🏷️ Basic Information Identification Make: Mercedes-Benz Model: 240D Production Years Covered: 1976-1985 Codes Chassis Code: W123 👋 Introduction Market Position Target Audience: Owners, DIY mechanics, independent repair shops specializing in classic Mercedes-Benz vehicles. Key Features Primary Benefit: Cost-effective vehicle maintenance and repair. Value Proposition: Empowers users to understand and maintain their vehicle, preventing future issues and saving money. 📋 Manual Details Coverage Areas Primary Coverage: Service and Repair Procedures Secondary Coverage: Maintenance Schedules, Diagnostics, Troubleshooting Page Count Estimated Page Count: Detailed (specific count not provided, but comprehensive) Manual Type Manual Type: Service and Repair Manual Language Language: English Format File Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine, Fuel System, Cooling System, Emission Control Powertrain Systems: Transmission (implied, typical for service manuals) Chassis Systems: Chassis Electrical Systems: Electrical System Body And Trim: Implied coverage for body maintenance and trim component access. Procedures Included Maintenance Procedures: Periodic Maintenance, Fluid Changes, Filter Replacements Repair Procedures: Engine Repair, Fuel System Repair, Cooling System Repair, Electrical Component Repair Diagnostic Procedures: Troubleshooting, Fault Finding Emission Control Service: Information on emission control systems relevant to the era, potentially including basic adjustments or component identification. Torque Specifications: Essential torque specifications for critical fasteners across all systems. Troubleshooting Charts: Systematic troubleshooting guides for common vehicle problems. Technical Depth Depth Of Information: Comprehensive, covering repairs for everyday issues to more complex mechanical tasks. Engine Repair Scope: Detailed engine overhaul procedures, including cylinder head removal, piston/ring replacement, crankshaft and bearing service. Fuel System Diagnostics: In-depth fuel system diagnostics, including fuel pump testing, injector flow testing, injection timing adjustments. Electrical System Schematics: Includes detailed wiring diagrams for all major electrical components and systems. Chassis Component Overhaul: Procedures for brake system repair (including disc and drum), steering system overhaul, suspension component replacement (shocks, bushings), and wheel bearing service. 📊 Manual Specifications File Format Printable: Fully Printable Viewing Features: Zoom IN/OUT Functionality Text Searchability: Likely text-searchable due to PDF format, facilitating quick information retrieval. Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinZip Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: Diesel Engine Code: OM615 Displacement: 2.4 Liters (2399 cc) Engine Configuration: Inline-4 Cylinder Performance Horsepower Range: Approximately 70-72 hp (SAE Gross at introduction) Torque Range: Approximately 130-135 Nm (100-100 lb-ft) at low RPM Fuel System Fuel Delivery: Bosch Inline Fuel Injection Pump Fuel Type: Diesel Fuel Cooling System Cooling System Type: Liquid-Cooled 🔧 Transmission Standard Transmission Type: 4-Speed Manual (standard) Optional Transmission Type Optional: 4-Speed Automatic (optional) Features Clutch Type: Single Dry Plate Clutch (for manual) 📐 Dimensions Exterior Body Styles Available: Sedan (W123), Wagon (S123), Coupe (C123), Limousine (V123 - less common for 240D) Weights Curb Weight: Approx. 1350-1500 kg (depending on body style and equipment) Gross Vehicle Weight Rating: Typically around 1900-2000 kg 🛡️ Safety Features Passive Features Body Construction: Reinforced passenger cell, crumple zones (typical Mercedes-Benz safety philosophy of the era) Interior Safety: Padded dashboard, safety belts (front and often rear), collapsible steering column. 💡 Technology Features Infotainment Infotainment System: Basic analog radio (AM/FM), optional cassette player. Driver Assistance Driver Assistance Features: Primarily focused on mechanical systems; driver assistance features as we know them today were not present. Connectivity Connectivity Options: None (pre-digital era). 🔧 Maintenance Service Intervals Oil Change Interval: Typically 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions. Fuel Filter Replacement: Recommended at 10,000-15,000 miles (16,000-24,000 km), or as per manual recommendations. Air Filter Replacement: Typically 15,000-20,000 miles (24,000-32,000 km). Transmission Fluid Change: Manual: As per manual (typically around 50,000 miles). Automatic: 30,000-50,000 miles or as specified. Fluid Specifications Engine Oil Specification: API CD or equivalent diesel engine oil (e.g., SAE 15W-40 or 10W-30 depending on climate). Refer to manual for specific viscosity. Coolant Specification: Ethylene glycol based coolant, typically a 50/50 mix with distilled water. Transmission Fluid Manual: GL-4 Gear Oil (e.g., SAE 75W-90 or 80W-90) Transmission Fluid Automatic: Dexron III or equivalent ATF (Automatic Transmission Fluid) Power Steering Fluid: Typically Mercedes-Benz Power Steering Fluid or equivalent Pentosin CHF 11S for later models, but manual will specify. Brake Fluid Specification: DOT 3 or DOT 4 brake fluid. Known Issues Common Wear Items: Glow plugs, injection pump seals, vacuum lines, front suspension bushings, exhaust system. Diesel Specific Concerns: Cold start performance, potential for air in fuel lines, injector nozzle wear. 📚 Vehicle History Brand Heritage Mercedes Benz Philosophy: Engineering excellence, durability, comfort, and safety. Model Evolution W123 Generation Context: Part of the highly successful W123 generation, known for its robustness and longevity. W123 Sedan Durability Reputation: The W123 series, including the 240D, is renowned globally for its exceptional durability and ability to withstand high mileage with proper maintenance. Production Production Period W123: 1976-1986 (W123 generation as a whole) 240D Market Positioning: Entry-level diesel model, known for fuel economy and reliability...