Mercedes Benz W126 1979-1992 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Mercedes-Benz Model: W126 Model Generation: First Generation (1979-1991) Body Style: SE (Standard Wheelbase Sedan), SEL (Long Wheelbase Sedan), SEC (Coupe) Codes Chassis Code: W126 👋 Introduction Market Position Segment: Full-size Luxury Sedan/Coupe Competitive Analysis Key Competitors: BMW 7 Series (E23/E32), Audi V8 Quattro, Jaguar XJ, Cadillac Fleetwood. Key Features Design Philosophy: Emphasized build quality, safety, comfort, and understated luxury. Introduction of advanced safety features and aerodynamic design principles for its era. Distinctive Elements: Iconic 'S-Class' styling, robust engineering, sophisticated ride quality, powerful straight-six and V8 engines, and available long-wheelbase (SEL) for increased rear passenger space. 📋 Manual Details Coverage Areas Vehicle Years Covered: 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992 Engine Variants Covered: All W126 engine variants including M110, M116, and M117 in their various displacements and fuel injection configurations. Page Count Total Pages: 5000+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Management: Detailed diagnostic, testing, and repair procedures for fuel injection (KE-Jetronic, K-Jetronic), ignition systems, emissions control. Drivetrain: Comprehensive coverage of automatic and manual transmissions, differential, driveshafts, and clutch (if applicable). Suspension Steering: Service, repair, and adjustment procedures for front and rear suspension, power steering system, including hydraulic components and steering gearbox. Brakes: Detailed instructions for hydraulic brake system, ABS (Anti-lock Braking System), brake disc/pad replacement, caliper service, and bleeding procedures. Electrical Electronics: Extensive coverage of wiring diagrams, fuse/relay identification, starter, alternator, battery, lighting systems, power windows, locks, mirrors, and climate control electronics. Body Exterior: Repair and adjustment of body panels, doors, hood, trunk, bumpers, glass, convertible top mechanisms (if applicable), and trim. Body Interior: Disassembly and reassembly of dashboard, seats, door panels, headliner, HVAC components, and interior trim. Climate Control: Service, diagnosis, and repair of air conditioning and heating systems, including refrigerant handling and component replacement. Fuel System Details: In-depth troubleshooting and repair of mechanical and electronic fuel injection systems, fuel pumps, fuel pressure regulators, injectors, and associated lines and sensors. Exhaust System: Information on catalytic converters, exhaust manifold, mufflers, and pipes, including diagnosis of leaks and component replacement. Emission Control Systems: Detailed procedures for diagnosing and servicing emissions control components, including secondary air injection, EGR (where applicable), and evaporative emission control systems. Lighting And Signals: Troubleshooting for headlights, taillights, turn signals, hazard lights, interior lighting, and related control modules. Wiper Washer System: Service and repair of wiper motor, linkage, wiper blades, and washer fluid pump and reservoir. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, lubrication points, spark plug replacement, and belt inspections. Troubleshooting: Systematic diagnostic procedures for common and complex issues, fault code interpretation (where applicable), and testing methods for various components. Component Repair Rebuild: Step-by-step instructions for removal, disassembly, inspection, repair, reassembly, and installation of virtually all major and minor vehicle components. Adjustments Calibrations: Detailed procedures for adjusting carburetors (early models), fuel injection systems, ignition timing, brake systems, parking brake, and suspension alignment parameters. Technical Specifications: Provides torque specifications, fluid capacities, electrical values, wear limits, and critical measurement data for all procedures. Torque Specifications: Extensive lists of torque values for all critical fasteners, ensuring proper assembly and preventing component damage. Diagrams Illustrations: Detailed exploded diagrams, wiring schematics, and photographic illustrations to guide users through repair processes. Technical Depth Depth Of Coverage: Comprehensive, bumper-to-bumper coverage suitable for professional technicians and advanced DIY enthusiasts. Includes detailed explanations and pictorial diagrams for complex tasks. Diagnostic Procedures: Focus on systematic fault diagnosis, including step-by-step guides for identifying issues within various vehicle systems. Special Tools: References to specific Mercedes-Benz special service tools required for certain operations, with explanations of their usage. Cooling System Coverage Cooling System: Radiator, water pump, thermostat, coolant hoses, expansion tank, and fan clutch service and replacement procedures. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Yes, all pages are printable for convenient workshop use. Binding Type Binding: Digital (PDF) Paper Type Digital Medium: Downloadable PDF Software Requirement Viewer: Adobe Reader Compatibility Operating Systems: Windows, macOS, Linux ⚙️ Engine Specifications Primary Engine Engine Options: M110 (2.8L I6), M116 (3.8L V8), M117 (4.2L V8, 5.0L V8, 5.6L V8) Performance Horsepower Range: Approximately 155 hp (2.8L) to 240 hp (5.6L) Torque Range: Approximately 177 lb-ft (2.8L) to 330 lb-ft (5.6L) Fuel System Injection Systems: Bosch K-Jetronic mechanical fuel injection (early models), Bosch KE-Jetronic electronic fuel injection (later models). Ignition System Ignition Type: Electronic ignition with distributors. Cooling System Coolant Type: Typically 50/50 mixture of Mercedes-Benz approved antifreeze and distilled water. Engine Management Engine Variants Detail: 2.8L M110 (DOHC I6), 3.8L M116 V8, 4.2L M117 V8, 5.0L M117 V8, 5.6L M117 V8 (later designated as 5.6L M117 E56). 🔧 Transmission Standard Standard Transmission: 4-speed automatic (e.g., 722.3) Optional Optional Transmission: 5-speed manual (rare, primarily on earlier European models). Features Transmission...
SE (Standard Wheelbase Sedan), SEL (Long Wheelbase Sedan), SEC (Coupe)
Codes
Chassis Code:
W126
👋 Introduction
Market Position
Segment:
Full-size Luxury Sedan/Coupe
Competitive Analysis
Key Competitors:
BMW 7 Series (E23/E32), Audi V8 Quattro, Jaguar XJ, Cadillac Fleetwood.
Key Features
Design Philosophy:
Emphasized build quality, safety, comfort, and understated luxury. Introduction of advanced safety features and aerodynamic design principles for its era.
Distinctive Elements:
Iconic 'S-Class' styling, robust engineering, sophisticated ride quality, powerful straight-six and V8 engines, and available long-wheelbase (SEL) for increased rear passenger space.
All W126 engine variants including M110, M116, and M117 in their various displacements and fuel injection configurations.
Page Count
Total Pages:
5000+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Management:
Detailed diagnostic, testing, and repair procedures for fuel injection (KE-Jetronic, K-Jetronic), ignition systems, emissions control.
Drivetrain:
Comprehensive coverage of automatic and manual transmissions, differential, driveshafts, and clutch (if applicable).
Suspension Steering:
Service, repair, and adjustment procedures for front and rear suspension, power steering system, including hydraulic components and steering gearbox.
Brakes:
Detailed instructions for hydraulic brake system, ABS (Anti-lock Braking System), brake disc/pad replacement, caliper service, and bleeding procedures.
Electrical Electronics:
Extensive coverage of wiring diagrams, fuse/relay identification, starter, alternator, battery, lighting systems, power windows, locks, mirrors, and climate control electronics.
Body Exterior:
Repair and adjustment of body panels, doors, hood, trunk, bumpers, glass, convertible top mechanisms (if applicable), and trim.
Body Interior:
Disassembly and reassembly of dashboard, seats, door panels, headliner, HVAC components, and interior trim.
Climate Control:
Service, diagnosis, and repair of air conditioning and heating systems, including refrigerant handling and component replacement.
Fuel System Details:
In-depth troubleshooting and repair of mechanical and electronic fuel injection systems, fuel pumps, fuel pressure regulators, injectors, and associated lines and sensors.
Exhaust System:
Information on catalytic converters, exhaust manifold, mufflers, and pipes, including diagnosis of leaks and component replacement.
Emission Control Systems:
Detailed procedures for diagnosing and servicing emissions control components, including secondary air injection, EGR (where applicable), and evaporative emission control systems.
Lighting And Signals:
Troubleshooting for headlights, taillights, turn signals, hazard lights, interior lighting, and related control modules.
Wiper Washer System:
Service and repair of wiper motor, linkage, wiper blades, and washer fluid pump and reservoir.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, lubrication points, spark plug replacement, and belt inspections.
Troubleshooting:
Systematic diagnostic procedures for common and complex issues, fault code interpretation (where applicable), and testing methods for various components.
Component Repair Rebuild:
Step-by-step instructions for removal, disassembly, inspection, repair, reassembly, and installation of virtually all major and minor vehicle components.
Adjustments Calibrations:
Detailed procedures for adjusting carburetors (early models), fuel injection systems, ignition timing, brake systems, parking brake, and suspension alignment parameters.
Technical Specifications:
Provides torque specifications, fluid capacities, electrical values, wear limits, and critical measurement data for all procedures.
Torque Specifications:
Extensive lists of torque values for all critical fasteners, ensuring proper assembly and preventing component damage.
Diagrams Illustrations:
Detailed exploded diagrams, wiring schematics, and photographic illustrations to guide users through repair processes.
Technical Depth
Depth Of Coverage:
Comprehensive, bumper-to-bumper coverage suitable for professional technicians and advanced DIY enthusiasts. Includes detailed explanations and pictorial diagrams for complex tasks.
Diagnostic Procedures:
Focus on systematic fault diagnosis, including step-by-step guides for identifying issues within various vehicle systems.
Special Tools:
References to specific Mercedes-Benz special service tools required for certain operations, with explanations of their usage.
Cooling System Coverage
Cooling System:
Radiator, water pump, thermostat, coolant hoses, expansion tank, and fan clutch service and replacement procedures.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Yes, all pages are printable for convenient workshop use.
Designed to meet and exceed safety standards of its time, featuring crumple zones and robust safety cage construction.
Active Features
Active Safety:
Anti-lock Braking System (ABS) became standard or optional depending on year and market. Power-assisted steering.
Passive Features
Passive Safety:
Driver and passenger airbags (introduced later in the production run), seatbelt pre-tensioners, reinforced doors, and impact-absorbing steering column.
💡 Technology Features
Infotainment
Audio Systems:
Factory-installed premium audio systems, often with cassette players. Some later models may have had CD changers as options.
Driver Assistance
Early Driver Aids:
Cruise control, power adjustable steering column, automatic climate control with recirculation mode.
Connectivity
Connectivity Features:
Limited by modern standards; primarily focused on in-car comfort and convenience features rather than external connectivity.
Comfort Features
Climate Control Advancement:
Fully automatic climate control with temperature and air distribution regulation was a significant feature for its time.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 - 10,000 miles or 12 months, depending on driving conditions and oil specification used.
Transmission Service:
Fluid and filter change recommended typically every 30,000 - 50,000 miles.
Engine Coolant Service:
Flush and replace coolant every 2-3 years or 30,000-50,000 miles.
Fluid Specifications
Engine Oil Spec:
API SG or higher, SAE 10W-40, 10W-50, or 20W-50 depending on climate. Refer to manual for precise MB approvals.
Brake Fluid Spec:
DOT 3 or DOT 4 approved brake fluid.
Coolant Capacity:
Approx. 8-10 liters (depending on engine size).
Power Steering Fluid Spec:
MB 236.3 approved hydraulic fluid or equivalent.
Known Issues
Common Faults:
Vacuum leaks in the central locking/climate control system, aging wiring harnesses, climate control blower motor resistor failure, self-leveling suspension issues (if equipped), fuel distributor issues (K-Jetronic), starter contact failure.
Common Wear Items:
Ball joints, tie rod ends, wheel bearings, exhaust system components, and shock absorbers/struts.
Recommended Parts
Key Maintenance Parts:
Fuel filters, air filters, oil filters, spark plugs, distributor caps and rotors, ignition wires, coolant hoses, drive belts, vacuum lines.
📚 Vehicle History
Brand Heritage
Mercedes Benz Legacy:
Continuation of Mercedes-Benz's reputation for engineering excellence, luxury, and safety, building upon the success of the W116 S-Class predecessor.
Model Evolution
W126 Development:
Introduced in 1979 as the second generation S-Class, it marked a significant step forward in aerodynamics, safety, and interior comfort. Received styling and technical updates throughout its production life, including engine displacements and feature enhancements.
Production
Production Years:
1979-1991
Production Locations
Manufacturing Sites:
Sindelfingen, Germany.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
Widely praised for its engineering, safety, and comfort upon release. Considered a benchmark for luxury sedans of the 1980s.