🏷️ Basic Information Identification Make: Mercedes-Benz Model: 240D Model Code: W123 (Sedan/Saloon) Codes Engine Code: OM616 (2.4L Diesel) 👋 Introduction Market Position Positioning: The Mercedes-Benz 240D (W123) was a cornerstone of Mercedes-Benz's reputation for durability, luxury, and engineering excellence in the late 1970s and early 1980s. It appealed to buyers seeking reliable, fuel-efficient, and comfortable transportation with the prestige of the Mercedes-Benz brand. Competitive Analysis Competitors: Competed with other executive sedans of the era, though its diesel engine offered a distinct advantage in fuel economy and longevity, differentiating it from gasoline-powered rivals from brands like BMW, Audi, and Volvo. Key Features Features: Robust build quality, distinctive W123 styling, reliable OM616 diesel engine, comfortable ride, focus on safety and longevity. 📋 Manual Details Coverage Areas Years Covered: 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985 Page Count Estimated Pages: N/A (Digital Format) Manual Type Type: Factory Service Workshop Manual Language Language: English Format Format: Digital Download (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed overhaul procedures, component testing, specifications, troubleshooting for the OM616 diesel engine. Fuel System: Injection pump (Bosch VE), injectors, fuel lines, filters, troubleshooting of diesel fuel delivery. Cooling System: Radiator, water pump, thermostat, hoses, coolant specifications, flush and fill procedures. Lubrication System: Oil pump, oil filter, oil cooler (if equipped), oil specifications, change intervals. Exhaust System: Exhaust manifold, pipes, muffler, catalytic converter (later models), emission control systems. Transmission Manual: 4-speed and 5-speed manual transmissions, clutch operation, overhaul, fluid specifications. Transmission Automatic: Automatic transmission (e.g., 722.1), torque converter, hydraulic system, overhaul, fluid specifications. Drivetrain Rear Axle: Differential, drive shafts, axle shafts, wheel bearings, lubrication, overhaul. Suspension Front: Independent front suspension, control arms, ball joints, springs, shock absorbers, steering knuckle, alignment specifications. Suspension Rear: Independent rear suspension (IRS) or solid axle depending on body style variant, trailing arms, springs, shock absorbers, alignment specifications. Steering System: Power steering system, steering box, tie rods, steering column, fluid specifications, troubleshooting. Brakes Front: Disc brakes, calipers, pads, rotors, brake fluid specifications, bleeding procedures. Brakes Rear: Disc brakes or drum brakes (depending on variant), parking brake system, fluid specifications, bleeding procedures. Electrical System 12V: Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting systems. Instrumentation Gauges: Speedometer, tachometer, fuel gauge, temperature gauge, warning lights, cluster repair. Lighting System: Headlights, taillights, turn signals, interior lighting, bulb specifications. HVAC System: Heating, ventilation, and air conditioning (if equipped), blower motor, heater core, refrigerant handling (later models). Body Panels: Door panels, hood, trunk lid, fenders, bumpers, trim, alignment, repair. Glass Windows: Windshield, side windows, rear window, seals, regulator mechanisms. Interior Trim: Seats, dashboard, door panels, headliner, carpet, removal and installation. Chassis Frame: Frame inspection, rust repair, structural components. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, lubrication points, spark plug replacement (gasoline variants, not 240D), timing belt inspection/replacement (N/A for OM616). Engine Overhaul: Complete engine disassembly, inspection, measurement, rebuilding of internal components (pistons, rings, bearings, valves, etc.). Transmission Repair: Manual and automatic transmission disassembly, component replacement, reassembly, adjustments. Brake Service: Pad/shoe replacement, rotor/drum machining or replacement, caliper/wheel cylinder rebuilding, brake line replacement, bleeding. Suspension Component Replacement: Ball joint, tie rod end, control arm, shock absorber, spring replacement. Electrical Troubleshooting: Diagnosis of electrical faults using wiring diagrams, testing of components. Diagnostics: Troubleshooting guides for various systems, identifying common problems and their solutions. Body Repair: Dent removal, panel replacement, rust treatment, welding procedures. HVAC Service: Component replacement, leak detection, refrigerant handling (where applicable). Technical Depth Depth: Comprehensive, covering full vehicle teardown, repair, and reassembly. Suitable for professional technicians and experienced DIYers. 📊 Manual Specifications File Format Quality: High-resolution scans of original factory documentation, typically searchable text within PDFs. Print Quality Print Readability: Designed for clarity and ease of reading in digital format. Print quality is dependent on user's printer. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Inline-4 Cylinder Diesel Engine Code: OM616.912 Displacement: 2399 cc (2.4 Liters) Bore X Stroke: 87.0 mm x 92.4 mm Compression Ratio: 21.0:1 Performance Horsepower Gross SAE: 72 hp @ 4000 rpm (approx.) Torque Gross SAE: 107 lb-ft @ 2400 rpm (approx.) Fuel System Injection Type: Bosch Inline Mechanical Fuel Injection (VE Pump) Fuel Type: Diesel Fuel 🔧 Transmission Standard Type: 4-speed Manual Optional Type: 4-speed Automatic (722.1) Features Clutch: Single dry plate, hydraulic actuation (manual transmission). Fluid Specs Manual Fluid: API GL-4 Gear Oil, SAE 75W-90 or 80W-90 Automatic Fluid: Dexron II Automatic Transmission Fluid 📐 Dimensions Exterior Wheelbase: 2794 mm (110 inches) Length: 4735 mm (186.4 inches) Width: 1788 mm (70.4 inches) Height: 1438 mm (56.6 inches) Weights Curb Weight Approx: 1460 kg (3219 lbs) Gross Vehicle Weight Rating Approx: 1900 kg (4189 lbs) 🛡️ Safety Features Ratings Historical Safety Standards: Designed to meet safety standards of the era, featuring crumple zones, safety steering...