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Introduction
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Market Position
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Positioning:
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The Mercedes-Benz W123 series, particularly the robust 240D diesel variant, was renowned for its durability, reliability, and engineering excellence in its era. It appealed to buyers prioritizing longevity and economical operation over outright performance.
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Competitive Analysis
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Competitors:
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Competed against other premium European sedans and luxury marques that offered diesel engines, though few matched the W123's reputation for build quality and longevity. Key competitors included BMW's 5-series diesels (though less common and often less fuel-efficient) and various luxury sedans from manufacturers like Volvo and Audi in different markets.
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Key Features
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Vehicle Highlights:
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Iconic 'brick' design, solid construction, comfortable ride, exceptional build quality, the naturally aspirated 616.912 diesel engine known for its extreme longevity and fuel efficiency. Served as a dependable workhorse and long-distance cruiser.
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Manual Value Proposition
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Manual Benefit:
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This manual provides dealership-level repair and maintenance information, empowering owners and independent mechanics to perform a wide range of tasks accurately, saving significant costs compared to authorized dealer service.
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Manual Details
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Coverage Areas
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General Maintenance Service:
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00 - Maintenance, service, technical data; General descriptions; Operating instructions; General considerations concerning service products (fluids, etc.); Jacking-up, towing-off, laying-up vehicle
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Engine Mechanical:
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01 - Engine, removal and installation; Crankcase, cylinder head, engine breathing; 03 - Crank assembly; 05 - Engine timing, valves
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Fuel System:
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07.1 - Diesel injection system; 07.2 - Carburetor system (Not applicable to 240D); 07.3 - Mechanically and mechanically/electronically controlled gasoline injection system (Not applicable to 240D); 07.4 - Electronically controlled gasoline injection system (Not applicable to 240D); 47 - Fuel system
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Intake Exhaust Emissions:
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09 - Air cleaner, intake air preheater; Exhaust gas turbocharger (Not applicable to standard 240D); 14 - Intake manifold, exhaust manifold; Engine brake, emission control system
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Engine Electrical:
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15 - Electrical system engine (ignition system, preheating system, starter, alternator)
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Engine Support Systems:
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13 - Air compressor, belt drives; 18 - Engine lubrication, engine oil cooler; 20 - Engine cooling system, coolant hoses, radiator; 22 - Engine mounting
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Drivetrain:
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25 - Clutch; 26 - Manual transmission, power take-offs; 27 - Automatic transmission; 28 - Transfer case (Not applicable to 240D); 29 - Pedals; 30 - Throttle control; 300 Adjusting throttle linkage; 310 Removal and installation of engine longitudinal regulating shaft; 320 Removal, installation and adjustment of front wall regulating shaft; 330 Removal and installation of accelerator pedal
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Chassis Suspension Steering:
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31 - Frame; Trailer operation; 32 - Suspension; 33 - Front axle; 35 - Rear axle, trailing axle; 40 - Wheels, chassis measurements; 46 - Steering
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Brakes:
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42 - Brakes - hydraulical and mechanical system; 43 - Brakes - pneumatic system and auxiliary brakes (Not applicable to standard 240D)
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Exhaust Propulsion:
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41 - Propeller shaft; 49 - Exhaust system, heat shield, outer
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Body Electrical Accessories:
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54 - Electrical system; Equipment and instruments; Speed control systems (Not applicable to standard 240D); 82 - Electrical system body; Radio, windshield washer system, light range regulator; 83 - Climate control; 86 - Emergency equipment, sanitary equipment, kitchen (Generally not covered in detail for this model); 88 - Attachments, outside flaps
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Body Structure Interior:
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60 - Body, general; 61 - Understructure; 62 - Front end and front wall; 63 - Side wall; 64 - Rear wall and rear end; 65 - Roof; 67 - Glass (panes) and windows; 68 - Interior equipment; 72 - Doors; 75 - Trunk lid, fuel flap; 77 - Slide roof (sun roof), top, racks; 91 - Seats, cots, restraint systems; 94 - Body noises, sound insulation; 97 - Body sealing, anti-corrosion protection; 98 - Paintwork
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Auxiliary Systems Documentation:
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55 - Auxiliary drives, hydraulic and articulated systems; 58 - Tools, test instruments, equipment; 99 - Technical literature; Validity list, administration
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Manual Types Included:
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Service Repair Manual, Maintenance Manual (MM), Owner's Manual (OM) references likely
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Page Count
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Estimated Pages:
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Likely 1000+ pages, typical for comprehensive workshop manuals of this era and detail level.
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Manual Type
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Type:
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Factory Service Manual (FSM) / Workshop Manual
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Language
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Language:
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English
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Format
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Format:
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PDF
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Manual Coverage
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Systems Covered
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Powertrain:
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Engine mechanicals (cylinder head, block, crankshaft, valvetrain), diesel injection system, lubrication, cooling, fuel system, clutch, manual and automatic transmissions, driveshafts.
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Chassis:
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Frame, suspension components (front and rear axles, control arms, springs, shocks), steering system, wheels, tires, chassis alignment.
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Brakes:
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Hydraulic brake system (master cylinder, wheel cylinders/calipers, lines, hoses), parking brake.
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Electrical:
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Engine electrical (starter, alternator, preheating system), lighting, instruments, gauges, wiring diagrams for various body and engine functions, windshield washer system.
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Body:
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Body structure (frame, panels, understructure), doors, windows, glass, interior trim, seats, trunk lid, fuel filler flap, sunroof, exterior trim, paint, anti-corrosion.
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HVAC:
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Climate control systems, heating, ventilation.
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Procedures Included
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Maintenance:
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Scheduled maintenance tasks, fluid changes, filter replacements, lubrication points, inspections.
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Diagnostics:
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Troubleshooting guides, symptom-based diagnostics, common issues and solutions for engine, drivetrain, chassis, and electrical systems.
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Repair Rebuild:
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Step-by-step removal, installation, and overhaul procedures for all major components and systems.
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Adjustments:
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Adjustment procedures for engine timing, valves, injection pump, throttle linkages, brakes, clutch, etc.
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Technical Data:
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Specifications, tolerances, torques, fluid capacities, wiring diagrams, schematics, diagnostic codes (if applicable).
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Technical Depth
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Depth:
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Comprehensive, covering everything from routine maintenance to complete engine rebuilds and bodywork repairs, suitable for professional mechanics and advanced DIYers.
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Maintenance
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Service Intervals
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Oil Change Interval:
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Typically every 5,000-7,500 miles (8,000-12,000 km) or annually, depending on driving conditions. Consult the OM for precise intervals. (Manual covers this).
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Fuel Filter Replacement:
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Every 15,000-20,000 miles (24,000-32,000 km) or as per manual recommendations. (Manual covers this).
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Air Filter Replacement:
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Every 10,000-15,000 miles (16,000-24,000 km) or as needed based on inspection. (Manual covers this).
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Fluid Specifications
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Engine Oil Specification:
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API CD or CE rated diesel engine oil, SAE 15W-40 or 10W-40 depending on climate. (Manual covers exact specs and capacities).
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Coolant Specification:
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Propylene glycol-based coolant (typically a 50/50 mix with distilled water) meeting Mercedes-Benz specifications for corrosion protection. (Manual covers exact spec).
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Brake Fluid Specification:
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DOT 3 or DOT 4 hydraulic brake fluid. (Manual covers exact spec).
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Known Issues
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Common Wear Items:
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Vacuum lines (for central locking, climate control, etc.), glow plug system, diesel injection pump seals, front suspension bushings, rear axle mounting points, rust (especially wheel wells, rocker panels, undercarriage). (Manual provides diagnostic procedures for these).
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Engine Longevity:
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The OM616 engine is renowned for its ability to exceed 300,000 miles (480,000 km) with proper maintenance, making it a highly desirable classic diesel engine.
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