123.133 / 300D Turbodiesel Sedan

00 - Maintenance, service, technical data; General descriptions; Operating instructions; General considerations concerning service products (fluids, etc.); Jacking-up, towing-off, laying-up vehicle

Intro 123 Chassis Manual Introduction
Intro 617 Engine Manual Introduction
005 Instructions for use of serivice manual
005/1 Model and unit survey
005/2 Identification of vehicles
010 Technical Data
010 Model and system identification
010 Engine and vehicle identification
015 Vehicle identification number locations
015 Vehicle identification number locations
020 Technical Data
020 Technical Data
030 Technical Data
040 Technical Data

01 - Engine, removal and installation; Crankcase, cylinder head, engine breathing

010 Checking compression pressure
015 Checking cylinders for leaks
020 Evaluation of cylinder bores
025 Measuring oil consumption
030 Removal and installation of engine (oil capacity)
040 Engine breather -- functional description
110 Measuring, boring and honing cylinder bores
115 Renewing, boring and honing cylinder liners
120 Facing cylinder crankcase parting surface
130 Knocking-out and inserting steel balls for main oil ducts
140 Replacing core hole closing cover in cylinder crankcase
215 Removal and installation of front cylinder crankcase cover
220 Removal and installation of intermediate flange
310 Removal and installation of complete oil pan
405 Cylinder head bolts and tightening of cylinder head bolts
415 Removal and installation of cylinder head
417 Removal and installation of pre-chambers
418 Facing cylinder head parting surface
420 Pressure-testing cylinder head

03 - Crank assembly

310 Checking, renewing and tightening connecting rod bolts
313 Reconditioning and squaring connecting rod
316 Removal and installation of pistons
318 Checking and reconditioning of crankshaft
320 Mounting of crankshaft
324 Renewing front crankshaft radial sealing ring
327 Renewing rear crankshaft radial sealing ring
340 Removal and installation of pulley, vibration damper and balancing disc
344 Static balancing of balancing disc
345 Checking and correcting adjustment of TDC transmitter
350 Removal and installation of crankshaft sprocket
410 Removal and installation of flywheel and driven plate
430 Renewing ring gear of flywheel
440 Statically balancing of flywheel
450 Instructions for full balancing of engine

05 - Engine timing, valves

210 Inspection and adjustment of valve clearance
215 Inspection and adjustment of camshaft timing
220 Removal and installation of camshaft
225 Grinding camshaft bearing journals
235 Removal and installation of rocker arms with rocker arm bearing brackets
240 Renewal of rocker arms and rocker arm bearing brackets
250 Removal and installation of valve springs
260 Checking valve springs
270 Replacement of valve stem seals
280 Checking and machining valves
285 Checking and renewing valve guides
291 Machining valve seats
310 Removal and installation of chain tensioner
320 Renewing timing chain
330 Removal and installation of tensioning rail
340 Removal and installation of slide rails
412 Removal and installation of intermediate sprocket shaft
440 Removal and installation of guide wheel

07.1 - Diesel injection system

001 Survey model -- engine -- inejection pump
010 Operation injection pump with governor
015 Operation engine-transmission overload protection
100 Adjustment of idle speed and idle speed adjuster
105 Checking maximum speed at no-load
108 Checking injection timing (begin of delivery) with digital tester (RIV method)
109 Checking injection timing (begin of delivery) (high pressure method)
110 Checking injection timing (begin of delivery) (flow pressure method)
111 Checking injection timing (begin of delivery) (position indicator RIV method)
114 Adjusting injection timing (begin of delivery) with digital tester (RIV method) -- following checkup
115 Adjusting injection timing (begin of delivery) (high pressure method) -- following checkup
116 Adjusting injection timing (begin of delivery) (position indicator RIV method) -- following checkup
135 Checking injection nozzles
137 Disassembly, cleaning, assembly and adjustment of injection nozzles
140 Venting injection system
145 Checking fuel pump and bypass valve
150 Checking vacuum shutoff for leaks
200 Removal and installation of injection pump
201 Installation of injection pump (with locking screw)
210 Replacement of pipe connection, delivery valve or copper sealing ring on injection pump
220 Replacement of vacuum control unit at injection pump
230 Removal and installation of injection nozzles
235 Removal and installation of fuel pump
240 Removal and installation of injection timing device

07.2 - Carburetor system

07.3 - Mechanically and mechanically/electronically controlled gasoline injection system

07.4 - Electronically controlled gasoline injection system

09 - Air cleaner, intake air preheater; Exhaust gas turbocharger

400 Removal and installation of air filter
425 Checking boost pressure of turbocharger
430 Removal and installation of exhaust gas turbocharger
450 Functional description of exhaust gas turbocharger with aneroid compensator

13 - Air compressor, belt drives

335 Instructions concerning renewal and tensioning of V-belts
340 Renewing and tensioning of V-belt

14 - Intake manifold, exhaust manifold; Engine brake, emission control system

001 Vehicle identification
050 Operation exhaust gas recirculation
100 Testing EGR
450 Removal and installation of intake manifold, replacement of gasket
470 Removal and installation of exhaust manifold

15 - Electrical system engine (ignition system, preheating system, starter, alternator)

705 Operation of preglow system
708 Installation preglow time relay with modified ventilation
710 Checking preglow system

18 - Engine lubrication, engine oil cooler

005 Oil circuit, oil pressure, pressure relief valve and oil filter
031 Removal and installation of oil return flow line of exhaust gas turbocharger
040 Removal and installation of oil spray nozzles
110 Removal and installation of oil filter
120 Checking thermostat in oil filter
125 Removal and installation of thermostat in oil filter
210 Removal and installation of oil pump
215 Removal and installation of oil pressure relief valve

20 - Engine cooling system, coolant hoses, ratiator

005 Coolant circuit and engine cooling
010 Draining and filling of coolant -- antifreeze table
015 Cleaning cooling system
110 Removal and installation of coolant thermostat
210 Removal and installation of coolant pump
220 Reconditioning of coolant pump
225 Sealing coolant pump
230 Removal and installation of coolant pump housing
310 Viscofan coupling, temperature-controlled
420 Removal and installation of radiator
425 Reconditioning of radiator
430 Checking of expansion tank closing cover
490 Illustrated thermostat layout

22 - Engine mounting

211 Removal and installation of front engine mounts
212 Removal and installation of rear engine mount
220 Adjusting engine stop -- model 123.193
240 Removal and installation of engin shock absorber

25 - Clutch

26 - Manual transmission, power take-offs

27 - Automatic transmission

28 - Transfer case

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

31 - Frame; Trailer operation

32 - Suspension

010 Permissible combinations springs--shock absorbers
100 Removal and installation of front shock absorber
110 Removal and installation of rear shock absorber
120 Checking shock absorber
125 Checking alignment of front shock absorbers
126 Checking alignment of rear shock absorbers
200 Removal and installation of front spring
205 Removal and installation of front spring (in combination with removal and installation of front axle half on vehicles following an accident 33-200)
220 Adjustment of front springs
230 Removal and installation of rear springs
240 Adjustment of rear springs
250 Test value of springs
300 Removal and installation of torsion bar on front axle
310 Removal and installation of torsion bar on rear axle
501 Functional description
510 Checking spring struts
520 Checking pressure reservoir
530 Checking pressure oil pump and level controller
610 Removal and installation of spring struts
620 Removal and installation of pressure reservoir
630 Draining and filling of pressure oil system
640 Removal and installation of pressure oil pump
641 Conversion of suction and pressure line on model 123 with diesel engine 3rd version
645 Replacement of radial sealing ring for pressure oil pump
660 Removal and installation of connecting rod of level controller
670 Removal and installation of level controller
671 Conversion of oil lines between level controller and pressure reservoir in the event of complaints about noise

33 - Front axle

200 Removal and installation of front axle half
300 Adjustment of wheel bearing and play
310 Removal and installation of front wheel hub
320 Disassembly, inspection, repair and assembly of front wheel hub
400 Removal and installation of steering knuckle
410 Checking the steering knuckle
420 Removal and installation of steering knuckle arm
425 Checking supporting and guide joint of steering knuckle bearing
430 Replacement of sleeves for supporting and guide joint of steering knuckle bearings
440 Replacement of supporting joint for steering knuckle bearing
500 Removal and installation of upper control arm
512 Removal, disassembly, assembly and installation of lower control arm
515 Removal and installation of brake support
520 Reconditioning bearing of lower control arm
540 Checking supporting joint and supporting tube of brake support
550 Checking and reconditining bearing of upper control arm
560 Checking upper control arm
570 Checking lower control arm

35 - Rear axle, trailing axle

010 Removal and installation of complete rear axle
040 Removal and installation of front rubber bearing of rear axle suspension
050 Removal and installation of rear rubber bearing of rear axle suspension
110 Removal and installation of semi-trailing arm, replacement of rubber bearings
130 Removal and installation of rear axle shaft flange, adjustment of bearings
310 Removal and installation of coupled semi-trailing arm, replacement of rubber bearing
330 Removal and installation of link between coupled semi-trailing arm and caliper carrier
350 Disassembly, assembly and adjustment of wheel carrier
360 Removal and istallation of caliper carrier and rear axle shaft flange, adjustment of wheel bearing
410 Complete inspection of rear axle wheel location
420 Inspection of semi-trailing arms
430 Inspection of rear axle carrier
500 Differentiating characteristics, installation survey for rear axle center piece
520 Removal and installation for rear axle center piece with rear axle shafts
530 Replacement of radial sealing ring on drive pinion (rear axle center piece installed)
540 Replacement of radial seald ring of rear axle shaft (rear axle center piece installed)
550 ?
550-2 ?
550-3 ?
550-4 ?
560 Reconditioning of differential
620 Removal and installation of rear axle shaft
660 Exchanging rubber sleeves on rear axle shaft
680 Removal and installation of ring-shaped weight on inner joints of rear axle shafts

40 - Wheels, chassis measurements

010 Lifting vehicle with jack
013 Positioning of jacking-up shoes and jacks
100 Survey rims and tires
102 Rims
104 Tires
106 Tire inflation pressure
108 Snow chains
110 Removing and mounting of wheels
111 Removing and mounting of wheel covers
112 Removal and installation of holding spring or annular spring for wheel cover
113 Removing and mounting hub cap for forged light alloy rims

41 - Propeller shaft

050 Removal and installation of propeller shaft
100 Removal and installation of propeller shaft intermediat bearing, replacement of radial ball bearing
200 Replacement of centering sleve

42 - Brakes - hydraulical and mechanical system

010 Bleeding the brake system or renewing the brake fluid
012 Checking brake lines and brake hoses
015 Checking the brake system for leaks
035 Checking warning device in expansion tank
040 Inspection or adjustment of mechanical brake light switch
100 Removal and installation of caliper on front axle
120 Removal and installation of caliper on rear axle
140 Checking piston release clearance in caliper
150 Replacement of piston seal on front axle caliper
155 Replacement of piston seal on rear axle caliper
160 Replacement of brake pads
220 Removal and installation of brake disc on front axle
228 Removal and installation of brake disc on rear axle
260 Cleaning of brake discs
310 Removal and installation of tandem main cylinder
315 Disassembly, inspection and assembly of stepped tandem main cylinder
510 Removal and installation of parking brake pedal system
515 Replacement of rubber stop in pedal system of parking brake
520 Removal and installation of front brake cable control
525 Removal and installation of rear brake cable control
530 Removal and installation of brake shoes of parking brake
540 Readjustment or adjustment of brake shoes of parking brake

43 - Brakes - pneumatic system and auxiliary brakes

023 Testing check valve
325 Checking brake booster
350 Removal and installation of brake booster
610 Removal and installation of single diaphragm vacuum pump
615 Removal and installation of double diaphragm vacuum pump
618 Removal and installation of piston vacuum pump
620 Replacing diaphragm and plate valves of single-diaphragm vacuum pump
625 Replacing diaphragm and plate valves of double diaphragm vacuum pump
628 Replacing piston seal and plate valves of piston vacuum pum
630 Replacing rocker arm of single diaphragm vacuum pump
635 Renewing rocker arm of piston vacuum pump
660 Checking single diaphragm, double diaphragm and piston vacuum pump

46 - Steering

010 Differentiating characteristics of steering gears
070 Reconditioning of steering gear
110 Checking play of steering components
120 Checking start of manual restriction
130 Checking oil pressure of power steering pump
220 Reconditioning of steering gear
220-2 Reconditioning of steering gear (continued)
310 Removal and installation of manual steering
412 Removal and installation of power steering
480 Adjustment of power steering in vehicle
510 Removal and installation of pitman arm
520 Removal and installation of intermediate steering arm
540 Removal and installation of track rod
550 Removal and installation of drag link
610 Removal and installation of steering wheel
620 Removal and installation of jacket tube
625 Disassembly and assembly of jacket tube
630 Removal and installation of steering shaft
640 Removal and installation of steering lock
640-2 Removal and installation of steering lock (continued)
700 Differentiating characteristics of power steering pump
705 Renewing radial sealing ring of power steering pump
710 Removal and installation of power steering pump
720 Disassembly, checkup and reconditioning of power steering pump
740 Assembly of power steering pump
760 Removal and installation of mounting bracket for power steering pump

47 - Fuel system

700 Removal and installation of fuel tank
705 Removal and installation of fuel expansion tank
710 Removal and installation of immersion tube indicator
715 Operation of immersion tube indicator for fuel gauge
720 Operation fuel tank positive and negative venting system

49 - Exhaust system, heat shield, outer

100 Removal and installation of exhaust system

54 - Electrical system; Equipment and instruments; Speed control systems

005 Battery test, service and maintenance
100 Designation and layout of grounding points
250 Removal and installation of instrument cluster
251 Removal and installation of indicating instruments
253 Removal and installation of tachometer
256 Function immersion tube transmitter for fuel gauge
257 Testing fuel gauge
258 Removal and installation of time clock
270 Pressure difference warning system wiring diagram [USA] 1977
305 Removal and installation of rotary light switch
310 Removal and installation of of combination switch
312 Testing, refinishing resetting of turnsignal arm
325 Removal and installation of turnsignal lamp and warning flasher switch with relay
326 Layout warning flasher relay starting September 1981
340 Removal and installation of switch console
350 Wiring diagram special versions for fog lamp, headlamp flasher, backup lamp
390 Renewing bulbs of control system, heater
391 Renewing bulb for ashtray light
410 Seatbelt warning device, ignition key, lamps [USA] starting 1978
500 Cruise control operation
504 Testing with adapter
506 Testing coding plug
510 Checking switch, control unit and line harness
515 Checking switch
520 Checking sensor
525 Checking cable control
530 Checking control unit
541 Removal and installation of acutator
545 Removal and installation of switch
550 Removal and installation of sensor on mechanical tachometer
555 Removal and installation of cable control
560 Adjustment of cable control
561 Adjustment of connecting rod
565 Removal and installation of control unit
575 Removal and installation of switch on clutch pedal
577 Removal and installation of relay decel shutoff / cruise control
580 Wiring diagram

55 - Auxiliary drives, hydraulic and articulated systems

58 - Tools, test instruments, equipment

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

100 Removal and installation of windshield
120 Removal and installation of ornamental frame on windshield
200 Removal and installation of back window
220 Removal and installation of of ornamental frame on back window

68 - Interior equipment

100 Removal and installation of instrument panel
105 Removal and installation of loudspeaker cover
120 Removal and installation of glove compartment lid
130 Removal and installation of glove compartment lid lock
140 Removal and installation of glove compartment
150 Removal and installation of bottom instrument panel cover
200 Removal and installation of center console
230 Removal and installation of gear shift lever cover
400 Removal and installation of reveal molding on top of windshield
405 Removal and installation of reveal molding on windshield
430 Removal and installation of headliner
449 Removal and installation of rear pillar trim
458 Removal and installation of hat rack and first aid kit
470 Removal and installation of center pillar trim
480 Removal and installation of trunk cover
490 Install interior padding at bulkhead (after renewal of bulkhead)
495 Removal and installation of cover on rear pillar, outside
510 Removal and installation of ornamental rod on edge of front or rear door
590 Removal and installation of trimstrips in range of entrance
700 Removal and installation of of partition between tank and trunk

72 - Doors

100 Removal and installation of front door liner
101 Removal and installation of rear door liner
110 Removal and installation of window regulator
140 Removal and installation of arm rest with grip
160 Removal and installation of inner sealing rail
170 Removal and installation of outer sealing rail
180 Removal and installation of front door window lift
181 Removal and installation of rear door window lift
185 Removal and installation of front door electric window controls
187 Removal and installation of rear door electric window controls
190 Removal and installation of front door crank operated window
191 Removal and installation of rear door crank operated window
195 Adjusting front door crank operated window
197 Removal and installation of rear door fixed window
198 Removal and installation of of flexible window running rail
210 Removal and installation of door retainer
214 Removal and installation of front door reveal molding
220 Removal and installation of front or rear door rubber frame
230 Removal and installation of front door inside controls
231 Removal and installation of rear door inside controls
240 Removal and installation of front door outside grip
241 Removal and installation of rear door outside grip
250 Removal and installation of front door lock
251 Removal and installation of rear door lock
258 Removal and installation of modified vacuum element
260 Removal and installation of striker
270 Removal and installation of exterior rear view mirror

75 - Trunk lid, fuel flap

100 Removal and installation of trunk lid
102 Removal and installation of trunk lid lock
300 Removal and installation of tank flap

77 - Slide roof (sun roof), top, racks

100 Removal and installation of sun roof lid (electric sun roof)
110 Adjusting sun roof lid (electric sun roof)
140 Removal and installation of teleflex cable
150 Removal and installation of teleflex tube
180 Removal and installation of holder with motor and gear
190 Troubleshooting instructions for electric sun roof
195 Checking and adjusting slip clutch of sun roof motor (round motor)
200 Removal and installation of sun roof lid (mechanical sun roof)
210 Adjusting sun roof lid (mechanical sun roof)
250 Removal and installation of sun roof wind deflector

80 - Central locking system, comfort hydraulics

010 General
020 Design and operation of central interlock
200 Removal and installation, as well as adjustment of vacuum switch of driver's door
210 Removal and installation of vacuum element of front passenger's door
220 Removal and installation of vacuum element for rear doors
230 Removal and installation of vacuum element of tank filler neck flap
240 Removal and installation of vacuum element for trunk lid
241 Removal and installation of vacuum element for rear door
250 Removal and installation of vacuum supply tank
260 Checking central interlock
900 Functional diagram central interlock
901 Functional diagram central interlock and air conditioning system
902 Functional diagram central and seat backrest locking system with air conditioning system

82 - Electrical system body; Radio, windshiold washer system, light range regulator

052 Removal and installation of lamp unit
062 Removal and installation of lamp unit bulbs
252 Removal and installation of tail lamp unit
348 Removal and installation of license plate lamp
500 Connection for radio
530 Function of automatic antenna (USA) starting 1977
610 Removal and installation of wiper arm
620 Removal and installation of wiper blade
625 Removal and installation of wiper blade rubber profile strip
630 Removal and installation of wiper linkage
680 Removal and installation of wiper motor
780 Wiring diagram roar window wiping washing system, 2nd version
800 Operation of seat heating system
810 Checking seat heating system
820 Removal and installation of pushbutton switch for seat heating system and renewing bulb
830 Renewing heating pad of seat heating system

83 - Climate control

100 Removal and installation of heater box
110 Removal and installation of heat exchange
112 Removal and installation, adjustment of bowden wires on water valve for heater
113 Removal and installation, adjustment of bowden wires on water valve for heater
115 Removal and installation of water valve for heater
120 Removal and installation of heater blower
140 Removal and installation of ornamental grille on air inlet
150 Removal and installation of ring nozzles right or left on instrument panel
256 [520] Removal and installation of electromagnetic clutch
500 General description and operation of air-conditioning system
502 Regrigerant circuit
504 Safety measures
506 Repair instructions for air-conditioning system
508 Control of air-conditioning system
510 Function test and quick test of air-conditioning system
512 Leak test and evacuation
514 Refilling or replenishing air-conditioning system
516 Draining of air-conditioning system
518 Cleaning of air conditioning system
520 Checking oil level in refrigerant compressor
522 Removal and installation of refrigerant compressor
524 Reonditioning of refrigerant compressor
526 Removal and installation of electromagnetic clutch
528 Removal and installation of condenser
530 Removal and installation of receiver dehydrator
532 Removal and installation of pressure switch or temperature switch in receiver dehydrator
534 Removal and installation of expansion valve
536 Removal and installation of evaporator housing
538 Removal and installation of evaporator
540 Removal and installation of blower
542 Removal and installation, adjustment or checkup of temperature vacuum switch or temperature dial and temperature sensor for air-conditioning system
544 Removal and installation of vacuum elements
545 Checking vacuum elements and temperature vacuum switch for leaks
546 Removal and installation of supplementary fan
600 Operation of automatic climate control
601 Manual and optical function test of automatic climate control
602 Preparation for test, connecting adapter to volt/ohm measuring instrument
603 Function test of total system and remedies (with adapter)
604 Vacuum function diagrams
607 Output test
614 Preparations for vacuum test
615 Testing check valve and vacuum reservoir
620 Testing vacuum circuit I, II and III
622 Testing vacuum circuit IV, V and VI
624 Testing vacuum circuit VII
625 Removal and installation of mono valve
628 Testing switchover valves
630 Removal and installation of recirculating pump
635 Removal, installation and disassembly of control unit
640 Removal and installation of in-car temperature sensor
643 Removal and installation of air jet nozzle
645 Removal and installation of temperature sensor for heat exchanger
650 Removal and installation of ETR switch
660 Removal and installation of switchover valves
665 Removal and installation of vacuum elements
675 Removal and installation of electronic switching unit for temperature control
676 Removal and installation of electronic switching unit for blower control
678 Removal, installation and checking of temperature switch for cold-engine lock

86 - Emergency equipment, sanitary equipment, kitchen

88 - Attachments, outside flaps

100 Removal and installation of front fender
200 Removal and installation of front bumper
205 Remove and install rubber cover at front bumper
220 Removal and installation of rear bumper
222 Removal and installation of rubber cover on rear bumper
300 Removal and installation of engine hood
305 Removal and installation of engine hood support
306 Removal and installation of engine hood hinge
310 Removal and installation of cable control for engine hood
400 Removal and installation of radiator shell
401 Removal and installation of radiator grille
402 Removal and installation of trim strips to radiator grille
405 Removal and installation of Mercedes star
410 Removal and installation of air flow grille under front bumper

91 - Seats, cots, restraint systems

100 Removal and installation of front seat (driver's seat)
110 Removal and installation of front seat (passenger's seat)
120 Removal and installation of reclining seat fittings
165 Removal and installation, reconditioning of folding armrest for driver's seat
170 Removal and installation of rear seat and rear seat backrest
300 Remedy for electrostatic charge on seat
500 Removal and installation of safety belt
550 Exchange instructions for safety belt