Mercedes 300 SD Turbo 1981-1985 Service Repair Manual
👋 Introduction
Market Position
Target Audience:
Mercedes-Benz 300 SD Turbo owners and independent mechanics seeking detailed repair and maintenance guidance.
Competitive Analysis
Value Proposition:
Provides comprehensive, year-specific service information for a critical period of the W126 chassis diesel models, essential for maintaining these robust vehicles.
Key Features
Key Features:
Covers multiple model years, detailed diagnostic and repair procedures, component inspection guidelines, fluid specifications, and troubleshooting tips.
📋 Manual Details
Coverage Areas
Model Years Covered:
1981, 1982, 1983, 1984, 1985
Page Count
Estimated Page Count:
Comprehensive (Specific page count not provided, but typical for a multi-year, multi-model service manual collection)
Troubleshooting vehicle problems, component condition inspection, line and hose inspection, suspension inspection, corrosion inspection, idle speed adjustment, injection timing checks
Repair Procedures:
Disassembly, inspection of parts for reuse, rebuilding, assembly of components, fuel filter replacement, air filter replacement, oxygen sensor replacement, spark plug replacement, coolant replacement, engine mount adjustment, clutch disk wear check, brake fluid replacement
Technical Depth
Technical Depth:
Comprehensive; covers basic maintenance to component rebuilding and diagnostic procedures for mechanics and knowledgeable DIY enthusiasts.
📊 Manual Specifications
File Format
File Format:
PDF / WINRAR
Print Quality
Print Quality:
Digital (High resolution, printable)
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Compatibility
Operating Systems:
Win95/98/ME/XP/vista/7/8/Linux/MAC, IOS, Android
Delivery
Delivery Method:
Instant Download
⚙️ Engine Specifications
Primary Engine
Engine Code:
OM617.951
Engine Type:
Inline 5-cylinder, turbocharged diesel
Performance
Displacement:
3.0 Liters (2998 cc)
Horsepower Approx:
123 hp @ 4350 rpm (varies slightly by year and specific output)
Torque Approx:
184 lb-ft (249 Nm) @ 2400 rpm (varies slightly by year and specific output)
Fuel System
Fuel Injection System:
Bosch inline injection pump with mechanical governor
Recommended Fuel:
Diesel fuel
Maintenance
Valve Adjustment Interval:
Typically every 10,000-15,000 miles or as specified in the manual.
Injection Timing Adjustment:
As needed, especially after fuel system work or if performance issues arise.
Technical Notes
Glow Plugs:
Essential for cold starting; manual covers inspection and replacement.
🔧 Transmission
Standard
Transmission Type:
4-speed automatic (common), 5-speed manual (less common for SD Turbo models, but covered in general W126 manuals)
Features
Automatic Transmission Model:
722.3 (e.g., 722.303)
Maintenance
Automatic Transmission Fluid Type:
Dexron III (or equivalent specification as per Mercedes-Benz)
Automatic Transmission Fluid Capacity:
Approximately 7-8 liters for a complete fluid and filter change (refer to manual for exact capacity).
Manual Transmission Oil Type:
GL-4 or GL-5 gear oil (specific viscosity recommended in manual)
📐 Dimensions
Exterior
Wheelbase:
112.6 inches (2860 mm)
Weights
Curb Weight Approx:
3,700 - 3,900 lbs (1678 - 1769 kg)
Gross Vehicle Weight Rating Approx:
4,850 lbs (2200 kg)
🛡️ Safety Features
Ratings
NHTSA Rating:
Not directly comparable to modern standards; known for robust construction.
Analog radio, cassette player (manual mentions cleaning tone head).
Driver Assistance
Driver Assistance Features:
ABS (Anti-lock Braking System) became available later in the W126 run, but not standard on early SD models. Level control systems (ADS, ASD) were also optional and covered.
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Every 3,000-5,000 miles or 6-12 months, depending on driving conditions (refer to manual for specific recommendations).
Fuel Filter Replacement Interval:
Typically every 15,000-20,000 miles or as indicated by symptoms.
Cooling System Service:
Coolant flush and replacement every 2-3 years or as recommended.
Fluid Specifications
Engine Oil Specification:
API CD or CE rated diesel engine oil, viscosity 15W-40 or 10W-40 (refer to manual for exact MB approval).
Coolant Specification:
Mercedes-Benz approved coolant (e.g., G05 or equivalent)
Brake Fluid Specification:
DOT 3 or DOT 4 hydraulic brake fluid.
Known Issues
Known Issues:
Vacuum system leaks (affecting door locks, climate control), rust in common areas (wheel wells, door bottoms), injector pump wear, glow plug system faults, potential for head gasket issues if overheated.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mercedes-Benz has a long-standing reputation for engineering excellence, durability, and luxury, particularly in its diesel models.
Model Evolution
Model Evolution:
The W126 S-Class, introduced in 1979, represented a significant step forward in automotive safety and comfort. The 300 SD Turbo (often referred to as the 'SD' in North America) was the entry-level diesel model, known for its fuel efficiency and longevity.
Production
Production Period W126:
1979-1991
300Sd Turbo Production Years:
1980-1985 (primarily for the US market, later models were 300SDL)
Manufacturing Location:
Germany
🏆 Awards & Recognition
Recognitions
Historical Recognition:
The W126 chassis was widely acclaimed for its safety, build quality, and comfort, often praised by automotive journalists of its era for being a benchmark in luxury sedans.
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