Mercedes Benz W124 Complete Workshop Service Repair Manual 1990 1991 1992 1993 1994 1995
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๐ท๏ธ Basic Information Identification Make: Mercedes-Benz Model: W124 Model Line Designation: E-Class (Second Generation) Codes Chassis Code: W124 ๐ Introduction Market Position Vehicle Segment: Executive Sedan/Coupe/Estate/Convertible Segment Positioning: The W124 represented the pinnacle of Mercedes-Benz engineering and build quality in its era, known for its durability, safety, and refinement. Competitive Analysis Primary Competitors: BMW 5 Series (E34), Audi 100/A6 (C3/C4), Volvo 700 Series, Lexus LS 400 (later models). Key Features Engineering Philosophy: Over-engineered for longevity, superior build quality, advanced safety features for its time, aerodynamic design. Manual Value Proposition: Empowers owners to perform comprehensive maintenance and repairs, saving significant costs while ensuring proper upkeep of a complex luxury vehicle. ๐ Manual Details Coverage Areas Years Covered: 1990, 1991, 1992, 1993, 1994, 1995 Body Styles Covered: Sedan (Saloon), Coupe, Estate (Station Wagon/T-Model), Convertible (Cabriolet) Model Variants Covered: All models, engines, trim levels, and transmission types within the specified years. Page Count Estimated Page Count: Extensive, likely exceeding 1500 pages (typical for complete Mercedes-Benz workshop manuals). Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Delivery Format: Downloadable Digital File Software Requirement: Adobe Reader (or compatible PDF viewer) ๐ Manual Coverage Systems Covered Powertrain: Engine mechanicals, fuel injection systems (KE-Jetronic, HFM, LH-Jetronic), ignition systems, exhaust systems, engine cooling systems. Transmission: Automatic transmission (e.g., 4-speed 722.4, 5-speed 722.5), manual transmission (if applicable to specific models within the range). Chassis And Suspension: Front and rear suspension, steering system, brake system (including ABS), wheel and tire specifications. Electrical And Electronics: Wiring diagrams, lighting systems, instrument cluster, power windows, central locking, climate control, engine control unit (ECU) diagnostics, body control modules. Body And Interior: Body panel removal and installation, interior trim, seats, doors, HVAC system. Procedures Included Maintenance: Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, spark plug replacement, belt checks. Repair: Engine overhaul, transmission repair, brake caliper replacement, suspension component replacement, electrical component diagnosis and repair. Troubleshooting: Diagnostic procedures, fault code interpretation (where applicable), symptom-based troubleshooting guides. Installation And Adjustment: Component installation, timing adjustments, pressure tests, alignment procedures. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complex engine and transmission rebuilds, including detailed diagnostic procedures and electrical schematics. ๐ Manual Specifications File Format File Type: PDF Print Quality Resolution: High-resolution, suitable for clear printing of text and diagrams. Features: Printable by chapter or entire document, searchable text for quick information retrieval. Binding Type Digital Binding: N/A (Digital File) Paper Type Digital Paper Type: N/A (Digital File) โ๏ธ Engine Specifications Primary Engine Engine Family: M102, M103, M104 (Inline-4, Inline-6 petrol), OM601, OM602, OM603 (Inline-4, Inline-5, Inline-6 diesel). Performance Power Output Range: Approximately 90 hp (diesel) to 270 hp (300CE-24/E320). Torque Range: Approximately 130 lb-ft (diesel) to 300 lb-ft (E320). Fuel System Petrol Injection Systems: Bosch KE-Jetronic (mechanical-hybrid), Bosch HFM (Hot Film Meter), Bosch LH-Jetronic (Mass Air Flow). Diesel Injection Systems: Bosch inline injection pumps, indirect injection (IDI). Technical Details Engine Management: Drivetrain Control Unit (DCU) or Engine Control Unit (ECU) depending on engine and year. ๐ง Transmission Standard Manual Option: Available on select models, typically 4 or 5-speed. Optional Automatic Option: Predominant transmission, 4-speed (722.4) or 5-speed (722.5) electronically controlled automatic. Features Automatic Modes: Comfort (C) and Sport (S) modes on some models. Fluid Requirements Automatic Transmission Fluid: MB 236.1, 236.3, or 236.7 (e.g., Dexron III equivalent or specialized MB fluids). ๐ Dimensions Exterior Length: Approx. 4740-4900 mm (Sedan/Coupe), 4775-4995 mm (Estate). Width: Approx. 1740-1750 mm. Height: Approx. 1430-1460 mm (Sedan/Coupe), 1485-1500 mm (Estate). Weights Curb Weight: Approx. 1400-1700 kg, depending on engine and body style. Gross Vehicle Weight: Varies by model, typically 1900-2200 kg. ๐ก๏ธ Safety Features Ratings Era Specific Safety: Considered exceptionally safe for its time, featuring a very strong safety cage, crumple zones, and advanced chassis design. Active Features Antilock Braking System: ABS standard on most models from 1990 onwards. Traction Control: ASR (Anti-Slip Regulation) available on higher-end models/engines. Passive Features Airbags: Driver's airbag became standard on most models during this period. Passenger airbags were optional or standard on later models. Seatbelts: Pre-tensioning front seatbelts. ๐ก Technology Features Infotainment Audio Systems: Factory-installed Becker radios with optional CD changers, cassette players. Climate Control: Manual or optional automatic climate control (Klimatronic). Driver Assistance Cruise Control: Standard on many models, cruise control functionality. Limited Slip Differential: Optional on some rear-wheel-drive models for improved traction. Connectivity Antenna System: Integrated antenna in rear window on sedans/coupes, mast antenna on estates/convertibles. ๐ง Maintenance Service Intervals Oil Change Interval: Typically 7,500 to 15,000 miles (12,000 to 24,000 km) or 12 months, depending on oil type and driving conditions. Refer to manual for specific interval. Major Service Interval: Major services including spark plugs, fuel filters, air filters typically around 30,000 miles (50,000 km). Fluid Specifications Engine Oil Specification: API SG or higher; ACEA A2-96 / B2-96. Viscosity grade often 10W-30, 10W-40, 15W-40,...
Automatic transmission (e.g., 4-speed 722.4, 5-speed 722.5), manual transmission (if applicable to specific models within the range).
Chassis And Suspension:
Front and rear suspension, steering system, brake system (including ABS), wheel and tire specifications.
Electrical And Electronics:
Wiring diagrams, lighting systems, instrument cluster, power windows, central locking, climate control, engine control unit (ECU) diagnostics, body control modules.
Body And Interior:
Body panel removal and installation, interior trim, seats, doors, HVAC system.
Comprehensive, covering everything from basic maintenance to complex engine and transmission rebuilds, including detailed diagnostic procedures and electrical schematics.
๐ Manual Specifications
File Format
File Type:
PDF
Print Quality
Resolution:
High-resolution, suitable for clear printing of text and diagrams.
Features:
Printable by chapter or entire document, searchable text for quick information retrieval.
Drivetrain Control Unit (DCU) or Engine Control Unit (ECU) depending on engine and year.
๐ง Transmission
Standard
Manual Option:
Available on select models, typically 4 or 5-speed.
Optional
Automatic Option:
Predominant transmission, 4-speed (722.4) or 5-speed (722.5) electronically controlled automatic.
Features
Automatic Modes:
Comfort (C) and Sport (S) modes on some models.
Fluid Requirements
Automatic Transmission Fluid:
MB 236.1, 236.3, or 236.7 (e.g., Dexron III equivalent or specialized MB fluids).
๐ Dimensions
Exterior
Length:
Approx. 4740-4900 mm (Sedan/Coupe), 4775-4995 mm (Estate).
Width:
Approx. 1740-1750 mm.
Height:
Approx. 1430-1460 mm (Sedan/Coupe), 1485-1500 mm (Estate).
Weights
Curb Weight:
Approx. 1400-1700 kg, depending on engine and body style.
Gross Vehicle Weight:
Varies by model, typically 1900-2200 kg.
๐ก๏ธ Safety Features
Ratings
Era Specific Safety:
Considered exceptionally safe for its time, featuring a very strong safety cage, crumple zones, and advanced chassis design.
Active Features
Antilock Braking System:
ABS standard on most models from 1990 onwards.
Traction Control:
ASR (Anti-Slip Regulation) available on higher-end models/engines.
Passive Features
Airbags:
Driver's airbag became standard on most models during this period. Passenger airbags were optional or standard on later models.
Seatbelts:
Pre-tensioning front seatbelts.
๐ก Technology Features
Infotainment
Audio Systems:
Factory-installed Becker radios with optional CD changers, cassette players.
Climate Control:
Manual or optional automatic climate control (Klimatronic).
Driver Assistance
Cruise Control:
Standard on many models, cruise control functionality.
Limited Slip Differential:
Optional on some rear-wheel-drive models for improved traction.
Connectivity
Antenna System:
Integrated antenna in rear window on sedans/coupes, mast antenna on estates/convertibles.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Typically 7,500 to 15,000 miles (12,000 to 24,000 km) or 12 months, depending on oil type and driving conditions. Refer to manual for specific interval.
Major Service Interval:
Major services including spark plugs, fuel filters, air filters typically around 30,000 miles (50,000 km).
Fluid Specifications
Engine Oil Specification:
API SG or higher; ACEA A2-96 / B2-96. Viscosity grade often 10W-30, 10W-40, 15W-40, or 5W-40 depending on climate. Check manual for specific engine recommendation (e.g., M102, M104).
Coolant Specification:
MB-Approval 325.0 (Glycol-ether-based antifreeze with corrosion inhibitors), typically a 50/50 mix with distilled water.
Brake Fluid Specification:
DOT 4 (MB-Approval 331.0).
Known Issues
Wiring Harness:
Biodegradable insulation on some engine wiring harnesses can become brittle and fail, leading to electrical issues.
Head Gasket:
Certain M104 engines (particularly early 24-valve variants) can be prone to head gasket failure due to design flaws or overheating.
Vacuum Lines:
Aging vacuum lines can leak, affecting engine idle, performance, and climate control operation.
Rust Corrosion:
Common areas include wheel arches, sills, door bottoms, and trunk lid edges, especially in regions with salt on roads.
๐ Vehicle History
Brand Heritage
Mercedes Benz Legacy:
Known for engineering excellence, luxury, durability, and pioneering automotive safety technologies.
Model Evolution
W124 Development:
Developed as a successor to the W123, the W124 was designed for extreme durability and market-leading aerodynamics, setting new standards in its class.
Facelift Impact:
The models covered (1990-1995) represent the later phase of the W124's lifecycle, including the 1993 facelift which introduced the 'E-Class' designation and revised styling (e.g., body-colored bumper inserts, revised grille).
Production
Production Period:
1984-1995 (with the facelift in 1993 renaming it the E-Class).
Manufacturing Locations:
Germany (Sindelfingen, Bremen), also assembled in other global locations.
๐ Awards & Recognition
Recognitions
Industry Acclaim:
Consistently ranked as one of the most reliable and durable vehicles of its era by various automotive publications.
Design Accolades:
Praised for its timeless design and aerodynamic efficiency, which contributed to its fuel economy and quiet operation.
Certifications
Quality Standards:
Met or exceeded all relevant automotive safety and emissions standards for the production years.