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Manual Coverage
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Systems Covered
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Engine:
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Complete engine overhaul, tuning, fuel injection systems (Bosch D-Jetronic, mechanical injection for diesels), ignition systems, cooling systems, lubrication systems.
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Transmission:
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Manual and automatic transmission service, repair, overhaul, clutch replacement, driveline components.
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Brakes:
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Hydraulic brake systems, disc brake overhaul (front and rear), drum brake service (rear), parking brake system, brake fluid specifications and bleeding procedures.
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Suspension:
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Front suspension (independent, ball joints, control arms, springs, shock absorbers), rear suspension (independent, semi-trailing arms, springs, shock absorbers), steering system (steering gear, linkages, power steering).
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Electrical:
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Complete wiring diagrams, starter system, charging system (alternator), battery, lighting systems (headlights, taillights, interior), instrumentation, wipers, horn, fuse panel diagnostics.
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Bodywork:
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Body panel removal and installation, door mechanisms, window regulators, seals, trim, convertible top mechanisms (for coupe models), structural repair recommendations.
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Climate Control:
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Heater core service, ventilation systems, optional air conditioning system diagnostics and repair (if equipped).
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Exhaust System:
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Exhaust manifold, catalytic converter (if equipped on later models), muffler, and pipe replacement and repair.
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Procedures Included
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Maintenance:
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Scheduled maintenance intervals, oil changes, filter replacements, lubrication points, coolant flushes, tune-up procedures.
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Troubleshooting:
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Diagnostic charts for common problems, fault finding for engine performance, electrical issues, braking system malfunctions.
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Repair:
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Detailed step-by-step repair procedures for all major systems, including component removal, disassembly, inspection, reassembly, and installation.
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Diagnostics:
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Component testing procedures, specifications for readings (e.g., compression, resistance, voltage), diagnostic tools required.
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Engine Mechanical:
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Engine assembly, disassembly, piston ring replacement, bearing replacement, valve guide and seat service, crankshaft and camshaft inspection and alignment, timing chain and gear replacement.
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Fuel System Gasoline:
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Carburetor overhaul and adjustment (e.g., Zenith Stromberg, Solex), fuel pump replacement, fuel filter service, fuel line routing and inspection. D-Jetronic system diagnostics, sensor testing, and control unit troubleshooting.
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Fuel System Diesel:
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Injector pump timing and adjustment, injection nozzle testing and replacement, glow plug system service, fuel filter replacement, bleeding the fuel system.
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Cooling System:
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Radiator removal and repair, water pump replacement, thermostat testing and replacement, coolant hose inspection and replacement, fan clutch service.
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Transmission Manual:
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Gearbox removal and disassembly, synchromesh ring replacement, gear set inspection, clutch replacement, driveshaft and universal joint service.
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Transmission Automatic:
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Automatic transmission overhaul, fluid and filter changes, torque converter testing, valve body diagnostics, kickdown cable adjustment.
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Steering System:
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Steering box adjustment and repair, tie rod end and drag link replacement, power steering pump and cylinder service, bleeding the power steering system.
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Electrical Diagnostics:
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Testing of starter motor, alternator output, voltage regulator, battery condition, and all lighting circuits using multimeter and wiring diagrams. Troubleshooting intermittent electrical faults.
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Interior Trim:
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Removal and installation of door panels, dashboard components, headliner, and seats for access to underlying systems. Convertible top mechanism adjustments and fabric replacement guidance.
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Body Hardware:
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Door lock mechanisms, window cranks/regulators, hood and trunk latches, exterior trim piece installation and removal.
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Heating And Ventilation:
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Blower motor service, heater control valve operation, flap adjustments, and ductwork inspection.
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Technical Depth
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Depth:
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Comprehensive factory-level detail suitable for professional mechanics and advanced DIY enthusiasts. Covers everything from routine maintenance to complete engine and transmission rebuilds.
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Torque Specifications:
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Precise torque values for all critical fasteners, including engine components, suspension parts, and wheel lug nuts.
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Clearances:
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Specified bearing clearances, piston ring end gap, valve lash settings (if applicable), and other critical component clearances.
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Catalogue References:
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Likely includes part number references for major components, facilitating parts sourcing.
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Wiring Diagrams:
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Comprehensive, often color-coded, wiring diagrams for all electrical systems.
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Diagnostic Charts:
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Systematic troubleshooting guides based on symptoms.
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Diagnostic Troubleshooting Trees:
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Flowcharts and step-by-step guides to diagnose issues based on symptoms, leading to the likely cause and repair.
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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 usage and oil quality.
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Tune Up Interval:
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Spark plug replacement, ignition timing adjustment, and carburetor/injection system checks were generally recommended every 15,000-25,000 miles (24,000-40,000 km).
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Fluid Specifications
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Engine Oil:
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SAE 10W-30 or 10W-40 API SF or SG rating for gasoline engines; SAE 15W-40 API CD or CE rating for diesel engines (consult manual for specific viscosity based on climate).
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Coolant:
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Ethylene glycol based antifreeze mixed 50/50 with distilled water. Mercedes-Benz specifications should be followed if available.
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Brake Fluid:
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DOT 3 or DOT 4 hydraulic brake fluid.
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Transmission Fluid Auto:
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Dexron II or equivalent ATF (Automatic Transmission Fluid).
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Differential Fluid:
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Typically GL-5 SAE 90 gear oil, though specific Mercedes-Benz specifications should be verified.
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Power Steering Fluid:
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Specific power steering fluid or ATF, depending on the system type. Consult manual.
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Known Issues
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Common Problems:
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Rust on body panels (especially wheel arches, rocker panels, window sills), aging rubber seals and bushings, potential wear in steering and suspension components, fuel injection system maintenance (especially older D-Jetronic), vacuum line deterioration, overheating on high-mileage diesel engines.
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Diesel Specific Issues:
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Glow plug reliability, injector pump maintenance, occasional wear in the OM617 engine's timing chain tensioner.
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Ignition System:
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Distributor wear, coil failure, spark plug fouling (especially in older gasoline models).
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