

Door panel removal, seat repair, headliner replacement, body panel alignment, rust repair techniques, glass replacement, bumper repair.

Diagnostic Procedures:

Fault code reading (where applicable for electronic systems), voltage drop testing, pressure testing, vacuum testing, and component resistance checks.

Technical Depth

Depth Of Coverage:

Comprehensive, covering everything from basic fluid checks and filter replacements to major engine rebuilds, transmission overhauls, and complex electrical diagnostics. Designed for both DIY enthusiasts and professional mechanics.

Specific Rebuild Procedures:

Detailed instructions for engine internal component rebuilding, transmission overhauls, differential rebuilds, and steering box rebuilding.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely searchable PDF, allowing users to quickly find specific terms and procedures.

Print Quality

Printability:

Fully printable without restrictions. High-resolution scans ensure clarity of text and diagrams.

Illustration Clarity:

High-quality scans ensuring clear, detailed illustrations, diagrams, and photographs essential for accurate repairs.

Binding Type

Binding:

Digital Download (PDF)

Paper Type

Paper Quality Equivalent:

High-quality, glossy paper equivalent (for printed versions).

⚙️ Engine Specifications

Primary Engine

Diesel Engines:

OM617 (2.9L Turbo Diesel - 300SD/SDL), OM603 (3.0L Turbo Diesel - 300SDL), OM602 (2.5L Turbo Diesel - 350SD/SDL).

Gasoline Engines:

M103 (3.0L Inline-6 - 300 SE/SEL), M116 (3.8L V8 - 380 SE/SEL/SEC), M117 (4.2L V8 - 420 SEL, 5.0L V8 - 500 SEL/SEC), M117 (5.6L V8 - 560 SEL/SEC).

Diesel Engine Displacement:

2.9L (OM617), 3.0L (OM603), 2.5L (OM602).

Gasoline Engine Displacement:

3.0L (M103), 3.8L (M116), 4.2L (M117), 5.0L (M117), 5.6L (M117).

Performance

Horsepower And Torque Range:

Varies significantly by engine. Diesel engines typically produced between 115-150 hp. Gasoline engines ranged from approximately 155 hp (3.0L) to over 238 hp (5.6L V8).

Engine Codes:

OM617.951 (300SD), OM603.961 (300SDL), M103.980 (300SE/SEL), M116.960 (380 SE/SEL/SEC), M117.963 (420 SEL), M117.968 (500 SEL/SEC), M117.967 (560 SEL/SEC).

Compression Ratio:

Diesel engines: approx. 21.5:1. Gasoline engines: approx. 8.0:1 to 10.0:1 depending on engine variant.

Fuel System

Fuel Delivery:

Diesel engines utilize Bosch mechanical injection pumps. Gasoline engines feature Bosch K-Jetronic (CIS) or KE-Jetronic (CIS-E) fuel injection systems, depending on the model year and engine variant.

🔧 Transmission

Standard

Transmission Type:

Primarily 4-speed and 5-speed automatic transmissions (e.g., 722.3, 722.4, 722.5). Manual transmissions were rare in North America for the W126 but available in some markets.

Optional

Optional Transmission:

5-speed automatic (e.g., 722.5 with a torque converter lock-up clutch) became more common in later models.

Features

Transmission Features:

Hydraulic control, self-leveling systems on some models, sophisticated torque converter designs for smooth power delivery.

📐 Dimensions

Exterior

Wheelbase And Length:

Standard wheelbase (e.g., 114.7 inches) and long wheelbase (e.g., 119.9 inches for SEL/SDL models). Overall length varies but typically around 198-204 inches.

Body Styles:

Sedan (W126) and Coupe (C126).

Interior

Cabin Space:

Spacious seating for five adults, with significantly more rear legroom in SEL/SDL long-wheelbase models. High-quality materials and ergonomic design.

Weights

Curb Weight:

Curb weight typically ranged from approximately 3,600 lbs for coupes to over 4,000 lbs for long-wheelbase sedans.

🛡️ Safety Features

Ratings

Crash Test Performance:

While formal crash test ratings as we know them today were less standardized, the W126 was engineered with a strong safety cage, crumple zones, and advanced safety features for its time, often exceeding contemporary standards.

Active Features

Active Safety:

Anti-lock Braking System (ABS) became standard or optional on most models during this period. Power-assisted steering for responsive handling.

Passive Features

Passive Safety:

Driver and passenger airbags (introduced later in the W126 production run), seatbelt pretensioners, reinforced body structure, side-impact protection beams.

Seat Belts:

3-point seat belts with automatic locking retractors for front occupants, conventional lap and shoulder belts for rear occupants.

💡 Technology Features

Infotainment

Audio System:

Original systems typically included high-fidelity AM/FM radio, cassette players, and often advanced features for the time like seek tuning and Dolby noise reduction. Premium sound options were available.

Driver Assistance

Driver Aid Systems:

ABS, cruise control, self-leveling suspension (on some models), power seats with memory functions, automatic climate control.

Suspension Features:

Independent suspension with coil springs and shock absorbers, optional self-leveling suspension system for the rear axle on some long-wheelbase models.

Connectivity

Original Connectivity:

Limited by modern standards. Primarily analog systems. Antennas were integrated into the windshield or body panels. Power windows, mirrors, and locks were electrically operated.

🔧 Maintenance

Service Intervals

Typical Maintenance Schedule:

Oil changes: every 5,000-10,000 miles or 1 year. Air filter: every 20,000-30,000 miles. Fuel filter: every 30,000-50,000 miles. Spark plugs: every 30,000-60,000 miles depending on type. Coolant flush: every 2-3 years or 30,000-50,000 miles. Brake fluid: every 2 years.

Brake Fluid Type:

Mercedes-Benz specification 331.0, equivalent to DOT 4.

Fluid Specifications

Engine Oil:

API SG or higher, SAE 15W-40 or 10W-40 for diesel engines. SAE 10W-30 or 5W-30 for gasoline engines (check owner's manual for specific viscosity based on climate).

Coolant:

Mercedes-Benz approved Antifreeze/Coolant (e.g., G48 or similar ethylene glycol-based). Mixture of 50% coolant and 50% distilled water.

Transmission Fluid:

MB 236.1 or MB 236.6 approved Automatic Transmission Fluid (ATF). Equivalent to Dexron III for some models.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

MB 236.3 approved hydraulic fluid, or an equivalent Dexron II/III ATF.

Differential Fluid:

SAE 90 Hypoid gear oil (API GL-5).

Known Issues

Common Problems:

Vacuum system leaks (affecting central locking, climate control, engine management), sagging headliner, SRS warning light illumination, differential seal leaks, rust in common areas (wheel arches, door bottoms), worn engine mounts, biodegradable wiring insulation breakdown (on later models).

Cooling System Issues:

Plastic coolant expansion tank cracks, water pump seal leaks, thermostat housing leaks, heater core leaks.

📚 Vehicle History

Brand Heritage

Mercedes Benz Legacy:

Mercedes-Benz has a long-standing reputation for engineering excellence, luxury, and safety. The S-Class line (Sonderklasse - Special Class) has always been the flagship model, showcasing the brand's latest innovations.

Model Evolution

W126 Development:

The W126 was a significant redesign from the W116, featuring improved aerodynamics, lighter construction, and enhanced safety. It introduced features like airbags and ABS to the S-Class. The model range expanded to include more engine options and body styles (coupe SEC).

Production

Production Period:

The W126 platform was produced from 1979 to 1991, making it one of the longest-running generations of the S-Class. The manual specifically covers the 1981-1991 period, encompassing all major engine and body style updates within that timeframe.

🏆 Awards & Recognition

Recognitions

Automotive Accolades:

The W126 S-Class consistently received praise from automotive journalists and critics for its luxury, build quality, ride comfort, and safety innovations, solidifying its reputation as one of the finest sedans of its generation. It was often considered the benchmark for luxury car engineering.