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Mercedes-Benz 560SEL w126 1986-1991 Factory Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: 560SEL Chassis Code: W126 Model Years Covered: 1986-1991 👋 Introduction Market Position Market Position: The Mercedes-Benz 560SEL (W126) represented the pinnacle of luxury and engineering in the late 1980s and early 1990s, targeting affluent individuals seeking a high-performance, sophisticated, and reliable grand tourer. This manual directly supports the maintenance and repair of these prestigious vehicles. Competitive Analysis Competitive Analysis: Competed against other flagship luxury sedans of the era, such as the BMW 7 Series, Jaguar XJ, and Cadillac Fleetwood. The 560SEL was renowned for its build quality, technological advancements, and smooth V8 power delivery. Key Features Key Features: Exceptional build quality, refined ride comfort, powerful V8 engine, advanced safety features for its time, and luxurious interior appointments. Interior Appointments: High-quality leather upholstery, wood trim accents, power-adjustable seats with memory, automatic climate control, power sunroof, power windows, and ample rear legroom contributing to its 'S-Class' designation (Sonderklasse - Special Class). 📋 Manual Details Coverage Coverage Areas: Engine, Drivetrain, Suspension, Steering, Brakes, Electrical System, Fuel System, Exhaust System, Bodywork, Interior Trim, Climate Control, Seats, Diagnostic Procedures, Troubleshooting Pages Page Count: Extensive (Specific page count not provided, but implied to be comprehensive as per dealer technician usage) Type Manual Type: Factory Workshop Service Repair Manual Language Language: English Format Format: HTML/Flash menu with PDF embedded files 📖 Manual Coverage Systems Systems Covered: All major mechanical, electrical, and body systems of the Mercedes-Benz 560SEL W126 Procedures Procedures Included: Routine maintenance, diagnostics, troubleshooting, component repair, component replacement, assembly, disassembly, system adjustments, wiring diagrams, diagnostic trouble codes (DTCs), torque specifications Depth Technical Depth: Comprehensive, covering basic maintenance to complete drivetrain and engine rebuilds, suitable for professional technicians and advanced DIY enthusiasts. Systems Covered Specific Electrical Systems: Engine control, ignition, lighting, power windows, central locking, SRS airbag system, instrument cluster, climate control, radio, antenna systems. Procedures Included Engine Rebuild Procedures: Detailed procedures for cylinder head removal/installation, piston and connecting rod removal/installation, crankshaft installation, timing chain and sprocket replacement, valve adjustment (if applicable to M117 variant). Transmission Repair Procedures: Overhaul procedures for the 4G-TRONIC transmission, including torque converter replacement, clutch pack replacement, valve body service, and seal replacement. Technical Depth Diagnostic Tools Required: While primarily mechanical, the manual details procedures for accessing and interpreting diagnostic data from the engine control unit (ECU) using specialized Mercedes-Benz diagnostic tools of the era (e.g., Star Diagnosis system if applicable to later W126 models, or basic multimeter testing for earlier systems). 📊 Manual Specifications File Format File Format: HTML with Flash Menu and embedded PDF documents, compatible with Windows (95/98/ME/XP/Vista/Win7), Linux, and MAC operating systems. Searchability: PDF format within the digital package allows for text searching of specific terms, greatly enhancing diagnostic efficiency. Print Quality Print Quality: High quality, suitable for printing individual pages or sections. Binding Type Binding Type: Digital Download (No physical binding) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: M117 V8 Displacement: 5.6 Liters (5549 cc) Bore X Stroke: 94.5 mm x 98.5 mm Compression Ratio: 9.1:1 Performance Horsepower: Approx. 238 hp @ 4750 rpm (US Spec) Torque: Approx. 317 lb-ft @ 3250 rpm (US Spec) Fuel System Fuel Injection: Bosch KE-Jetronic (CIS-E with Lambda control) Fuel Type Fuel Type: Unleaded Gasoline Cooling System Cooling System Type: Pressurized liquid cooling system Engine Management Engine Control Unit: Bosch DME (Digital Motor Electronics) for ignition timing, integrated with CIS-E for fuel management. Lubrication System Oil Capacity: Approx. 8.5 US quarts (8.0 Liters) with filter change (Refer to manual for exact capacity). Engine Features Valve Train: Overhead Camshaft (OHC) per bank, two valves per cylinder. 🔧 Transmission Standard Transmission Type: 4-Speed Automatic (4G-TRONIC) Features Transmission Features: Lock-up torque converter, electronic control for shift points and line pressure. Fluid Type Transmission Fluid Specification: MB 236.8 or Dexron III/Mercon (Refer to manual for exact specification for the period) Gear Ratios Transmission Gear Ratios: Specific gear ratios vary by model year and final drive, but typically designed for smooth acceleration and highway cruising. (Detailed ratios available in manual) 📐 Dimensions Exterior Length: Approx. 199.9 inches (5078 mm) Width: Approx. 70.5 inches (1791 mm) Height: Approx. 55.7 inches (1415 mm) Wheelbase Wheelbase: Approx. 117.9 inches (3000 mm) Weights Curb Weight: Approx. 3900-4100 lbs (1769-1860 kg) Gross Vehicle Weight Rating: Varies by specification, but generally around 4800-5000 lbs (2177-2268 kg) (Refer to manual for exact GVWR). Interior Interior Volume: Spacious cabin, particularly for rear passengers due to the long wheelbase. 🛡️ Safety Features Passive Features Passive Safety Features: Reinforced passenger cell, crumple zones, dual front airbags, anti-lock braking system (ABS), seatbelt pre-tensioners. Active Features Active Safety Features: Anti-lock Braking System (ABS), power-assisted steering, advanced suspension for stability. Crash Test Results Crash Test Ratings: While formal crash test ratings like NHTSA's star system were not as prevalent or standardized in the 1980s as they are...
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Mercedes-Benz 560SEL w126 1986-1991 Factory Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
560SEL
Chassis Code:
W126
Model Years Covered:
1986-1991
👋 Introduction
Market Position
Market Position:
The Mercedes-Benz 560SEL (W126) represented the pinnacle of luxury and engineering in the late 1980s and early 1990s, targeting affluent individuals seeking a high-performance, sophisticated, and reliable grand tourer. This manual directly supports the maintenance and repair of these prestigious vehicles.
Competitive Analysis
Competitive Analysis:
Competed against other flagship luxury sedans of the era, such as the BMW 7 Series, Jaguar XJ, and Cadillac Fleetwood. The 560SEL was renowned for its build quality, technological advancements, and smooth V8 power delivery.
Key Features
Key Features:
Exceptional build quality, refined ride comfort, powerful V8 engine, advanced safety features for its time, and luxurious interior appointments.
Interior Appointments:
High-quality leather upholstery, wood trim accents, power-adjustable seats with memory, automatic climate control, power sunroof, power windows, and ample rear legroom contributing to its 'S-Class' designation (Sonderklasse - Special Class).
📋 Manual Details
Coverage
Coverage Areas:
Engine, Drivetrain, Suspension, Steering, Brakes, Electrical System, Fuel System, Exhaust System, Bodywork, Interior Trim, Climate Control, Seats, Diagnostic Procedures, Troubleshooting
Pages
Page Count:
Extensive (Specific page count not provided, but implied to be comprehensive as per dealer technician usage)
Type
Manual Type:
Factory Workshop Service Repair Manual
Language
Language:
English
Format
Format:
HTML/Flash menu with PDF embedded files
📖 Manual Coverage
Systems
Systems Covered:
All major mechanical, electrical, and body systems of the Mercedes-Benz 560SEL W126
Procedures
Procedures Included:
Routine maintenance, diagnostics, troubleshooting, component repair, component replacement, assembly, disassembly, system adjustments, wiring diagrams, diagnostic trouble codes (DTCs), torque specifications
Depth
Technical Depth:
Comprehensive, covering basic maintenance to complete drivetrain and engine rebuilds, suitable for professional technicians and advanced DIY enthusiasts.
Systems Covered
Specific Electrical Systems:
Engine control, ignition, lighting, power windows, central locking, SRS airbag system, instrument cluster, climate control, radio, antenna systems.
Procedures Included
Engine Rebuild Procedures:
Detailed procedures for cylinder head removal/installation, piston and connecting rod removal/installation, crankshaft installation, timing chain and sprocket replacement, valve adjustment (if applicable to M117 variant).
Transmission Repair Procedures:
Overhaul procedures for the 4G-TRONIC transmission, including torque converter replacement, clutch pack replacement, valve body service, and seal replacement.
Technical Depth
Diagnostic Tools Required:
While primarily mechanical, the manual details procedures for accessing and interpreting diagnostic data from the engine control unit (ECU) using specialized Mercedes-Benz diagnostic tools of the era (e.g., Star Diagnosis system if applicable to later W126 models, or basic multimeter testing for earlier systems).
📊 Manual Specifications
File Format
File Format:
HTML with Flash Menu and embedded PDF documents, compatible with Windows (95/98/ME/XP/Vista/Win7), Linux, and MAC operating systems.
Searchability:
PDF format within the digital package allows for text searching of specific terms, greatly enhancing diagnostic efficiency.
Print Quality
Print Quality:
High quality, suitable for printing individual pages or sections.
Binding Type
Binding Type:
Digital Download (No physical binding)
Paper Type
Paper Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
M117 V8
Displacement:
5.6 Liters (5549 cc)
Bore X Stroke:
94.5 mm x 98.5 mm
Compression Ratio:
9.1:1
Performance
Horsepower:
Approx. 238 hp @ 4750 rpm (US Spec)
Torque:
Approx. 317 lb-ft @ 3250 rpm (US Spec)
Fuel System
Fuel Injection:
Bosch KE-Jetronic (CIS-E with Lambda control)
Fuel Type
Fuel Type:
Unleaded Gasoline
Cooling System
Cooling System Type:
Pressurized liquid cooling system
Engine Management
Engine Control Unit:
Bosch DME (Digital Motor Electronics) for ignition timing, integrated with CIS-E for fuel management.
Lubrication System
Oil Capacity:
Approx. 8.5 US quarts (8.0 Liters) with filter change (Refer to manual for exact capacity).
Engine Features
Valve Train:
Overhead Camshaft (OHC) per bank, two valves per cylinder.
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic (4G-TRONIC)
Features
Transmission Features:
Lock-up torque converter, electronic control for shift points and line pressure.
Fluid Type
Transmission Fluid Specification:
MB 236.8 or Dexron III/Mercon (Refer to manual for exact specification for the period)
Gear Ratios
Transmission Gear Ratios:
Specific gear ratios vary by model year and final drive, but typically designed for smooth acceleration and highway cruising. (Detailed ratios available in manual)
📐 Dimensions
Exterior
Length:
Approx. 199.9 inches (5078 mm)
Width:
Approx. 70.5 inches (1791 mm)
Height:
Approx. 55.7 inches (1415 mm)
Wheelbase
Wheelbase:
Approx. 117.9 inches (3000 mm)
Weights
Curb Weight:
Approx. 3900-4100 lbs (1769-1860 kg)
Gross Vehicle Weight Rating:
Varies by specification, but generally around 4800-5000 lbs (2177-2268 kg) (Refer to manual for exact GVWR).
Interior
Interior Volume:
Spacious cabin, particularly for rear passengers due to the long wheelbase.
🛡️ Safety Features
Passive Features
Passive Safety Features:
Reinforced passenger cell, crumple zones, dual front airbags, anti-lock braking system (ABS), seatbelt pre-tensioners.
Active Features
Active Safety Features:
Anti-lock Braking System (ABS), power-assisted steering, advanced suspension for stability.
Crash Test Results
Crash Test Ratings:
While formal crash test ratings like NHTSA's star system were not as prevalent or standardized in the 1980s as they are today, the W126 was engineered with advanced safety structures for its time, exceeding many contemporary standards.
💡 Technology Features
Infotainment
Infotainment System:
Premium analog sound system, often with cassette player. Optional CD changer. Manual climate control or optional automatic climate control (Thermotronic).
Driver Assistance
Driver Assistance Features:
Cruise Control, Automatic Climate Control (Thermotronic), ABS.
Connectivity
Connectivity:
Limited by era standards; primarily focused on vehicle systems and audio.
Lighting
Lighting Features:
Halogen headlights, front and rear fog lights, interior courtesy lighting.
Chassis Control
Chassis Control Systems:
Hydropneumatic self-leveling rear suspension (optional on some models, standard on SEL), hydraulic power steering.
Safety
Airbag System:
Supplemental Restraint System (SRS) including dual front airbags and seatbelt pre-tensioners, a significant safety advancement for the era.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 miles or 12 months, whichever comes first (Refer to manual for exact recommendation).
Major Service Intervals:
Major services involving coolant, brake fluid, transmission fluid changes, and spark plug replacements occur at higher mileage intervals (e.g., 30,000, 60,000 miles), as detailed in the manual.
Fluid Specifications
Engine Oil Specification:
API SF or SG, SAE 10W-30 or 10W-40 (depending on climate), specifically MB 229.1 or equivalent (Consult manual for precise specification and viscosity for the specific model year).
Coolant Specification:
MB 325.0 (Ethylene Glycol based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water)
Brake Fluid Specification:
DOT 3 or DOT 4
Power Steering Fluid Specification:
MB 236.3 (Dexron II or equivalent)
Coolant Capacity:
Approx. 10.5 US quarts (9.9 Liters) (Refer to manual for exact capacity).
Known Issues
Common Issues:
Head gasket leaks, valve stem seals, vacuum hose deterioration, SRS system faults, climate control panel issues, ABS sensor failures, fuel distributor leaks (CIS-E system), window regulator failures, door lock actuator problems, sagging headliner.
Cooling System Concerns:
Radiator leaks, heater control valve failures, thermostat issues, water pump leaks, and degradation of coolant hoses over time due to heat and age.
Filters
Oil Filter Part Number Example:
Mann-Filter W110/1 or equivalent (Refer to manual for exact part number)
Air Filter Part Number Example:
Mann-Filter C33109/2 or equivalent (Refer to manual for exact part number)
Spark Plugs
Spark Plug Type Example:
Bosch W8AC or equivalent (Refer to manual for exact specification and gap)
Troubleshooting
Troubleshooting Methodology:
The manual provides systematic troubleshooting guides based on symptoms, diagnostic trouble codes (DTCs) for electronic systems, and detailed diagnostic procedures for mechanical components.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mercedes-Benz has a long-standing reputation for automotive engineering excellence, safety, and luxury since its inception.
Model Evolution
Model Evolution:
The W126 S-Class chassis, introduced in 1979, was a significant advancement for Mercedes-Benz. The 560SEL, with its larger V8 engine, represented the top-tier long-wheelbase luxury sedan within this generation, emphasizing performance and interior space.
Key Updates During Production:
Minor updates included refinements to the engine management, interior appointments, and safety features throughout its production run. The 560SEL emerged as the flagship performance model.
Production
Production Years:
W126 series produced from 1979 to 1992. The 560SEL variant was primarily produced from 1985/1986 to 1991.
🏆 Awards & Recognition
Recognitions
Recognitions:
Consistently ranked among the best luxury sedans of its era by automotive journalists for its comfort, performance, and build quality. Often featured in 'best of' lists for classic luxury cars.
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