🏷️ Basic Information Identification Make: Mercedes-Benz Model: 300 SD Chassis Code: W116 Model Years Covered: 1978, 1979, 1980 Codes Engine Code: OM617 (3.0L Inline-5 Turbo Diesel) 👋 Introduction Market Position Target Audience: Mercedes-Benz W116 300 SD owners (DIY enthusiasts), independent repair shops, professional mechanics Competitive Analysis Unique Selling Proposition: Vehicle-specific, factory-level repair information, including diagrams, schematics, and step-by-step procedures, comparable to dealer service manuals. Key Features Key Features: Detailed illustrations, wiring schematics, diagnostic flowcharts, part specifications, torque values, comprehensive troubleshooting. 📋 Manual Details Coverage Areas Systems Covered: General Information, Engine Mechanical, Engine Electrical, Emission Control, Fuel System, Clutch System, Manual Transaxle, Automatic Transaxle, Driveshaft & Axle, Suspension System, Steering System, Restraint System, Brake System, Body (Interior & Exterior), Body Electrical System, HVAC Page Count Page Count: Not Specified (Comprehensive) Manual Type Manual Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Digital Delivery: Speed Download Features Usability Enhancement: Ability to print individual pages for use in the workshop, preventing damage to the original manual. 📖 Manual Coverage Systems Covered Engine Mechanical: Cylinder head, block, pistons, crankshaft, camshaft, timing, lubrication, cooling Engine Electrical: Ignition system, starter, alternator, battery, wiring diagrams Fuel System: Diesel injection pump (Bosch), injectors, fuel lines, filters, glow plug system Transmission: Manual and automatic transmission overhaul, clutch service, driveshaft and axle repair Suspension And Steering: Front and rear suspension components, steering gear, power steering system Brakes: Hydraulic system, disc brakes, parking brake, ABS (if equipped) Body And Interior: Body panel removal/installation, interior trim, seats, doors, windows Body Electrical: Lighting, instrumentation, power accessories, central locking, wiring schematics HVAC: Heating, ventilation, and air conditioning system diagnosis and repair Emission Control: Catalytic converter system (if equipped for certain markets), EGR valve (if equipped), emission control vacuum circuits. Driveshaft And Axle: U-joints, CV joints (if applicable), differential maintenance, axle shaft replacement. Restraint: Seat belt inspection and replacement, airbag systems (if applicable to specific market/late models, though unlikely for 1978-1980). Procedures Included Procedures Included: Step-by-step repair instructions, troubleshooting guides, diagnostic procedures, routine maintenance, component replacement, overhaul procedures, wiring schematic interpretation Diagnostic Procedures: Includes procedures for diagnosing engine performance, electrical faults, and mechanical issues using visual inspection, measurement, and component testing. Technical Depth Technical Depth: Comprehensive (from basic maintenance to complete engine and transmission rebuilds) 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: Printable individual pages (Adobe PDF Reader required) Binding Type Binding Type: Digital (No physical binding) Paper Type Paper Type: N/A (Digital Format) Compatibility Compatibility: All Versions of Windows and Mac Features Searchable Text: Likely searchable (common in PDF manuals, highly beneficial for quick lookups) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 5-Cylinder Turbocharged Diesel Displacement: 2998 cc (3.0 Liters) Bore X Stroke: 87.0 mm x 84.0 mm Compression Ratio: 21.0:1 (typical for OM617) Performance Horsepower: 115-125 hp @ 4350-4500 rpm (approximate, depending on specific tune) Torque: 170-185 lb-ft @ 2400 rpm (approximate, depending on specific tune) Fuel System Injection System: Bosch Inline Injection Pump (Plunger type) Fuel Type: Diesel Engine Management Glow Plug System: Pre-glow and post-glow system for cold starts 🔧 Transmission Standard Transmission Type: 4-speed Automatic (e.g., 4G-Tronic) Optional Transmission Type: 5-speed Manual (less common on 300 SD) Features Automatic Features: Torque converter, hydraulic control 📐 Dimensions Exterior Length: 4,995 mm (196.7 in) Width: 1,810 mm (71.3 in) Height: 1,450 mm (57.1 in) Weights Curb Weight: Approx. 1,750 kg (3,858 lbs) 🛡️ Safety Features Ratings Safety Standard: Reflects 1970s safety standards; features include crumple zones, robust body structure. Passive Features Passive Safety: Safety glass, padded dashboard, energy-absorbing steering column, reinforced A-pillars. Restraint System Seatbelts: Front and rear seat belts (lap and shoulder belts in front, likely lap belts in rear depending on configuration). 💡 Technology Features Infotainment Infotainment Features: Basic AM/FM radio with cassette player, analog gauges, mechanical climate control. Driver Assistance Driver Assistance Features: Power steering, cruise control (optional), limited driver assistance compared to modern vehicles. Connectivity Connectivity Features: N/A (No modern connectivity options like Bluetooth or USB). Body Electrical Central Locking System: Vacuum-operated central locking system, common issue with hoses and actuators. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000-7,500 miles or 6-12 months, with a filter change at each interval. Fuel Filter Interval: Recommended every 10,000-15,000 miles or annually, especially important for diesel engines. Air Filter Interval: Typically every 15,000-30,000 miles, or more frequently in dusty conditions. Fluid Specifications Engine Oil Type: Diesel engine oil, e.g., API CD or later, with appropriate viscosity for climate (e.g., 15W-40, 10W-30). Coolant Type: Ethylene glycol-based antifreeze (e.g., MB Spec 325.0 or equivalent). Transmission Fluid Automatic: Dexron II or III equivalent. Power Steering Fluid: MB Power Steering Fluid or equivalent hydraulic fluid. Known Issues Common Issues: Rusted fuel lines, vacuum leak issues (affecting central locking, HVAC, engine idle), worn engine mounts, injector pump seal leaks, potential for injector pump timing issues,...