Mercedes Benz W124 1986-1993 Service Repair Workshop Manual Pdf
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🏷️ Basic Information Identification Make: Mercedes-Benz Model: W124 (E-Class) Chassis Code: W124 Body Styles Covered: Saloon (Sedan), Estate (Station Wagon), Coupe, Cabriolet Codes Internal Project Code: W124 👋 Introduction Market Position Vehicle Segment: Executive Car (mid-size luxury) Target Audience: Discerning buyers seeking refined comfort, durability, and engineering excellence Competitive Analysis Key Competitors: BMW 5 Series (E28/E34), Audi 100/200, Volvo 240/740, Jaguar XJ Key Features Engineering Philosophy: Over-engineered for durability and long-term reliability, focus on safety and comfort Design Era: Epitome of Mercedes-Benz 'build quality' era, known for robust construction 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Workshop Manual Language: English Format: PDF Download Page Count Estimated Page Count: Hundreds (Specific count not provided, but described as 'very detailed') Licensing Licensing Terms: Lifetime use, no expiry, no renewal fees Compatibility Operating Systems: Windows and macOS Features Printing Capability: Printable (single pages or entire manual) Device Compatibility: Usable on multiple computers, tablets, and smartphones 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, component diagnosis, fuel injection systems (CIS-E, KE-Jetronic, HFM), ignition systems, cooling system, lubrication system Transmission Drivetrain: Manual and automatic transmission repair and overhaul, differential, driveshafts, axles Suspension Steering: Front and rear suspension components, shock absorbers, springs, ball joints, steering box, power steering system Brakes: Brake system diagnosis, hydraulic components, ABS (Anti-lock Braking System) troubleshooting and repair, brake pad/disc replacement Electrical Systems: Wiring diagrams, starter motor, alternator, battery, lighting systems, fuse box, relays, dashboard instrumentation, power windows, central locking Body Chassis: Bodywork repair, rust prevention, door mechanisms, glass replacement, trim, underbody coatings HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system service and repair Fuel System: Fuel tank, fuel pump, fuel lines, fuel filter replacement Procedures Included Maintenance: Scheduled maintenance tasks, fluid changes, filter replacements, belt adjustments Diagnostics: Troubleshooting guides, symptom-based diagnostics, fault code interpretation (where applicable) Repair: Step-by-step instructions for all major and minor repairs, component replacement Overhaul: Complete engine and transmission rebuild procedures Calibration Adjustment: Ignition timing, idle speed, fuel mixture adjustments Technical Depth Depth Of Information: Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts Illustrations: Hundreds of detailed photos and exploded diagrams Data Tables: Specifications, tolerances, torque values, fluid capacities 📊 Manual Specifications File Format File Type: PDF Searchability: Assumed to be text-searchable due to professional format Print Quality Print Resolution: High-quality, suitable for clear printing of diagrams and text Binding Type Digital Format: Downloadable file Paper Type Physical Equivalent: Comparable to professional workshop manuals typically printed on durable paper stock ⚙️ Engine Specifications Primary Engine Engine Families Covered: M102 (4-cylinder), M103 (6-cylinder), M104 (6-cylinder, DOHC), OM601 (4-cylinder Diesel), OM602 (5-cylinder Diesel), OM603 (6-cylinder Diesel) Engine Displacement Examples 2.0L: Approx. 1997cc (M102) 2.3L: Approx. 2299cc (M102, M103), 2298cc (OM601) 2.6L: Approx. 2597cc (M103) 3.0L: Approx. 2996cc (M103, M104, OM603), 2962cc (OM602) 3.2L: Approx. 3199cc (M104) 2.5L Diesel: Approx. 2497cc (OM601) 2.9L Diesel: Approx. 2874cc (OM602) 3.0L Diesel: Approx. 2996cc (OM603) Performance Horsepower Range: 75 hp (Diesel) to 231 hp (3.2L 24V) Torque Range: 125 lb-ft (Diesel) to 228 lb-ft (3.2L 24V) Fuel System Injection Systems: Bosch CIS-E (Continuous Injection System - Electronic), KE-Jetronic, HFM (Hot Film Air Mass sensor) Fuel Type: Unleaded gasoline (Octane rating specific to market and engine), Diesel fuel Engine Construction Block Material: Cast Iron Head Material: Aluminum Alloy 🔧 Transmission Standard Transmission Types: 4-speed and 5-speed manual transmissions, 4-speed and 5-speed automatic transmissions (722.3, 722.4, 722.5, 722.6) Optional Optional Transmissions: 5-speed automatic transmission (722.6, introduced later in production) Features Automatic Features: Lock-up clutch, electronic control (later models), sport/economy modes 📐 Dimensions Exterior Wheelbase: Approx. 2795 mm (110.0 in) for Saloon/Coupe, 2800 mm (110.2 in) for Estate Length: Varies by body style and model year, e.g., Saloon approx. 4740-4770 mm Width: Approx. 1740-1760 mm Height: Approx. 1420-1450 mm Weights Curb Weight: Varies significantly by engine and body style, typically 1400-1700 kg 🛡️ Safety Features Ratings Historical Safety Design: Designed with a strong emphasis on occupant safety for its era, high levels of passive safety Active Features ABS: Anti-lock Braking System (ABS) widely available and often standard on higher trims Traction Control: ASR (Anti-Slip Regulation) introduced on some later models Passive Features Airbags: Driver's airbag became widely available and standard during this generation Seatbelts: Front and rear seat belts, often with pre-tensioners on front belts Crash Structure: Advanced crumple zones, reinforced passenger cell for superior impact protection 💡 Technology Features Infotainment Audio Systems: Various OEM Becker audio systems, often with cassette players and optional CD changers. Manual covers basic electrical connections and troubleshooting. Driver Assistance Cruise Control: Standard on many models, a sophisticated vacuum-actuated system for its time. Climate Control: Manual or automatic climate control systems, featuring sophisticated vacuum controls and servo actuators. Connectivity Antenna Systems: Integrated antenna systems in windshield or rear window on some models. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 10,000 - 15,000 km (6,000 - 9,000...
Bosch CIS-E (Continuous Injection System - Electronic), KE-Jetronic, HFM (Hot Film Air Mass sensor)
Fuel Type:
Unleaded gasoline (Octane rating specific to market and engine), Diesel fuel
Engine Construction
Block Material:
Cast Iron
Head Material:
Aluminum Alloy
🔧 Transmission
Standard
Transmission Types:
4-speed and 5-speed manual transmissions, 4-speed and 5-speed automatic transmissions (722.3, 722.4, 722.5, 722.6)
Optional
Optional Transmissions:
5-speed automatic transmission (722.6, introduced later in production)
Features
Automatic Features:
Lock-up clutch, electronic control (later models), sport/economy modes
📐 Dimensions
Exterior
Wheelbase:
Approx. 2795 mm (110.0 in) for Saloon/Coupe, 2800 mm (110.2 in) for Estate
Length:
Varies by body style and model year, e.g., Saloon approx. 4740-4770 mm
Width:
Approx. 1740-1760 mm
Height:
Approx. 1420-1450 mm
Weights
Curb Weight:
Varies significantly by engine and body style, typically 1400-1700 kg
🛡️ Safety Features
Ratings
Historical Safety Design:
Designed with a strong emphasis on occupant safety for its era, high levels of passive safety
Active Features
ABS:
Anti-lock Braking System (ABS) widely available and often standard on higher trims
Traction Control:
ASR (Anti-Slip Regulation) introduced on some later models
Passive Features
Airbags:
Driver's airbag became widely available and standard during this generation
Seatbelts:
Front and rear seat belts, often with pre-tensioners on front belts
Crash Structure:
Advanced crumple zones, reinforced passenger cell for superior impact protection
💡 Technology Features
Infotainment
Audio Systems:
Various OEM Becker audio systems, often with cassette players and optional CD changers. Manual covers basic electrical connections and troubleshooting.
Driver Assistance
Cruise Control:
Standard on many models, a sophisticated vacuum-actuated system for its time.
Climate Control:
Manual or automatic climate control systems, featuring sophisticated vacuum controls and servo actuators.
Connectivity
Antenna Systems:
Integrated antenna systems in windshield or rear window on some models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 10,000 - 15,000 km (6,000 - 9,000 miles) or annually, depending on driving conditions and oil type used.
Major Service Interval:
Around 40,000 - 60,000 km (25,000 - 37,000 miles) for spark plug replacement, fuel filter, air filter, and transmission fluid/filter changes.
Fluid Specifications
Engine Oil Viscosity:
Varies by engine and climate, commonly 10W-40, 15W-40, 5W-40 (synthetic for cooler climates or high performance)
Coolant Type:
Proprietary Mercedes-Benz coolant or equivalent (e.g., Glysantin G05)
Transmission Fluid:
MB 236.1 or MB 236.3 for 4-speed automatics (e.g., Dexron II), MB 236.10/11 for later 5-speed automatics
Brake Fluid Type:
DOT 4
Known Issues
Wiring Harness Degradation:
Common issue with older Mercedes, insulation can become brittle and fail. Manual provides diagnostic and repair procedures.
Rust Susceptibility:
Certain areas like wheel arches, sills, and boot lid edges can be prone to rust. Manual covers body repair and prevention.
Biodegradable Engine Wiring:
Some early M104 engines used biodegradable engine wiring harnesses; the manual details identification and replacement.
Vacuum Lines:
Aging vacuum lines can lead to performance issues and unintended system operation (e.g., cruise control, climate control).
Automatic Transmission Leaks:
Common leak points include the transmission cooler lines and the connector sleeve.
📚 Vehicle History
Brand Heritage
Mercedes Benz Legacy:
Established reputation for engineering, luxury, and durability dating back to the early 20th century
Model Evolution
W124 Introduction:
Launched in 1984 (model year 1985 in some markets), with significant updates throughout its lifecycle, including the 1989 facelift and introduction of the M104 engines.
Facelifts:
Significant facelift in 1989 introduced revised styling (e.g., side protective strips integrated into body color), improved aerodynamics, and updated engine options.
Production
Production Period:
1984/1985 - 1995/1996 (W124 chassis generation), with this manual covering the primary 1986-1993 range.
Production Locations:
Primarily Germany (Sindelfingen, Bremen), also assembly in other countries.
🏆 Awards & Recognition
Recognitions
Reputation For Durability:
Widely recognized for exceptional build quality and longevity, often referred to as one of the best Mercedes-Benz models ever made.
Design Awards:
While specific design awards are not highlighted in the product description, the W124's aerodynamic and functional design was highly regarded.