pt [ THIS MANUAL COVERS: eee Mercedes-Benz Transporter 207D, 307D, 210D, 410D, 208D, 308D, 310D, 408D 601, 602 and 616 Engines DETAILED DESCRIPTION OF REMOVAL, INSTALLATION, “ADJUSTMENTS, REPAIRS, OVERHAUL AND SERVICING OF ALL THE MAJOR, VEHICLE PARTS (except body), INCL. ENGINE, VALVES, DIESEL FUEL INJECTION SYSTEM, CLUTCH, BRAKES, STEERING, TRANSMISSION (oxcopt overhaul), FRONT AND REAR AXLES AND | SUSPENSION, ENGINE “ELECTRICS — WITH EXPLODED VIEWS ANO COMPLETE TECHNICAL | DATA AND WIRING DIAGRANS. PLaLIHED BY PETER AUSSEK PUBLICATIONS LTD, ‘wwnctussek-manuals.co.uk | as CSS 2.3, 2.4 AND 2.9 LITRE DIESEL ENGINES ADJUSTMENTS ¢ TUNE-UP REPAIRS @ OVERHAULS SERVICING © FAULT FINDING 207D, 307D, 210D, 410D 208D, 308D, 310D, 408D MANUALSPOCKET MECHANIC Mercedes-Benz 207D, 307D, 210D, 3100, 410D, 208D, 308D, 408D 2.3, 2.4 and 2.9 Litre Diesel COVERIN' GENERAL INFORMATION, DMENSIONS, WEIGHTS, ‘CAPACITIES, GENERAL, SERVICING NOTES. ENGINES LUBRICATION SYSTEM COOLING SYSTEM DIESEL FUEL NJECTION SYSTEM CLUTCH, MANUAL TRANSMISSION FRONT AXLE, FEAR AXLE AND PROPELLER SHAFT. FRONT AND REAR SUSPENSION ‘STEERING BRAKE SYSTEM ELECTRICAL SYSTEM, 24 LITRE DIESEL ENGINE TYPE 616 SERVICING AND MAINTENANCE FAULT FINDING SECTION. WIRING DIAGRANS. 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Sea te he ae ta mca etre cet foung babe sty cern! gems a opens heey hatte ao he man nn (dla cante lett att te cose oka te mao {pecs ei camel aon, ibe tl’ oes he See wt reed fon he von on tos mg ash Sc 08 Oath a its 13mm ain fon Ne cae Ca, ime ceaperar reads ast ‘ed betes Back Te tend ego rw form ste ur {he Rem aise athe ay eth Lash rees eng eb "wom! anon be ore, teens ee! bat ep (ts sued a teach ‘era he taremaeion anh ye ovat yr aye tancter tl 220 ra th nd it he tl ba amine reartwora tr. stows nF Tory ane “—_ Tecan Mp 3-year eg fst ow edt nm wer as et bese phar ih nF) Aigo tet ion ctr end'Z-Fo 1) to cane rece sow: "oni in te gee ove ate he ws hn iv epg twa Fee hes swale 60 Teh th gana atten atoning At anton py tater am Note Recacenet inde INES esac @°Srgne. Ghech wh yur deter bee consaera ROE yeas ht yundngtadvo moto ns, {Batic her moses Kine ak se charge he een oo I seve tors yr hear Oi Wo are422, CRANKSHAFT AND BEARINGS 1330, Technica ate "ae tater tomas 908m Mie teerot case eis Ms tapes cea (eanin-v Books ainsi Soran #0060 en peso eros 5180-5 45 mm ‘ning lomaDianae—st8enine “ cramp sve ‘400-2422 anaes enon cali ‘obtionn wantepedbeor) reps ne 51.8-515 0m 1102-0 oe.) i8a5090° nm esto etd meena ws cata aS Be se BS BE eng in gs Baas ea pale ac osnin esate 8 ar sas i ah oe Bo rece oat oS gnc th AF 61334, Gants Ror an eaten Reve tarnion tone ee, Tl one ho dt he ech + Stet ren ite mnt and sy sien ha eeh ro ara maint n Sci {34° Remove ie ot snp a ‘sina eeribetinsaciont ST | SEIS Sem sea ry sane etree Sa Se tay MSM ec © Phekirs ostigtecwor + Tepbessche win owe ste nn ena, hse te eli 13:2, it nt Dae rn a mt nna mace teeaamaneaiooe actoerg nar ace vp the srk ‘dextne tener ae yng carr or ae aed tod raver eee . es ‘ewe cnajun Lids et set ie | 1.834. Flywheel or orve Patebet ett aie cytes PE, aT eS Ben see one ‘inc iybeal Te vet ha iar ve rm ore wn ning wn ita a hen FETE Tofurctns at eno nt ars ite tb [Spe ae Th wig oi 65 rene ogres nae 5 A Te eke ofthe ening ng st wor, tate Be vont your el have ‘ie bal soarng ne eho he ero A rang Pons tenes I a 1.8.3.5 Crankshalt Pulley and Vitraton Damper Terres iat cana rte ones eon einen a‘one ‘ore tn pre, rngnaarmay bn rc wo 1 CEL imap we un coroe ‘etn tt ch pe ah rh ten emp ee te he cel i aca ey be od hb wth fsitay dare ty nate arent Pace e tre apng once corety citi iD ge Te cwnnet mast otek anonaoanon + Flue ren dper andthe carta pu, 1 Thatenanngepertons sm cred ou nvvee ca, 4338. RearCrantshat Ol Sex! and Oi Seal Came ‘ara tal na ine age ih eed “nnenision an es ii di pats be removed tei hel sa. SURE a Tea aptcenan lee ag exctay oan acer ee Bhsae th fng fe al cor no be reeved omate Be la Pout este erie eho tn Abe ere oe atat he Fp 8 aml eae nan, ‘Sopot and oe eh he ‘Sonar pne orate, any top Tie ta Fost then te to lower bos and ten the ther ets, The tore bs Fotamira th 4332. Front Crankshaft Ol Seal “ert en oral ated nth ti ae, eke at hi pst can ‘SLeSSTanea Stig nia Se ptt elect pissy ea 00. “Ty hb te wba done at (he "een cy aoe Soot eea ete raced SeGhnbe ceca emer eh a ‘ot (ve, 100) Sent pute ona’ th ren head. Siete ees mae wh a Poet le ne ace ea ang se puto pth Sit “att taner Sone © hoee sews 134, TIMING COVER Tre tg ear const crane a rom. nae ey nom TEUty fee toe a espera ate tty te ae th re TTde's the cpnte Rock Tn ea bowers gener ane erie Sheygaes ly min espa ee sinter inst rw sede ea be each Theta cove er brenoved win eg ea Fe. towate pr obe "Scent nn te ae of nt ec stn Rens he * Reba the umer to of ie sheck soscer Heme the cover fe Me [DhlStngeve sever ne bt pareve Pe er 3+ enor hentia yang St at ks A te meng tare + Renovetnerematog tig covert ad ae tt oe, Met ft ang aes he ing cota 1 eer ok tm {ou te ang fa he cova wth ening compan. Mca yrahe \se'cun't ithe panos seaie wi Pat Reto 87 3 Coen ‘Noumiig er nto denagna toner nea pate, 1 Fle ster it be trang eon et ae eh {fle cna aetna wen pared Ime te rng ow an re © ERR a tnt ttn, at be ae {nd ine acacited par, b shoal foto th all engnes are ates so ene rin nn cm et cae Sorte eaten pene Sorte BERG elt taes Seme cnc een igi areal er tea corr fone sn a i ac). ‘Sersincer rad cover nen Boonremaved 135. TIMING MECHANISM Peer Somes ‘helen mig cans egos tthe asta chs, neon ‘Tutor he evans ered ty rane of true chan ener whch izes nine crnttne an sues Sa ago a hat eal Fi oy mew oath oh sete ty 8 Wena fo eee to Cinearng canst we gwerimsacten 340 ites soca n be carts snd wn pony Ea SES een meds —_" # 1.35.0. Chain Tonsiener— Remora and nstataton seca snc hn ‘Seong ott ihe tan eng eee by or 1 ne ensner Gok te chinenene yu wt gery aye ae V 5 NN satan Desmarais alt SSeS ees ie eine eee flict obs Sg Serena SET Fiche at Eorearis So Shei ce comes a a58 Sacre caso ri as re an 1343. Removal and Intataton of Timing Chain 5.15 mow ty arangurnt ft ung Theat opr “hsraton The soca fhe ceneae eae ona sacle ie ra oat cote the abreast breed cn eats eo 2 Ataris ring machine mat be crn Tene bg Ws acta ck cae ee {henna nena oem ye 9 cans ed chick a eshte ar pst ett + Fimo-cie ae seein charged dung ponucon 3 we faye a pm emir aad vars wa enon ttre wscup rs nt a enon ec (vat ie rata ot cg Sioens Sena cone ee eda ieee se ca ct na senitat fold "Ds nd an by tama by tans yee Deco hing tan te ow chen ae nti he nie wera twee Woo Rottneceaut eft wf tac SSCS G Reso oe te rst acento summon ar _ ESET oi ciny cca neha (32 Tong Ret -Ressaor 1282 mpc a s5 Pace at SEE ecco crate omer a ot + EEE te tang ovr Scion 134) ante chan teow (Secor retina tatu be ing ean an ck kere e oam ng 3 a ana epee od a ar anno marth cara spect Reo th + Sauget rae ares wha ct spcea wan sched tat arcing atowrdthli ren rope alts She tieg t's SO ncaa ete pn me ete hs mew Rb. Te can rl be hl a ‘See er naw a aon ob eae 4.952 Sle Rats Removal and Instaaion ‘ne youn fe se tai shoen mi. | An mont nant Wh 8 Tras acess the ond oe bot Provcnd te these tok can be stared, bet can tenses wom Sie up nese ne a 38 ape mo bn at Looe eases Soiee hehe [Rema cana ect a any Sse + Wms we ening ee enorme ny RPILRNE AS Sac tue overt bar par cea Wate ot 9Inette Sr ita Stan teen tn we sen apg ett oma spr ae etry ah Re he ni ev mt inte, aug i bed nna Pb en 2 itt omni bomor the Rege wth el campoint * Mihara ante Seng at andi bat inp tt ‘ia tte wee ove sn Yoana twats he na Ft eon Ce tonne same ranma" Cartetll ede at ge ering Co stan fr nie fort ant, eta vent be Bey in pers re etna ai ren cen, 1.09 ato (det sore te pt tne eink cont, Tn ere Beata “ave oe dred WSeden 3.4 anand at fev io bear bres Fie ew seal pen ne he ag 11354. Grarkshaf Sprocket- Removal and instalation 1+ Remove thing cove (Sct 134) ae a he nt pat ooton by oaratatuley aero Cin rained 1) amore nae pnpctan sve dre eee the * Miowoarsctpowonto Sencar | Pn eso 0 me aor 1 Eemo te sarah aos Th insane gure wth ‘gankahot met Chet the cardin the West oy the cra SS ey cote momen oa ate The da hh ‘aie sarah sire an alg para i eat wh he 0 enon cmeprtn er i cat as eaceeencneaincne + Elta pae ne se ean te aron Fi 168m ut Seeman tes yo rors we 1265. conhit-Renaeansalon 12a eenen anya cam i icutrrenene seyeariey neta oe SEER ES alice she SSkaaeeskemns re Reweiete ee See Sam "hansen + Remave te ef et comeson on adore armaon he 1 RTH Sate eaten ean wine pte | at ‘hair mn ig mbar Pe eee uncomaee Pte sane = ener 7 Seer est cists” Eater eee "Sree fant ear a nem eee en mS abate I conenpean act Isr Alpe hat shod be Pawo the beeeng Bom ‘crea rnoennage ie Eigie mieretoches a endo ne pace tah tse teh Bes Te sara era rapa arc ih th ruber ten he tne ng cn tat arte 8 tay aa jet aangage taro te er Sher “erie, FEE an scone (ihe! corre fos ‘ralesre bearg ay hrs Been rence, chek fe bering Seca wh ss tod bake we ey 8 eet meh natant te ah Toc mice any "wring er W you te ak 1 "Grea apps sng 9 srt nan a gel es ot Stage tet apacnt 5 sas cc ak "Chace ing minh somal acorns we Fg 116. Te mae imation whens pete | efron net wy ed come ett ene tea coe {Rote tperstin cried et reve oir reno pocadare. Ate oo3st vavotinne aioe sent we pe te zn ne ei mean, ce, ence sh a ee tt Sage oe eS er - srencases Spewaee ooee 16 ‘Tightening Torcue Values ‘rams! minded exe finde 01am 208) en rnc comics opel Some ann Snren sa elas - cmc SSenee =SSaee e siemaes! Eoeeeee— Sey — Seats ais 4.7, Lubrication Bystern tte eanT) ‘otpien90- 10 sonst pat come ns oeemmnr ae chgeageente= 1 “Newgts) Scumeciase ior enh) come art mth a aoe a a apie eeerre mee ee rie gt Tredeie e Rei sere oni SSeS) nerve as a od igeenits eet sSuecets) 30 a0 gma 204) inate cine bed fects'Sgn 80) : dtp 2he) Bitten + atin sie ato ae tn Gia mahal bat ate made aana omens hie he Syctt ms ajae wh fe bre te dove pnb aaa + Ete aman Soman ts ue ht 20m (4) ‘rouse tepinyea icepock "2 Svan Mae hte + fettne tg chan rane 2 Reinecke stn ene, fash facie! ae cal whch shat ie wi 2a imate cy hate spect be sen by ky at Recent paw ug ab Agathe at eae + Rate eas seats pr oe ‘ovine rt oe teat 812. Cylinder Head -Dismentiag ‘Totton declan aimee te ini rent brn Hon np cia eke tora aia anc hear Tt at ‘ated oases rave apg ce Qe 6193680001) andl ae BS Sarat oe rk ies meee te Sree Sopa Vate sere cape hve ban md 0p he sean shown fo. 3.46 ‘ae Ueno aching ‘mo eo tah cont oa idan be eevee be ern Sine ations nde Reno he epg ce, ae sping ave sam of etl and “bow ‘Sere spmge wh si eoour Liteon ap {epacadReovevave wom ol sesh eachay wins scevarer Cm a a = Seid nghapies sadn espa ino sol Aesth sn Soeecne Scones reece eee 91.3 Oylnder Head Overhaul (andine wernameetay” SeePaye toto sonadete ee ae B__| Vane guces have eon mies Fob tices am rarager Sonne Seance sown Wie ee iaiSameeneoen tetas oe a SQorareeR aaaee ave tem ogo. oh Snes teten he ey ha {tient se gudes nf SS G7 inte sue be mat some Meriter ‘Retr hood mst be reamed oe (te per canton of ie car adept ane a ee Seman rpeet eer ponte sms caiat Beton cneen canis fea testown ig att ‘Shap ee corsa aveseas: tne carta ‘hac ae sate ge fingt vou Sige aan ‘ing th viv seang aes uo te cee of ave set sie sure bat eve rhe teste yrs oat pote therer ova wave cat erga a et Sgn wet {in 18 mtn as shown ty nig 812Alay ne he moca yee srt ine a unde ny rae hansen a SSPDTAS SET rn oe om ne er apie ey Hi tert Page 27 nade ug sme an 91 an 0008.8) stiches, sorte ir gland sg os sn, ue he yes shld be ro gab. Themen heght of We cra nent mt mt ta ace BG ee Bi.) he ene ad erate cote te fig Siren of wld Cer! ot0)wcerary Tw one ea oe Lizz ET hte lotowea sane The feta ame mat be ea erg 86 tm sha fe att rpc Ch he e14 {mse ieee nad esa tte seme oan, he “et ae ane ws gel wet en bo cae + ke em nae tant rate erg ‘eral proceaie. The Vales mud beads ab decribed n Sesion 915 2.15. Valve Clearance - Checkhg and Adjusting NMareades workshops wie sei ypanetst> adus the vave clearance oe dewstie “Ts Reuaed a acid engine [00 nem ae ores hot ‘nm minus vate) _Difgert vases arly he deans cess caring ‘Sen awamnengoe (0 rm int vahos,O 35m eosusvabes) {ate erin lh aves of ede we ed Fi 95 aw ‘eforton@nat on ust oe fone me spate, sow phe eroeoberd fp. ft ne ay ete Seon teamed + ptt to abe ing ‘Seaton oreo Be ie ard + ee are FeeT TTS heen me os souk aon enone Mera a TATE Ean essed 181Seo ry a Aare arse P8561 puna a a, + fee ant cance tes, otf cre no potion ant ‘jut a socricd tov oungine ayer shown ny 6 any ale operadores oe thee prom (Gibco a patos tara sgt ay nny al Igamattpoaes mest Be cara ew hr td by 22.0, Removal and instataton of Rocker Mechanism “Toefl po mit be rte nent eka ars paca ‘Souter tn stg ore + Dlscrnst ne rete tara nage {Romaine cash ut acter an eit tne are EET ee ia ie aos revoetyeocer patos, showin Fi * gedistacanbefond wha pies hoe maiel " ‘Basie enn sbonsonpue wad Toei a {iw ae puaandrettin reves Gero Be ka ams pees eae Saeek ‘cla cone dearest eben aceSIS CRS ee oe ‘yan at ea © 33 gn Gr) naar Hajee Cook atone ene {er eae se rer wit bts a tened. he came ra Fite timiposto ahem FD ETS a wv carat nando Tian he Rice BEam's ey Sorel ahn ee Grats wa conan rhea eterna ae aed Re famovate cama whe engi ed eons Sunercnte oa coon BS BE nm sei atc a te Rn ercceee sms Soueiaeremrmarammate Saeco aes oe cane cre areas eeamatee sg fa a ety can antec ct! opp on ioe sagt ror fe cath bhewttotngate fede ww ef fe spannge he sche ve be IReshat"Retorene an n™ Det tng teaterwrson eles scaon ‘exon cape ae bed by etna odo a Sen eamahat bering cage rsa ere He Tam Sete eo aren a at + at Steneet nm manent hinenn peo pe 1+ Hine more ent athe art an fie sna eh ig shan wert coms wens ba pt mats eocnargh ments et salience okt "Seance fhe incarnate mt 82.2. Removal ad installation of Chain Tensioner ate eng ns eo oar ren In nay bo opis schinininabiiai thers" sug paneer omar be cama ae: 2 rant os yer + Rerovete nema bousg cont conse ‘he allan ne ater one ale the bore (Fed) and necamny pace ‘upte win tbe pats ethetnng mectarary hs meee Beene es+ amt pts wows eran tte esky sen 8.23. Removal ard installation of Tering Cain £8 922 some Aranar nn char Teli omar cn be shadoutoy lena isan hls elenng ps bc en, Mena nob bas oe mari ater an eds ig + Boe ven tag da etch a rhe Wan wet nasa dy he pedo ot mine. AS _gsteie ene toe eg unbarand mal ot fice eis etn ean wo eg an ca operat. At pm ingen ans aacn meet se Aenove te nde nad cre lett Seton 92 tf et Deno, errr Geto 923) Renate compra aa cnitonng ten ined. 168 + avr chan camer ih age aren ona prcie Yam ry se 1 a can oy ng dow oe i hg cn Deed sSitine psig ote + Simi e Carr eon oan, wg 427 men eke spies tether ty tt ne eng San Pat Sin pee ah be-cnaha ka wht sw aisha a roand Bl a Carat 1,22 Maing of eco enti ian epg oaoE ng FE83 ne chontasrmty min sens Shares ve rhe, rey “ ie the ten ew ni te raed er recy acts» ona 3a Sot Evia "a Naa wee se are! oe # breed dp, be ene ie he Seeing bl + Henovetheraair anc ecealnan rane eshte ke Scdonsa rcetin tae ad move mtorr? mide gre Ecc Reno necetnese te anes ete rae Rotten chat fectan of wn, eg 2 mm a ae sek test crt pays eat noe ser+ Lg an, cath oy ban ig da cna ‘Shoal spec's can townie kaa . Rare te ie a se atom te jad tte cor ‘Tea dah ate tng al (en F972), ash * Sumi cna y nee ey et tot tae sftncaran ol en enen be opuol tak Roto 8S + Fase ta tn te et tong Seng by bing te it fw sie tart Spemteney Gi Baa habe oe ela eee ria snp co ag eR pa ee Re Fores al. 522 ton amet asto sctncesing tb asi pp serena Ferovete eth ne, eave ea coe adhe Nese party aan femme ne ten 9, ear ey wo congestion ne ‘ude imal enpaeain te bear pene eg Se 188i ng ce, aa a he i ee ne cg Rei eee a 6) Fig 8.2 lis 2 neve nemo ouingan andi vacsumpunp teh aes ut 1 ameve rein het core theron rg dn {Ramee om being bats nw le aby mat ne mg aoa and 1Srended sep ae nso sr tare oe i euingsonpaun gam sngage se pg hae a “The tticaion syn ie apreszn fous ey gnc lpn, cnestg of Sure oe fueled She tio selene ay en ‘rotadSeans mtb pine incase oldorape lta item patti ack. ve Bra cher rox stan vats Te ole anced eS aay 10 Sat Santee hee tae oe is! beavalabe the pe ‘Relstuamanbe mul b rene 24.0, Tecra! oat Spe ie me pg. Seeabove oat oa Sp Ce yea 7 ani ive ange GStnee itt eim eh StScnprac me Saissitee 3 065m BO) 94.1, OIL PUMP -REMOVAL AND INSTALLATION eesti tn Pee amass meester ate eee any Aaya se ene gail few, Fath ene with cones ay 842 Ol SUMP-REMOVAL AND INSTALLATION + Pacrinefonten othe wee en sce aa ans. anos te ening tones gemefote cata Reeve tbe et ‘Shemneranee ter ties eee aha aeres eee te + thy wok on aaron emer rot ar ech of te et ene ourge om baw) and uct be wanimenbe hate sue bal he (pra Weise spends ”4a, @Fiter faces septs nt ote cme iter en fea at be ‘ating ance ne har bee ema So a He "nh Roma esa mee lameces oe 20 ce thee ve ant ely hatiesteine et or ate moa ate ere an Ya rt Yousrg an the th arent n yt She Et) Rt tr con hms wn Se ‘otha, as apse 8.5. cooling Systm ‘incarnate lenpertr 8 afc i om ‘ouing omacedy meas ascen punp mn sew tt Sou Bas ud en he bak 0 LO Np 2 afl csi an ano he nat pan dn ba in decode 952. Ome BottTersion Seta sas en tes fet pi, tena cna iy Ser Teineai “acca apron Sm (4m fn una pose Teton be obo) anda) nF 933 he theconcteson ana 4 £54. Draining and Fng the Cooing System40. SERVICING AND MAINTENANCE | Most of the melatenarce operations can be caries ost wou many [TREuSee!a any caso ke Mamever beter to hove can mantenarce Shersions caved oath a uhop se experence ond speci lent ‘irerompis at inert, af reuret te cay ngatant set rai! nspecons and shecks whe ‘Gloinions tobe carted ou ates cutah menge ae Jenete ote In {She seen and thet ll aie hon spec abe Stout be fet fo & Maceies Deer 400. Regular Maintenance DitLevel Check: Checkthe engine lave very SCD les Wh te vei ‘Stand on level ound, romave thet pick and wpe clean with @ einige ie pp eirnt he of te are ere ‘ok an he peek Wt of lel eelow ye lowe ark, tp wth ‘She aio se carect acolyte ell quai been het a Spbtox beweon 9. 0ane a fies andi te aleve ndected you nil ES eat an auch oe ming ever over tee ena» the lvl ‘mus neve be abovethe usr ape ma CCecking the Brake Fi Leo The take fides he eng {ershork ne the ad lel betwen the "Mond “Mae rk ocesery op up late Mee mance cee tate hid hechng tn Brake Light: Te pwn fh ake ee career be “nny howl ese aa th gene doar Opera th bake pel Sina shuck he recon othe beak igs can be vet os he geage 0% By eonngtougste ex en aor ° CGheckingthe Vehicle Light; In tn check every vaio. ght \felstag he nor andthe hazard wana Hoh system Rea? nhs snd ‘versng gis en be eveckad nce dan fone a gage com, wRtOut [ering te vencie ‘Checking he Tye Pressures: Checkthetye pressures at pat Ston Presergs af ferent or ha varus modes ERher your Operators dns Gripe chats wage You be comet proceuee Ircantwuois speeds of nae than 100 ph are ened, Incense the re preaure ty Os mye on (SPs) fieop ven he erine ick 16 — [Chackingthe Fei Level a the Automate Tanemission: The st ove! mamas 1+ Asply the fandeate and pice the ger selector lover into the = ‘aston State engl arid ow te ef 10 2m. “+ Remive he ot dpsikttem he tranerision and red off he ite transmission at ere torratie the eel aybe us 10m (Gz in} bw the hn marke reason ‘+ Itnocescary top tho transiston wh ATE fd trough the Mid ‘he ranemission| 104. Service every 6000 Mites Cchangingthe Engine avd Ol Fite Some ptr satons i cary Sutan at thange ee of churgeYo ont pay fer theo. The sre apne ew on ar ee ay Dee weet ct haa. bd wot coy tat Eaton be abet bina Mercedes eo etange te fer youre fete toPage 8 rte the evant secten athe ond of he manual wen 8 Ea eg (0a ed The ge of range ao decode Lubrlston Jobe: Ape rom the engine lution there are futher Iubneaton pons whe shal be stoned 1. These ncude te tote ‘ge sat oy rete se pr) te eg ue eth 102. Additional Serice Every 1,000 Miles Checking the Speedie ongnene onto las at ped ha llespend checked anéWneseasaty adured your Dele AlrFiter Serdce: Remove the or titer eemanttor leaning, a cess on Page 164 Checking the Brake System: Ino rele has been experienced win the Yale ster hr mo cayalexentive sie ro mend [Binns Insc fg’ iterate mat cine hare ee ‘Rebate sore ur Melts nsoe sigh eokeg since ”“Te brake pace mustbe checked eth malig rat idiness een cached Sean “Brakes fr he tots a rates, Adjusing the Pang Brake: Asut bearing Wake as exces in Brae Te A at recorded aM a os wc Yourself orate ptr a8 You expe tart Ofterwise ave he toe tsi one anammets. Ths taut of ie mat wl shew You FReettency ft bake sytem ore for mee Stewie romano bothwheas nd Che tha thoct abetbes fins af ‘route, adesing fad wane ‘heck he te ply othe stetng wn. the tern wheal ane moved Dy inn tues gn hin] fo the Hat ene reepond, hate the owing checkod nossa, Check the rubber dist boots of the tack fod and eag ink bl jit ‘Mhougribbe oot an be elaced vastly have eters the [Bi steaiy nia ese replase te slant ona poss ‘Snek te al love. in the mashing. Rerove the frig snd ‘hes eee poh hr ug bore hal. Frees eps Wah ‘Ferecemmensevo {fa povorasisted Seeing fs ed, 22K He fae ern he vest Saber Secton 62° fr tutte Wer fade see moar oo the [2tG0 oes chs sped ee tr in he eyo Se Ye Tyre Check: Jack wp te vi and chook a res fF tnenan wou fre eel te een wom on tha ana urtace Unewn wast athe at cute edge of rent tyes ports to misalgrmert te fen wheel eomety “Have ie gecmery sued ot out dene Nake sure at 2 Hear doth ef Cine ett Ye toremain vain the legal vaquremonic US siteto fy sutase Yor your ode may fy By hen ar an ‘deport fe company Re-Sgtton Whee! Bots: Re-ighfen he vn bes 18.0 180 ig (118, “]30 fie) Tighten aver tocond bot in tur ula Bots Nave Bee r= checking tha Cooling Syste: Check a count Noses fr a, ean nd ott darage_ Shuck the radater fr les rormaly need by ‘epout lo by fe leckirg ank-toec. Sigh edt leaks can be stopped ‘ethone ata propncary senate walabe fr ths pupase ‘Checking the Clutch: Chee he cites open The tid reser shoud {he ehtletes desir. guage ved fe ete preraion ate ave ‘hinder puro is a glk check ard may prove! the diet ven pe (Bhaeardown the mets wwe Checking the Antttnze: The stengh of fhe antteere sous be ‘Sheed evay 12000 mee Ftd stone noma fave a hystonrto ary ect ie shack Make ur ht nly atone elle Moree ‘signs suse. Checking the Manual Tanamissin Fulé Level: Rett to Secton 23 onvage 6. Checking the Rear Axle Ot Level: Reet Seton 8.3 Pape 198 10.3, Additional Service every 36,000 Miles ‘Automate Tanamlaslon OU and Fier Changs: Thase operons ‘Shonda cred oy + Ona [Ar leaner Eemant Change: Ret to Seton 19899 Page 108 Diesel OM Fter- Changs: Rep'ace te Wel iter es cascites in Sten PSorragess. Bhedthe sytem whe speci pou aaa mf rate Fuld Change: We rcomemand to have te ale fui changed ot Your cele ‘Raed salay i iveved and heb shoud be eames ot Hotesonaly you ee mpwietced Wit) bexe’Sitens, flow thy 10. once every 2 Years oatng System: The a-eere mute changes, Rei to Sesten 181 FAULT FINDING SECTION {Pe otro sco tes ny ne coer mi hat an eo Malas a ee Se gc ‘elon sided ro varous eseaeies ard shou be posite l ceale SS! ine y Yering he aoe gp eine wea et we ed fo sarge gl woes we indy eatng 8 Sl AO flea fs 17cause endo carry ut re necessary famed, ins is wane he scepe of euros ENGINE FAULTS. ovine eae oder eee Ser eoc ven cairn si uae mare [ot max sped. 5to8, 10,2 1 ae ete a riven Eo, 6.6.7, 10 ZeRSnNB causes ino mene 2 Engine ooo thick. Ths can be causes by usng the wong ol low Ses peceerehcea arvana Son jeck eae eee Seats Se aioe sh reat, + TE. meeps myer opie ceemmane yet Deamon paneeuen a HRS ea a rot sna ath pie Hane Se ear dare danse Seen eee ie eteatene nee ee eon rane ioe ttcren eee teens crtacas a oy ac 1 EEE we eguvtmen te temo Se magoe mma te nate «, Syubscannetcercmrcantgi af esnaust pets) hod pipes) of colapsd Sencar Repar at Ser 180 ir loner dosha te vahes ape Top sretteiof get ead 1. Blctng vos sunt ecoa caron dpon or wook vale sts, Teal ia es ae 13. Giinder hed gate! own. Replace gahet and check eek and hed sacs or Stee, ® 14 Cama wom nc opening of soxing ore ef th vaesoreer Dover pope’ crlasion Cnscane froeesay Whee ea 15, lrorect nave (opal desrance, Thre cou bea Ui Me yoahe ‘pes 18, Gir srs, sensor ss war. Cuca the en cn ibrar be cra har yal ian So Sat 12 Mina gis mnt ive sen op overau atoso 12 ayaa Conta Topeut's os {tLe wanna as we pts gear ana pe. rect as necessary. = 2, Leave gw pug 8 etcapg pat eae pug sng waster are or ender block Omit vertaate ane rears a stv tata) Top overt ve 0) GLOWPLUG FAULTS hesk tape! iow up a oe "Reno egg fn om he cer lov fig and tom te + orn 972 vate emg oa ps foi fhe tery an th theater ea of he amo fue nfs te connecting treads ach show ple thy sug setae tant et lap oss Se he Pt mn wn ge yn es po ey Se ns sor = dnt oealtton tego an tna mn Sia iene sry te soa ever er hence se 5 ROSS te sheen tee +» TAR cael rt ares Sarton Sepia ed eet ~ Rare ee wip near ne om Sa Rtrormriaa + ERERES EGFR ene ne yur pon coca 1 BERR S ecgameectmpennrer + Mortem eta 481LUBRICATION SYSTEM FAULTS The ony pobiam the Livseton sytem shou give ly xcezsoe ot itaumjon er tw olf aressure ih ol warning ign gong at Excess ol cansunyton ean be causes by wor eynder Eve, pons ‘tale pron nego, wom ave ude worn vee atch soc or dead {tanks lea o leaung gasket Gy any of be sngne pata in nel ‘lees the engine ust dshaedte acs the hak Lineal naire ear be saved by minut sl ecsure jogs See wo ing cn ue wae og Sie ete Sop 9 Epes sek Be al vel bat al ahevacieee neers Brest tnd apa olthe engine Ifthe ol waring tae says on Swies shine Sand INavEDIaTELY. a dle tau sasecahpte staan os ‘COOLING SYSTEM FAULTS Common taut are: Gveheding, las of cola a fe orgie ‘verneatng: "Lack of coolant Cpan te radidor cap wth care to avid juss ‘ever pau sole wat lye on otetwstad angie Wot snd rai ool doen and pow inoodan wha ngs neweng 2, Rajaor sore obwtucied by laven, nonin, tion wt 88 Tic te ack ine aaa’ ore nate dean 9. Coutng fan ot opraing: Cheek Tan proper en ai cutout Tenparatie W enconray ange te opus Sa oe You Bear 5. Thammostat steking: I stckng in he saved postin, cal can ly rata wann tw apne head o Bock Remove Heron ind check os deseabed secon “Cooing Mane ‘roe snl eniee sig ean Yor te engne ‘un sdtin tape. "Drve wince separation tank cap fo have he Drosutein he sam ao oe natal Sesion iat pmg ba lanes ‘ater pump inoperative: Resace wae: pum Grlrer hot gash blown: Repiase be yr bead gash. a Loss of Ceoant: 1 Rater leaks: Sign aks may b0 sopped by wing rdiaoe seatng compound (eon tv instustons the marie hergoney Snood et" be staked aan and paced Ws atabr hee neo 2 Rove leaks See Ui 5 "Overeating, 182 5. We pa abs: Chek he gsit rope sean optic he ae @ Lona Warming porn 1 Theimialaickng the pen pestin: Remove thao, heck ‘ana recess tec DIESEL FUEL SYSTEM FAULTS. Enginels ditto ator does nc sat ten {Engne stats, but stop ston ateretes prey Engnematrs cots te Bed ing rs) ‘Blok wh of tide ease sek noo toaster Soa Eneeena tel coneunptin ops CAUSES AND RENEDIES Foal tank apy Rout 2. Bregletgtinetoochat. Operate wl wang itt gore 3 Goa sing devo vot seated Poca shoe ahr ape (Ge pug eto incparatv. Rafe tow Pug Fats: Elesromapntic item deve oora cere sarett Chek abe toc stat diction ramp: Aske second pron pets gion Begg gece trap erent cpp ATi fit system: Operate starter mor unt ut is devin, 7 Fu sip ay, Scher te hs pips at Feson and chek Nels ning ot Ota Tet had Noster econ fps oc oar, fn retin est bcked” fea ol & het pies retedin wong ode ate pa 4 meton fg of punp ou pace Have he aGustnartchected 16, Ghee ate ators tay ety o incorrect injetn pressure Have bjedanopare eles bor! 11. leon para ne opraig pope. Fan exchange pum or have it econ rary oon pup. 12 Vibes rt epring prepay. 12. Comores psutton ion Sooltem under"Engin aus! ot ropa ane, Aas Papen was scr Roa hn 1. Fuel note detente ond pany ot igntecd ope ahten connctane panna oie 17, Reet moiing tinecton ur oss oases Tphan plc.18 Seeitone 7.9.44, 12 and 13 1, Engnemountng nt Ynioned propery or wom. Toten or replace. 20. Sting acsletaa pata. Free ot pees, 21. Engnenet ot opemrgtmperaure Check aul vroke our again 22, Yoomuch scsi lw revs. Use indi! pears accacinoe 23, Lrdamerconarinted Clean or writee 28 Fs far ontamnates:Repace 25. ax sfeee agustnest reorect re asust 24 Injstom ao png rave tum elocod 2 repce aly on, 21 Inter nazis tc er broker. Replace ctr BE tn pessoa res Gein ond gests A Tht cable Val estrted Reveust Check at oor mats cannot, Behue pods moverent 231, Tivae dele not coc agus, Re-agst 2. peaing lve toesacon pnp, Resigten 435, Wax speed not ait Reradjustmac speo! orheveitodusted S* Shoe ad neck tat dometerie at ae Som icon atest sting gusts nda eco ol sea o daaped 8 emcee ryecbes and Gece Rapace'Wnoceseay YE fe waskes 26, esion prasewe af jocrs wrong Hive ter reagusted 37 Seotemee 7, 5,11 nat 38. Sectem 20 38. See toms 23.24, 26 na277 4G. Fost eae dag. ales sce or wil Denings rt wing 444. Engh not rain “he! Flatow o rads gine ‘2 Fuel sytar ean. Chosk hoses, pes, Hey, neta pump, ste for 43. Fuel ronan tne lores. Clean wn conocer a posse ldo peud oo gh Re-agert 45. tht Spmedtoa ign henedust 4 Seotems 107, Bena ts a Seotoms 24,2827 28 CLUTCH FAULTS chten sizing naga ton una eengage tay 4804 ‘ig ta un ne fc deposed oe Gh hole when ing og Guich nove dung engegemert: 2 14 (CAUSES AND RENEDIES 1. Instr etch to play at pedal 2 Chater ase nnge vem Marden, ed, owe ot token, Oke ‘Goad of db boss Cen ee mute replace 4 Preuare pate fauty Repre cash { Arimnpamute sete Cow hl fli ch opncer eervor 5 Intec ay see pedal are ce vlan ety ae decried eninihe ©. Exceute tee pay im lease unsage (oly for cae epee hh fi apoleaiey Aalst er reptce wart pare ‘Moalgnint of cach Roush Vey fate tut, bat gossble on trons wn spate uch nce Ro eights cafes” 1 Glch shad tcing 99 spas of mat ie te on hale {Gitte en spines Reeve such and ean sd check spe Chien tes tgs ose of bokan, Replace de 40. rectum pate tore Fegan cutee morieeee engine mourns {3 Retna poner sects Rerave cuca mace beat 14 A‘Sen cach thas lover Caect lover and nace shen, Dotsbe +The atve tuts an remeies ae for hdentcanamechaicl cut operation ad sheuldbe ead as oxgeate fo themed tne, lecich aut ting easton etter fare pes icaschapeon STEERING FAULTS Seeing very have tes Sheng vat woes seg rior Seong wheal wobbies sates tele ‘erie pus toa sie 4 a'te tatotn ‘Slouing whee aes nel rdumto conte postion 68,18 fonormal ye meat 1.47109 140619 ctng ne ctu ere CAUSES AND REMEDIES 2 Uackotinsced song 3, Sitsteereginage tals, Repice bal osm qisten 4 bested sergio mimes cotc rcs. : your dai fora Steming eure teaings (60 taht or soe or esing ou bo rect nee 085. Fron wheel bowings wor, damage loose. Replace beg Fron! suspansien pts locra Chackand cat 40. Vines! nts wots, Regen. 11, Stein whee cote Re tghien nut 18, Stung geer worn Replace he soci pear 14. Stung wack ededolecure elense Desairerortcenoninaae 18, Stapanson sprage weak o token Replace pig In questen er bath. {7 Bianes ae pug b ove de Ses vide "Sake Felt 1% ene Feve ne comglite suspension cheched 1, rcp eso i cn inet al you how ive and ae gute BRAKE FAULTS Beane Fate: Wlake shoe ngs fact aicessay wor, roarect rake fier overhaul econ bce fas ua isk insta ender itech snd lp’ fala Redes we obo i eh ricer inscor graven era mt rote ingy colori fide, sry ete pte eed inh iemetvame ie ene ees ae seal ote «hi oo ge oo Beane ea be oat eet coe Renee eee are meena fiegugent nen ee mentee ES et ee aero ner Meee erento cer ge Rrra ne mas ar are Cae pee tin her ican aaa ate ideas Ar tec ie Pe aegis aroner tie Slee ooreeees ase brake adlutmnt noxrect (a! ting naw tea shows tn ea crac pam ea ey aaa ae me naar woes Excessive pada pressure requlre: Sake shue lintas or pass worn, ‘cored or ohn pinto, toned” Exh = Aeciy a nocecsay Brates squeding”G1ako shoe Inngs of pads vor sft that mea & thang aga Sur oat ae Srp tt fry ek Rao {ndtepars er aan othe drums nt ale rake Not: operaton on eg ard ate seri mut be cae ot {otey' cer ae ute Make suey uc he covet Tu the poe Sod steneg and he somec rave fu ‘aus ran ABS sysior shouts nvesigsteg bya cook. (Change the ake Md ragulr teva (pan avery # yer) ELECTRICAL FAULTS Ne arr ter dive e380? hae waite ht emai on 3.1012 {tags wari bt esa Cove on Zane Batey sede teavani toring. un ons Brecon inleaers not wena epety 2,3.8.13.44 Baty reqwoy aechrgoe Sas ‘CAUSES AND REMEDIES Tig engin check sca. Statermaier nen omen free! Reese ‘se 6,7 an 8. Stter moor delcive, no napement Syed! Dinan Bywnost wom soleroleentcr datecine, Corset 9s 2 Gnonisurtaautehineperatve Replice 10. Bho batoeseorbreker Aue orice 12, Generales naperton Otto piace, 4. Sub bur out Replace sua 19. Planer unt eeive Replace ant 2 s 5 v7i i i Pages 191 -192- Wiring Diagrams St Say ren azagzee+ i » enone 2 = oe = * 63 Naber plate ~ 4 fies © eee d £ eee so : fe ies 8 ee: é ae imma, 3 ZS a eoaaes fe Fame Poa | : Beis : $e PEs | Sicmres | i “ ahaa 2 " eee i é EE ene z E Pinas 3 § | : | = Satie : one iin Obarim Legend Te 1-20 3 ne 7 corer : Ret 3 Seon shor z RS 3 eens 2 Boa : RE os oo 8 Geshe ligt, born 5 cetente 5 es Pages 191 -197-Legend 5 at oe wee nay I Shaoe menason Se Titec a tea 12 Srpacerocion : 8) Sty Seana” as Hane ter mo 3 Nordae ft Sore St she Somer oon10 Baste tan ve: ‘oer iin nck 11 Sart aka pasar | ey “Cog ie wo By ioe 812, ir bat ar A Saori upon Br ete Aid ate | XS Sew compart Bee 14 bind ner et So Sedo ae ae sani Sib Citterpancgigte ee et Ete Rit repent Fie (i Sorat Fé deteriora EZ RAL arpa | se Sede iG Wing tt and a et iy Greene sarah ie Waring ih et ack 16 ratng tt rte pa a er ie ea XY Trlr aoaat co Eire tng wea Lt Legend ~ See Pages 18 10188t po SGLegend See Pages 188 to 189 Legend ~See Pages 18810 188 18s®» a eS r aa | ss Legend — See Pages 19810180 Legend ~ See Pages 188 10189 487Legend See Pages 188 10 190,(ay eg 8k (5 Legend —See Page 149 0 190 Legena—see Pages 189 t0 190