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Mercedes-Benz 240D 1974 1975 1976 Factory Workshop Service Repair Manual
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Basic Information Identification Make: Mercedes-Benz Model: 240D Chassis Code: W115 Model Years Covered: 1974, 1975, 1976 Introduction Market Position Target Audience: Mercedes-Benz 240D owners, independent repair shops, DIY enthusiasts, classic...
Type: Cars
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Sku: 143769
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| Basic Information | |
| Identification | |
| Make: | Mercedes-Benz |
| Model: | 240D |
| Chassis Code: | W115 |
| Model Years Covered: | 1974, 1975, 1976 |
| Introduction | |
| Market Position | |
| Target Audience: | Mercedes-Benz 240D owners, independent repair shops, DIY enthusiasts, classic Mercedes-Benz collectors. |
| Value Proposition: | Provides access to the same authoritative repair information used by authorized Mercedes-Benz technicians. |
| Competitive Analysis | |
| Comparison To Other Manuals: | Superior to generic repair guides due to factory specificity and comprehensive coverage; offers a more in-depth resource than owner's manuals. |
| Key Features | |
| Authenticity: | Genuine Mercedes-Benz factory publication, ensuring accuracy and completeness. |
| Breadth Of Coverage: | Covers virtually every system and component of the vehicle for maintenance and repair. |
| Ease Of Use: | Digital format with menu-driven navigation and searchable PDFs enhances user experience. |
| Manual Details | |
| Coverage Areas | |
| Manual Type: | Factory Workshop Service Repair Manual |
| Language: | English |
| Format: | HTML/Flash menu with PDF files |
| Digital Format Compatibility: | Windows (95, 98, ME, XP, Vista, 7), Linux, MAC |
| Manual Coverage | |
| Systems Covered | |
| Engine General: | Complete overhaul and repair procedures for the OM616 diesel engine. |
| Engine Mechanical: | Engine block, cylinder head, pistons, connecting rods, crankshaft, camshaft, valve train, timing belt/chain, lubrication system, cooling system. |
| Engine Fuel System: | Diesel injection pump (Bosch VE type), injectors, fuel lines, glow plug system, fuel filters, fuel tank and pump. |
| Transmission: | Repair and overhaul of manual and automatic transmissions (if applicable for the model years), clutch, driveshafts. |
| Brakes: | Hydraulic system, brake discs, brake pads, brake calipers, wheel cylinders, master cylinder, parking brake, bleeding procedures. |
| Suspension: | Front and rear suspension components, shock absorbers, springs, control arms, ball joints, bushings, steering linkage. |
| Steering: | Steering gearbox, steering column, tie rods, steering linkage, power steering system (if equipped). |
| Electrical System: | Battery, alternator, starter motor, ignition system (less emphasis on gasoline engines as it's a diesel), lighting, wiring diagrams, fuses, relays, dashboard instruments. |
| Body And Interior: | Body panels, doors, windows, interior trim, seats, dashboard, HVAC system, upholstery, exterior trim, bumpers. |
| HVAC: | Heating, ventilation, and air conditioning system components, controls, refrigerant system (if applicable). |
| Procedures Included | |
| Routine Maintenance: | Oil changes, filter replacements (oil, fuel, air), fluid checks and top-offs, tire rotation, battery maintenance. |
| Major Repairs: | Engine rebuilding, transmission overhaul, brake system overhauls, suspension component replacement, steering system repair. |
| Diagnostics: | Troubleshooting guides for common issues, diagnostic procedures for engine performance, electrical faults, and mechanical problems. |
| Adjustments: | Valve adjustments, idle speed adjustments, timing adjustments, brake adjustments. |
| Bodywork: | Panel replacement, rust repair, glass replacement, trim installation. |
| Technical Depth | |
| Depth Level: | Comprehensive, covering everything from basic preventative maintenance to complete vehicle rebuilds and advanced diagnostics. |
| Diagnostic Charts: | Includes detailed diagnostic charts and flowcharts for troubleshooting various systems. |
| Torque Specifications: | Provides specific torque values for all critical fasteners throughout the vehicle. |
| Wiring Diagrams: | Detailed electrical wiring diagrams for all major systems. |
| Special Tools: | Identifies and describes required special tools for specific repair procedures. |
| Manual Specifications | |
| File Format | |
| File Type: | HTML/Flash menu with PDF embedded files |
| Searchability: | PDF files are likely searchable if optically character recognized (OCR), menu provides navigation. |
| Printability: | PDF files are printable for physical reference. |
| Print Quality | |
| Resolution: | Dependent on the original scan quality of the factory manual; typically high resolution for factory documents. |
| Clarity: | Professional clarity, including diagrams, illustrations, and text. |
| Binding Type | |
| Binding: | N/A (Digital Product) |
| Paper Type | |
| Paper Quality: | N/A (Digital Product) |
| Engine Specifications | |
| Primary Engine | |
| Engine Code: | OM616 |
| Engine Type: | Inline 4-cylinder, naturally aspirated diesel |
| Displacement: | 2.4 Liters (2399 cc) |
| Performance | |
| Horsepower: | Approximately 68-72 hp (depending on specific market and tuning) |
| Torque: | Approximately 100-103 lb-ft (depending on specific market and tuning) |
| Fuel System | |
| Injection System: | Bosch inline mechanical injection pump (VE type) |
| Fuel Type: | Diesel fuel |
| Cooling System | |
| Cooling Medium: | Engine coolant (typically a 50/50 mix of ethylene glycol and water) |
| Lubrication System | |
| Oil Type Specification: | API CD or ACEA B3 specification diesel engine oil (e.g., SAE 15W-40 or 10W-40 depending on climate) |
| Transmission | |
| Standard | |
| Transmission Type: | 4-speed manual transmission |
| Optional | |
| Transmission Type: | 4-speed automatic transmission (optional) |
| Features | |
| Clutch Type: | Single dry plate, hydraulically operated clutch (for manual) |
| Automatic Transmission Fluid: | Dexron II or equivalent automatic transmission fluid (for automatic) |
| Dimensions | |
| Exterior | |
| Wheelbase: | Approx. 2750 mm (108.3 inches) |
| Length: | Approx. 4700 mm (185.0 inches) |
| Width: | Approx. 1750 mm (68.9 inches) |
| Height: | Approx. 1420 mm (55.9 inches) |
| Weights | |
| Curb Weight: | Approx. 1400-1500 kg (3086-3307 lbs) |
| Wheels And Tires | |
| Standard Wheel Size: | 14-inch or 15-inch steel wheels |
| Standard Tire Size: | 175 SR 14 or 185 SR 14 |
| Bolt Pattern: | 5 x 112 mm |
| Safety Features | |
| Ratings | |
| Crash Test Information: | Modern crash test ratings are not directly applicable to vehicles of this era. However, Mercedes-Benz's reputation for build quality and safety was strong during this period. |
| Active Features | |
| Braking System: | Front disc brakes, rear drum brakes. Power assisted. |
| Passive Features | |
| Seat Belts: | Standard front seat belts, rear lap belts (three-point belts may have been optional or standard on later models). |
| Body Structure: | Reinforced safety cage, crumple zones (advanced for its time). |
| Steering Column: | Collapsible steering column designed to absorb impact energy. |
| Technology Features | |
| Infotainment | |
| Audio System: | Original systems likely consisted of analog radio (AM/FM), possibly with a cassette player in later stages. Modern upgrades are common. |
| Driver Assistance | |
| Advanced Features: | Very limited driver assistance features. Focus was on robust mechanical engineering. ABS was not standard or widely available for this model. |
| Connectivity | |
| Connectivity Options: | No built-in connectivity features by modern standards. |
| Maintenance | |
| Service Intervals | |
| Engine Oil Change: | Typically every 5,000-10,000 km (3,000-6,000 miles) or 6-12 months, depending on driving conditions and oil quality. |
| Fuel Filter Replacement: | Every 20,000-30,000 km (12,000-18,000 miles). |
| Air Filter Replacement: | Every 20,000-30,000 km (12,000-18,000 miles). |
| Coolant Flush: | Every 2-3 years or 40,000-60,000 km (24,000-36,000 miles). |
| Valve Adjustment: | Recommended every 40,000-60,000 km (24,000-36,000 miles) or as per manual specifications. |
| Fluid Specifications | |
| Engine Oil Capacity: | Approx. 6.5 Liters (6.9 US Quarts) with filter change. |
| Coolant Capacity: | Approx. 8.5 Liters (8.9 US Quarts). |
| Brake Fluid Type: | DOT 3 or DOT 4 brake fluid. |
| Known Issues | |
| Common Wear Items: | Bushings, ball joints, tie rod ends (due to age and mileage), vacuum lines, glow plug system reliability. |
| Diesel Specific Concerns: | Injection pump timing and sealing, injector nozzle wear, glow plug failures, fuel heater issues. |
| Rust Prone Areas: | Wheel wells, rocker panels, around window seals, jacking points (common for vehicles of this age). |
| Vehicle History | |
| Brand Heritage | |
| Manufacturer Legacy: | Mercedes-Benz, a pioneer in automotive engineering and safety, known for luxury, durability, and innovation. |
| Model Evolution | |
| W115 Introduction: | The W115 chassis (part of the '/8' or 'Strich Acht' series) was introduced in 1968, offering a more modern and spacious design compared to its predecessors. |
| 240D Introduction: | The 240D variant, powered by the reliable OM616 diesel engine, became a popular choice for its fuel economy and long-term durability, particularly in markets prioritizing efficiency. |
| Production | |
| Production Period: | The W115 series was produced from 1968 to 1976. The 240D was a key model within this range. |
| Manufacturing Locations: | Primarily manufactured in Germany, with production also occurring in other international facilities. |
| Awards & Recognition | |
| Recognitions | |
| Industry Acclaim: | While specific awards for the 240D model might not be widely documented, the W115 series was lauded for its engineering, durability, and market appeal, contributing to Mercedes-Benz's strong global reputation for quality and reliability. |