SERVICE MANUAL & INDEX - Mercedes-Benz Forum
 
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post #1 of 4 (permalink) Old 08-29-2008, 12:36 AM Thread Starter
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Date registered: Sep 2005
Vehicle: 1988 420 SE; 2015 ML 400
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Post SERVICE MANUAL & INDEX

Now, don't get all excited, this is the service manual 'on-line' http://www.startekinfo.com/StarTek/o...tedDocId=12253



What it is, is the Steve Nervig index to the 126 service manual (at this point just the gen 2 V8 - but I will get around to the others however the group numbers are generally the same).

You can download the index for your CDs from here.

The aim of this index is to allow YOU to SEARCH the archives using the service group and sub-group number to see if it has been posted before, if not, to ask someone to kindly post up the appropriate pages... as they get posted, I also try to link them here for ease of finding them later.

What you will also see, is that not all service groups are there, this means they are not on the service disk so it is unlikely that anyone has posted them or will be able to...

Hope it is helpful...

Mercedes-Benz Model 126 - M116 4.2 L & M117 5.6 L
Maintenance Manuals

1986-1991 420SEL
Chassis Type 126.035

Engine Type 116.965
1986-1991 560SEL
Chassis Type 126.039

Engine Type 117.968
1986-1991 560SEC
Chassis Type 126.045

Engine Type 117.968


________________________________________
00 - Maintenance Procedures, Identification and Owner's Manuals
Maintenance Jobs
• 0050 - Inspecting component condition
• 0051 - Inspecting condition of lines and hoses
• 0053 - Inspecting components, lines and hoses
• 0090 - Suspension and body structure inspection
• 0091 - Water leakage and corrosion inspection
Service Manual, Engine 116/4.2 L & 117/5.6 L
• 00-005 - Instructions for use of service manual
• 00-010 - Engine and vehicle identification
• 00-015 - Vehicle identification number locations
• 00-020 - Technical data

01 - Engine, removal and installation; Crankcase, Cylinder Head, Engine Breathing
Maintenance Jobs
• 0101 - Engine oil and filter change
Engine
• 01-001 - Engine and model survey
• 01-010 - Checking compression pressure
• 01-015 - Checking cylinders for leaks
• 01-020 - Evaluating cylinder bores
• 01-030 - Removal and installation of engine (oil capacity)
• 01-040 - Engine breathing system - operation
Crankcase
• 01-112 - Measuring, honing and silicon-lapping cylinder bores
• 01-120 - Machining crankcase mating surface
• 01-122 - Reconditioning of threaded bores for cylinder head bolts
• 01-124 - Reconditioning threaded bores for intermediate flange and transmission mounting
• 01-126 - Coolant preheater in crankcase (installation instruction)
Timing housing cover, crankcase cover and intermediate flange
• 01-210 - Removal and installation of timing case cover
• 01-220 - Installation and centering of intermediate flange
• 01-222 - Removal and installation of end cover
Oil Pan
• 01-310 - Removal and installation of oil pan
Cylinder head
• 01-415 - Removal and installation of cylinder head
• 01-418 - Facing cylinder head mating surface
• 01-420 - Pressure-testing cylinder head

03 - Crank Assembly
Crankshaft, connecting rods and pistons
• 03-310 - Checking, renewing and tightening connecting rod bolts
• 03-313 - Reconditioning and squaring connecting rods
• 03-316 - Removal and installation of pistons
• 03-317 - Renewal of pistons rings
• 03-318 - Checking and reconditioning of crankshaft
• 03-320 - Mounting of crankshaft
• 03-324 - Replacing front crankshaft radial sealing ring
• 03-327 - Replacing rear crankshaft radial sealing ring
• 03-342 - Removal and installation of hub, vibration damper and V-belt pulley
• 03-345 - Checking and correcting adjustment of TDC transmitter
Driven plates and ring gear
• 03-410 - Removal and installation of driven plates
• 03-430 - Renewing ring gear

05 - Engine, Camshaft and Valve Train
Maintenance Jobs
• 0561 - Checking valve clearance
Camshaft, rocker arm and valves
• 05-211 - Checking and replacing hydraulic valve clearance compensating elements
• 05-213 - Checking and correcting basic position of hydraulic valve clearance compensating elements
• 05-215 - Checking and adjusting camshaft timing
• 05-220 - Removal and installation of camshafts
• 05-225 - Grinding camshaft bearing journals
• 05-230 - Removal and installation of rocker arms
• 05-250 - Removal and installation of valve springs
• 05-260 - Checking valve springs and valve spring preload
• 05-270 - Replacing valve stem seals
• 05-280 - Checking and machining valves
• 05-285 - Checking, replacing valve guides
• 05-290 - Replacing valve seat rings
• 05-291 - Machining valve seats
• 05-293 - Decoking valves
Timing chain, chain tensioner, tension and slide rails
• 05-310 - Removal and installation of chain tensioner
• 05-320 - Replacing timing chain
• 05-330 - Removal and installation of tension rail
• 05-340 - Removal and installation of slide rails
Oil pump and dristributor drive
• 05-434 - Removal and installation of intermediate gear for distributor drive
• 05-440 - Removal and installation of return sprocket

07 - Mechanical/Electronic Gasoline Injection
Maintenance Jobs
• 0780 - Replacing fuel filter
Test and adjustment work
• 07.3-001 - Additional Designations for Model and Components
• 07.3-002 - Models and Components Survey
• 07.3-004 - Vehicle Characteristics
• 07.3-005 - Influencing Parameters of Mechanical/Electronic Mixture Adaptation
• 07.3-009 - Influencing Parameters of Idle Speed Control
• 07.3-013 - Function Diagram CIS-E Injection System
• 07.3-105 - Testing on/off ratio
07.3-110 - Testing, adjusting engine
• 07.3-112 - Testing electronic idle speed control
• 07.3-120 - Testing fuel pressures and internal leakage
07.3-121 - Testing electrical components of CIS-E injection system
• 07.3-124 - Testing starting device
• 07.3-126 - Testing starting valve control
• 07.3-127 - Performing cold start
07.3-128 - Electrical wiring diagrams
• 07.3-130 - Checking fuel pump
• 07.3-135 - Checking injection valves
• 07.3-152 - Checking, renewing throttle valve switch
• 07.3-160 - Checking fuel quantity comparative measurement
• 07.3-165 - Checking fuel pump relay
• 07.3-167 - Checking kick down switch
Assembly job
• 07.3-205 - Removal, reinstallation of fuel distributor
• 07.3-207 - Renewing sealing ring for control piston
• 07.3-215 - Removal, reinstallation of injection valves
• 07.3-216 - Removal, reinstallation of insulating sleeve
• 07.3-220 - Renewing air flow sensor
• 07.3-225 - Removal, reinstallation of mixture control unit
• 07.3-230 - Removal, reinstallation of throttle assembly
07.3-245 - Renewing, centering sensor plate and checking and adjusting zero position of sensor plate
• 07.3-250 - Removal, reinstallation of CIS-E control unit
• 07.3-251 - Removal, reinstallation of idle speed control unit
• 07.3-255 - Renewing electro hydraulic adjusting element
• 07.3-258 - Renewing oxygen sensor
• 07.3-268 - Renewing rubber buffer for fuel pump assembly
• 07.3-269 - Removal, reinstallation of fuel pump assembly
• 07.3-270 - Removal, reinstallation of fuel accumulator
• 07.3-275 - Removal, reinstallation of fuel filter
• 07.3-280 - Removal, reinstallation of fuel pump
• 07.3-285 - Renewing check valve for fuel pump

09 - Air Cleaner
Maintenance Jobs
• 0932 - Cleaning metal-reinforced air filter element
• 0981 - Replacing air filter elements (M116, M117)
General
• 09-400 - Removal and installation of air cleaner
• 09-402 - Renewing intake scoop

13 - Accessory Belt
Maintenance Job
• 1350 - Checking condition and tension of V-belts (M110, M116, M117, OM616, OM617)
General
• 13-335 - Instructions concerning V-belt replacement and tensioning
• 13-340 - Replacing and tensioning V-belt

14 - Intake Manifold, Exhaust Manifold, Emissions Control System
Maintenance Jobs
• 1480 - Replacing oxygen sensor (gasoline)
Emission control
• 14-001 - Identification features (information plate for emission control)
• 14-050 - Function of emission control system
• 14-116 - Checking oxygen sensor failure indicator
• 14-200 - Removal, reinstallation of catalytic converter
• 14-250 - Removal, reinstallation of air pump
• 14-260 - Removal, reinstallation of electromagnetic clutch
Intake and exhaust manifolds
• 14-450 - Removal, reinstallation of intake manifold, renewing gaskets
• 14-455 - Renewing intake manifold (intake manifold removed)
• 14-470 - Removal, reinstallation of exhaust manifold
• 14-471 - Renewing transverse pipe
• 14-472 - Survey exhaust manifolds
Emissions
• 14-475 - Checking exhaust gas recirculation (EGR)
• 14-478 - Checking air injection
• 14-487 - General instructions for vehicles with catalytic converter

15 - Engine Electrical System
Maintenance Jobs
• 1550 - Check spark plugs, replace if necessary (gasoline)
• 1580 - Replacing spark plugs (gasoline)
General
• How a Starter and Solenoid Operate
Electrical system, engine
• 15-505 - Instructions regarding work on breakerless transistorized ignition system
• 15-510 - Function of electronic ignition system with electronic timing adjustment (EZL)
• 15-515 - Testing ignition timing
• 15-525 - Analyzing oscilloscope pattern
• 15-530 - Renewing spark plugs
• 15-535 - Removing and installing high voltage distributor
15-540 - Testing electronic ignition system with electronic timing adjustment (EZL)
Charging system, starter
• 15-600 - Testing alternator and regulator in vehicle
• 15-642 - Replacing alternator fan assembly
• 15-700 - R and R starter

Ross


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post #2 of 4 (permalink) Old 08-29-2008, 12:37 AM Thread Starter
slightly creased
 
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Date registered: Sep 2005
Vehicle: 1988 420 SE; 2015 ML 400
Location: Gold Coast, QLD, AUS & Doha, Qatar
Posts: 16,550
Mentioned: 2 Post(s)
Quoted: 258 Post(s)
Lifetime Premium Member
(Thread Starter)
18 - Engine Lubrication, Engine Oil Cooler
Oil circuit
• 18-005 - Oil circuit
• 18-010 - Oil pressure, valves in oil circuit, oil filter and thermostat (model 126)
Oil filter
• 18-110 - Removal and installation of oil filter
Oil pump, oil level indication
• 18-210 - Removal and installation of oil pump
• 18-215 - Removal and installation of oil pressure relief valve
• 18-220 - Checking oil level indication
• 18-230 - Removal and installation of oil level transmitter

20 - Cooling System
Maintenance Jobs
• 2010 - Checking coolant level/antifreeze protection
• 2011 - Checking coolant level
• 2050 - Checking cooling and heating system
• 2080 - Replacing coolant
Cooling system
• 20-005 - Cooling circuit and engine cooling
• 20-010 - Draining and filling-in of coolant - antifreeze table
• 20-015 - Cleaning cooling and heating system
Cooling thermostat
• 20-110 - Removal and installation of cooling thermostat
Cooling pump
• 20-210 - Removal and installation of coolant pump
• 20-220 - Reconditioning of coolant pump
• 20-225 - Sealing coolant pump
Fan coupling
• 20-320 - Viscofan clutch
Radiator
• 20-420 - Removal and installation of radiator
• 20-425 - Repairing radiator
• 20-430 - Checking expansion tank cap
More information
• Oil in cooling system? After repair, use Alkaline cleaner, Disodium trioxosilicate, pentahydrate.
o Part number is 001 986 21 71 (500 grams)
• Scale in cooling system? Use Citric Acid at 100 grams per liter.
o Part number is 000 989 10 25 (500 grams)
• Cooling System Diagnostics

22 - Engine Mounts
 22-211 - Removal and installation of front engine mount
 22-212 - Removal and installation of rear engine mount
 22-240 - Removal and installation of engine shock absorber

24 - Electrical Troubleshooting Note: this PDF is too large to be posted on Benzworld
1986-1991
• Introduction
• How to Use this Manual
• Symbols
• Troubleshooting
• Index of Electrical Circuits
• Component Locations
• Index of Electrical Circuits - Automatic Climate Control

29 – Pedals
Maintenance Jobs
• 2910 - Clutch system, checking, correcting fluid level
• 2950 - Clutch system, inspect
General
• 29-320 - R and R pedals
• 29-330 - Disassembling and assembling pedals

30 - Acceleration Control System
Maintenance Job
• 3022 - Inspecting, lubricating throttle linkage
General
• 30-300 - Checking, adjusting accelerator control
• 30-310 - Removing and installing engine longitudinal control shaft
• 30-320 - Removing and installing, adjusting firewall accelerator control shaft
• 30-330 - Removing and installing, renewing accelerator pedal
• 30-335 - Greasing accelerator control linkage and shafts
• 30-350 - Design and function of electronic accelerator
• 30-355 - Instructions for test and repair work
• 30-360 - ABS/ASR and electronic accelerator input test
• 30-365 - Testing electronic accelerator
• 30-370 - Testing cruise control (vehicle with ASR)

32 – Suspension
Maintenance Jobs
• 3211 - Level control, ADS, ASD, 4MATIC, fluid level
• 3251 - Inspecting self-leveling suspension
Misc
• George Murphy on installing shocks
General
• 32-010 - Survey of springs - shock absorbers/spring struts
Shock absorbers
• 32-100 - R and R front shock absorbers
• 32-110 - R and R rear shock absorbers
• 32-120 - Checking shock absorbers
• 32-125 - Checking alignment of front shock absorbers
• 32-126 - Checking alignment of rear shock absorbers
Springs
• 32-200 - R and R front springs
• 32-220 - Adjustment of front springs
• 32-230 - R and R rear springs
• 32-240 - Adjustment of rear springs
• 32-250 - Test specifications of springs
Stabilizer bars
• 32-300 - R and R front stabilizer bar
• 32-310 - R and R rear stabilizer bar
• 32-320 - R and R rear stabilizer bar (suspension w/ anti-squat geometry)
• 32-325 - R and R rear wheel carrier support on stabilizer bar
Level control system
• 32-501 - Functional description of level control system (see also 40-310 - Adjusting)
• 32-510 - Checking spring struts
• 32-520 - Checking pressure reservoir
• 32-530 - Checking pressure oil pump and level controller
• 32-610 - R and R spring struts
• 32-620 - R and R pressure reservoir
• 32-630 - Draining and filling hydraulic system
• 32-640 - R and R pressure oil pump
• 32-645 - Replacement of pressure oil pump seal
• 32-660 - R and R controller connecting link
• 32-670 - R and R level controller

33 - Front Axle
Maintenance Jobs
• 3353 - Checking front axle ball joints
• 3355 - Checking ball joints using special tool
Misc
• Bad Wheel Bearing?
Front axle halves
• 33-200 - R and R front axle half
Front wheel hub
• 33-300 - Adjustment of wheel bearing and play
• 33-310 - R and R front wheel hub
• 33-320 - Disassembly, inspection, repair and assembly of front wheel hub
Steering knuckle
• 33-400 - R and R steering knuckle
• 33-410 - Checking steering knuckle
• 33-420 - R and R steering knuckle arm
• 33-425 - Checking upper and lower ball joints
• 33-430 - Replacing ball joint boots
• 33-440 - Replacing lower ball joint
Control arm
• 33-500 - R and R upper control arm
• 33-512 - Removal, disassembly, assembly and installation of lower control arm
• 33-520 - R and R lower control arm bushing
• 33-540 - Checking brake support link and ball joint
• 33-550 - Checking and replacing upper control arm bearing
• 33-560 - Checking upper control arm
• 33-570 - Checking lower control arm
Front axle carrier
• 33-600 - R and R braking support link ball joint carrier
• 33-610 - R and R ball joint carrier bushing
• 33-615 - R and R braking support link ball joint

35 - Rear Axle
Maintenance Jobs
• 3501 - Rear axle oil change
• 3510 - Rear axle, checking, correcting oil level
Misc
• Bad Wheel Bearing?
• Trailing Arm Bushing Replacement
Note: the 35-xxxx files seem to be the later version of the 35-xxx
• 35-0005 - Identifying differential housing mounting
Rear axle
• 35-010 - R and R complete rear axle
• 35-0010 - R and R complete rear axle assembly
• 35-040 - R and R rear axle subframe front bushings
• 35-0040 - R and R front mounts of rear axle subframe
• 35-050 - R and R rear axle subframe rear bushing
• 35-0050 - R and R rear mount of rear axle subframe
Semi-trailing arm
• 35-110 - R and R semi-trailing arm
• 35-0110 - R and R semi-trailing arm/bushing
• 35-130 - R and R rear axle shaft flange, adjustment bearings
• 35-0130 - R and R rear wheel hub, adjustment of bearings
• 35-310 - R and R coupled semi-trailing arm
• 35-0310 - R and R coupled semi-trailing arm / bushing
• 35-330 - R and R link between coupled semi-trailing arm and caliper carrier
• 35-0330 - R and R link between coupled semi-trailing arm and caliper carrier
• 35-350 - R and R and adjust wheel carrier
• 35-0350 - R and R and adjust wheel carrier
• 35-360 - R and R caliper carrier and hub, Adjust wheel bearing
• 35-0360 - R and R caliper carrier and hub, Adjust wheel bearing
Inspection of wheel location
• 35-410 - Inspection of rear axle assembly
• 35-420 - Checking semi-trailing arms
• 35-430 - Checking rear axle subframe
Rear axle center piece
• 35-500 - Differentiating characteristics, differential installation survey
• 35-520 - R and R rear axle differential housing with rear axle shafts
• 35-530 - R and R drive pinion seal with differential housing installed
• 35-540 - R and R rear axle shaft seal with differential housing installed
• 35-550 - R and R differential gear set
• 35-560 - Reconditioning differential
Rear axle center piece with Automatic Locking Differential (ASD)
• 35-510 - ASD design and function
• 35-511 - Important notes on towing, brake testing, and repair work
• 35-512 - R and R ASD control module
• 35-513 - R and R ASD solenoid valve
• 35-514 - R and R ASD hydraulic unit
• 35-516 - Testing ASD electrical system - Diagnostic Trouble Code (DTC) readout
• 35-517 - Testing ASD hydraulic system pressure
• 35-518 - Testing ASD frictional torque
• 35-519 - Bleeding ASD hydraulic system
• 35-545 - Repairing ASD ring cylinder
Rear axle shaft
• 35-620 - R and R rear axle shaft
• 35-650 - R and R rear axle shaft damper weights
• 35-660 - R and R constant velocity joint boots
• 35-670 - R and R rear axle shaft flange with differential housing installed
• 35-680 - R and R rear axle shaft damper weights

40 - Wheels, Chassis Measurements
Maintenance Jobs
• 4050 - Inspecting/rotating wheels
• 4051 - Checking tires
• 4060 - Correcting tire pressure
• 4070 - Tightening wheel bolts
General
• 40-0100 - Survey wheels and tires
• 40-0102 - Wheels
• 40-0104 - Tires
• 40-0106 - Tire inflation pressure labels
• 40-0108 - Snow chains
• 40-0110 - Remove and replace wheel covers
• 40-0111 - Remove and replace wheel cover retaining clip and spring
• 40-0112 - Remove and replace center cap on light-alloy wheels
• 40-0113 - Remove and replace wheels
• 40-0120 - Replacing tires
• 40-0130 - Balancing wheels
• 40-0140 - Checking wheel runout
Alignment
• 40-200 - General checks and preliminary jobs for wheel alignment
• 40-210 - Positioning of wheels
• 40-220 - Aligning vehicle over measuring pit or hoist
• 40-230 - Attachment of wheel mirrors
• 40-280 - Checking chassis alignment measuring instruments
40-300 - Checking vehicle level on front and rear axle
• 40-310 - Checking vehicle level on rear axle of vehicles with level control
• 40-320 - Front axle wheel alignment
• 40-330 - Rear axle wheel alignment
• 40-400 - Checking collision damaged vehicles
• 40-420 - Checking inclination of lower control arm bushing

Ross


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post #3 of 4 (permalink) Old 08-29-2008, 12:39 AM Thread Starter
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Date registered: Sep 2005
Vehicle: 1988 420 SE; 2015 ML 400
Location: Gold Coast, QLD, AUS & Doha, Qatar
Posts: 16,550
Mentioned: 2 Post(s)
Quoted: 258 Post(s)
Lifetime Premium Member
(Thread Starter)
41 - Propeller Shaft
Maintenance Jobs
• 4152 - Inspecting drive shaft flexible coupling
Misc
• 41-050 - Remove and replace drive shaft
• 41-100 - Remove and replace center bearing
• 41-200 - Remove and replace centering sleeve

42 - Brake - Hydraulical and Mechanical System
Maintenance Jobs
• 4210 - Checking brake fluid level
• 4250 - Inspecting brake lines for damage
• 4251 - Checking brake pad/disk thickness
• 4252 - Inspecting, cleaning brake disks
• 4256 - Inspecting parking brake cable
• 4261 - Adjusting parking brake
• 4280 - Replacing brake fluid
• 4290 - Brake test, parking brake check
Misc
• Brake Caliper Rebuild
Brake system
• 42-0010 - Bleeding brake system or replacing brake fluid
• 42-0012 - Checking and cleaning brake lines and brake hoses
• 42-0013 - Replacing brake hoses
• 42-0015 - Pressure testing brake system
• 42-0035 - Checking warning device in reservoir
• 42-0040 - Remove and replace and adjust mechanical brake light switch
Brake disc
• 42-0260 - Cleaning brake discs with cleaning pads
Master cylinder
• 42-0310 - Remove and replace master cylinder
• 42-0315 - Reconditioning master cylinder
Parking brake
• 42-0510 - Remove and replace parking brake pedal assembly
• 42-0520 - Remove and replace front brake cable control
• 42-0525 - Remove and replace rear brake cable control
• 42-0530 - Remove and replace parking brake shoes
• 42-0540 - Adjustment of parking brake
Brakes, anti-locking brake system (ABS)
• 42-700 - Design and function of anti-lock braking system
• 42-702 - Important notes for repair work
• 42-705 - Remove and replace ABS hydraulic unit (A7)
• 42-708 - Remove and replace ABS control module (N30)
• 42-710 - Remove and replace motor and valve relays
• 42-711 - Remove and replace overvoltage protection
• 42-712 - Remove and replace front axle VSS sensors (L6/1, L6/2)
• 42-714 - Remove and replace rear axle VSS sensors (L6)
• 42-720 - Electrical testing
• 42-725 - Function/test of overvoltage protection relay as of 09/85
Brakes, anti-locking brake system (ABS, ASR)
• 42-800 - Design and function of acceleration slip regulation ASR-II
• 42-0810 - Notes for towing, test and repair work
• 42-0816 - Remove and replace ABS/ASR hydraulic unit (A7/3)
• 42-0818 - Remove and replace ASR charging pump (M15)
• 42-0819 - Remove and replace accumulator
• 42-0820 - Remove and replace left/right VSS sensors
• 42-0821 - Remove and replace ASR control module (N30/1)
• 42-0822 - Electrical test program - ASR II
• 42-0824 - Hydraulic test program - ASR II

43 - Brake - Pneumatic System
Brake unit
• 43-0023 - Testing check valve
• 43-0325 - Testing brake booster
• 43-0350 - Remove and replace brake booster
• 43-0618 - Remove and replace piston vacuum pump
• 43-0628 - Remove and replace vacuum pump piston seal and plate valves
• 43-0635 - Replacement of piston vacuum pump swing arm
• 43-0660 - Checking piston vacuum pump

46 - Steering System
Maintenance Jobs
• 4611 - Checking power steering fluid level
• 4650 - Checking steering play
• 4671 - Retightening steering bolts
Checking of steering
• 46-050 - Technical data
• 46-110 - Checking steering play
• 46-130 - Checking power steering pump oil pressure
• 46-140 - Replacing steering following accident
• 46-220 - Reconditioning steering gear
Power steering
• 46-412 - Remove and replace steering gear
• 46-480 - Readjustment of steering gear in vehicle
Steering linkage, steering arms
• 46-512 - Remove and replace pitman arm and lower housing cover seal
• 46-520 - Check idler arm play, remove and replace idler arm bushing
• 46-540 - Remove and replace tie rod ends
• 46-550 - Remove and replace center link
• 46-560 - Remove and replace center link and tie rod end boots
Steering wheel, steering column, steering shaft, steering lock
• 46-610 - Remove and replace steering wheel
• 46-612 - Remove and replace steering wheel slip ring
• 46-620 - Remove and replace steering column
• 46-625 - Steering column disassembly/assembly
• 46-640 - Remove and replace steering wheel lock
Power steering pump
• 46-700 - Power steering pump identification
• 46-705 - Remove and replace power steering pump seal
• 46-710 - Remove and replace power steering pump
• 46-715 - Filling and bleeding power steering pump
• 46-720 - Disassembly/assembly power steering pump

47 - Fuel system
Maintenance Job
• 4750 - Checking fuel system condition
General
• 47-010 - Function of fuel tank with steadying bowl
• 47-020 - Function of fuel gauge sending unit
47-030 - Function of fuel tank venting
47-100 - Removing and installing fuel tank
• 47-110 - Removing and installing fuel expansion tank (model 107)
47-120 - Removing and installing fuel gauge sending unit
47-200 - Function of fuel evaporation control system
47-300 - Checking fuel evaporation control system
• 47-400 - Function of fuel cooler

49 - Exhaust System
Maintenance Jobs
• 4970 - Retightening exhaust flange
• 4971 - Retightening exhaust system connections
General
• 49-100 - Removing and installing exhaust system

54 - Chassis Electrical, Instrument
Maintenance Jobs
• 5410 - Checking and correcting battery fluid level
• 5451 - Checking warning and indicator lamps
Misc
• Battery Cradle Inspection and Cleanup
Battery
• 54-001 - Filling battery with overfill protection
• 54-005 - Testing and charging battery
Ground connection points
• 54-100 - Designations and locations of ground points
• 54-110 - Connector and terminal block locations
• 54-152 - Electrical connections for special equipment
Fuses
• 54-160 - R and R fuse and relay box
• 54-180 - Installation of separate fuse for blower motor
Instruments
• 54-240 - Bulb failure indicator
• 54-242 - Overvoltage protection relay
• 54-250 - R and R instrument cluster
• 54-251 - R and R indicator instrument
• 54-252 - Testing electronic speedometer
• 54-253 - R and R speedometer
• 54-254 - Testing electrical oil pressure gauge
• 54-255 - Testing ECONOMY vacuum gauge
• 54-256 - Low fuel sensor
• 54-257 - Testing fuel gauge
• 54-258 - R and R speedometer
• 54-261 - Testing outside temperature gauge
• 54-262 - Instrument illumination intensity control
• 54-264 - Testing low washer fluid indicator
Switches
• 54-305 - R and R rotary light switch
• 54-310 - R and R combination switch
• 54-330 - R and R upper console switches
• 54-335 - R and R center console upper/lower
• 54-345 - Relay and control module locations
• 54-350 - Wiring diagrams - indicator lamp monitoring, 3rd brake lamp
Ashtray, sun visor
• 54-391 - Renewing bulb for ashtray light
• 54-395 - Sun visor with illuminated mirror
Seat belt warning device
• 54-410 - Warning device for seat belt, ignition key, light
Cruise control
• 54-500 - Cruise control operation
• 54-504 - Testing cruise control with adaptor
• 54-506 - Testing coding plug
• 54-541 - R and R actuator
• 54-545 - R and R cruise control switch
• 54-561 - Adjustment of connecting link
• 54-565 - R and R control module
• 54-566 - R and R control module coding plug (starting 01/87)
• 54-577 - R and R decel shutoff relay
• 54-579 - Connector locations (starting 09/85)

67 – Windows
Windshield
• 67-100 - R and R windshield
• 67-120 - R and R windshield molding
Rear window
• 67-200 - R and R rear window
• 67-220 - R and R rear window molding
Rear side windows
67-400 - R and R/adjust rear side glass (coupe)
• 67-415 - R and R rear side glass power window motor
• 67-420 - Adjusting rear side glass

68 - Interior Equipment
Instrument panel
• 68-100 - R and R instrument panel
• 68-105 - R and R speaker cover
• 68-110 - R and R instrument trim strip
• 68-120 - R and R glove box cover
• 68-130 - R and R glove compartment lid lock
• 68-140 - R and R glove compartment
• 68-150 - R and R cover under instrument panel
Center console
• 68-200 - R and R center console
• 68-230 - R and R cover at selector lever
Paneling
• 68-400 - R and R upper windshield reveal molding
• 68-405 - R and R A-pillar moldings
• 68-430 - R and R headliner
• 68-435 - R and R headliner (coupe)
• 68-447 - R and R rear roof frame paneling
• 68-449 - R and R C-pillar trim
• 68-456 - R and R rear side panels
• 68-458 - R and R rear shelf
• 68-470 - R and R B-pillar molding
• 68-480 - R and R trunk liner
• 68-485 - R and R rear center trunk panel
• 68-490 - R and R firewall sound deadening
• 68-700 - R and R fuel tank trunk panel

72 – Doors
Maintenance Jobs
• 7220 - Lubricating door hinges
• 7221 - Lubricating door locks
Misc
• Door Panel Removal
General
• 72-050 - Remove and replace front door
72-051 - Dismantling front door
• 72-060 - Remove and replace rear door
• 72-061 - Dismantling rear door
• 72-100 - Remove and replace front door inner trim panel
• 72-101 - Remove and replace rear door inner trim panel
• 72-102 - Remove and replace window frame inner trim
• 72-103 - Remove and replace door inner trim panel (coupe)
• 72-140 - Remove and replace arm rest
• 72-160 - Remove and replace inner sealing strip
• 72-170 - Remove and replace outer sealing strip
• 72-185 - Remove and replace front door power window mechanism
• 72-187 - Remove and replace rear door power window mechanism
• 72-197 - Remove and replace rear door fixed glass
• 72-198 - Remove and replace flexible window run channel
• 72-200 - Remove and replace guide holder with guide rail (coupe)
• 72-210 - Remove and replace door holder
• 72-220 - Remove and replace door sealing frame
• 72-230 - Remove and replace front door inside handle
• 72-231 - Remove and replace rear door inside handle
• 72-240 - Remove and replace front door outside handle
• 72-241 - Remove and replace rear door outside handle
• 72-250 - Remove and replace front door latch
• 72-251 - Remove and replace rear door latch

77 – Roofs
Maintenance Jobs
• 7710 - Hydraulic top, checking and correcting fluid level
• 7730 - Sun roof, clean and grease rails
• 7750 - Soft top, checking locking tabs
Sliding roof
• 77-050 - Remove and replace headliner of sliding/lifting roof
• 77-100 - Remove and replace sliding roof cover (panel)
• 77-110 - Adjusting sliding roof cover (panel)
• 77-130 - Remove and replace sealing and holding rails on sliding/lifting roof opening
• 77-140 - Remove and replace sliding roof control (cable)
• 77-150 - Remove and replace tubing
• 77-170 - Remove and replace lifting arm of sliding/lifting roof
• 77-180 - Remove and replace mounting bracket with motor and gear unit (round motor)
• 77-195 - Checking and adjusting sliding roof motor clutch (round motor)
• 77-250 - Remove and replace sliding roof wind deflector
• 77-300 - Remove and replace sliding roof frame
MB slide paste
• P/N - 001 989 14 51

80 - Central Locking System
Central locking system
• 80-010 - General description of central locking system
• 80-090 - Checking function of central locking system
• 80-104 - Testing electrical function of central locking system
• 80-108 - Checking pneumatic function of supply pump
• 80-112 - Checking electrical function of actuator
• 80-116 - Checking pneumatic function of actuator
• 80-120 - Checking central locking system for leaks
• 80-215 - Remove and replace door and trunk actuators (S47, S48, S49)
• 80-220 - Remove and replace rear door actuator
• 80-230 - Remove and replace tank flap actuator
• 80-270 - Remove and replace supply pump (M14/1)
Electrical and function diagrams
• 80-800 - Electrical wiring diagrams
• 80-900 - Function diagrams

Ross


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post #4 of 4 (permalink) Old 08-29-2008, 12:40 AM Thread Starter
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Date registered: Sep 2005
Vehicle: 1988 420 SE; 2015 ML 400
Location: Gold Coast, QLD, AUS & Doha, Qatar
Posts: 16,550
Mentioned: 2 Post(s)
Quoted: 258 Post(s)
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(Thread Starter)
82 - Lights, Wipers, Radio, Antenna, Misc Body Electrics
Maintenance Jobs
• 8210 - Checking, correcting windshield washer fluid level
• 8230 - Cleaning cassette deck tone head
• 8231 - Cleaning antenna mast
• 8251 - Headlamp and exterior lamp inspection
• 8252 - Windshield and headlamp wiper/washer inspection
• 8280 - Replacing windshield wiper blade
Electrical system of the body
• 82-0010 - Removal and installation of front and rear dome lamps
• 82-0012 - Function of dome lamp control module
• 82-0052 - Removal and installation of headlamp unit
• 82-0053 - Removal and installation of fog lamps (coupe)
• 82-0062 - Removal and installation of lamp unit bulbs
• 82-0063 - Removal and installation of fog lamp bulb (coupe)
• 82-0067 - Removal and installation of headlamp lens
• 82-0070 - Daytime running lamps
• 82-0071 - Installation instructions for daytime running lamp circuit
• 82-0080 - R and R lamp unit reflector
• 82-0250 - R and R center high mounted brake lamp
• 82-0252 - Removal and installation of rear lamp
• 82-0348 - Removal and installation of license plate lamp
• 82-0392 - Function of sliding/pop-up roof, wiring diagrams
Radio
• 82-0505 - Removal and installation of radio
• 82-0507 - FM and FM stereo reception in moving vehicles
• 82-0510 - Interference due to short-term interference sources
• 82-0512 - Removal and installation of front, rear and door loudspeakers
• 82-0513 - M-B sound system
Antenna
• 82-0530 - Function of automatic antenna
• 82-0537 - Removal and installation of antenna
• 82-0538 - Removal and installation of telescoping antenna mast
• 82-0539 - Removal and installation of antenna cable
• 82-0540 - Function of headlamp cleaning system
• 82-0680 - Removal and installation of wiper motor
• 82-0795 - Windshield washer system
• 82-0797 - Function, wiring diagram heated windshield washer system
Seat heating, mirrors
• 82-0800 - Seat heater with automatic shut-off function
• 82-0805 - Wiring diagrams seat heater with automatic shut-off
• 82-0833 - Electrically adjustable outside mirror
• 82-0834 - Electrically heated outside mirror
Power windows
• 82-0840 - Wiring diagrams power windows
Power seats
• 82-0860 - Electrical seat adjustment front
• 82-0865 - Removal and installation of front power seat switch
• 82-0880 - Function of electric rear seat adjustment
• 82-0881 - Removal and installation of electric rear seat adjustment
• 82-0885 - Electrical wiring diagram backrest lock, coupe
Anti-theft alarm
• 82-0980 - Function of the anti-theft alarm (ATA)
• 82-0985 - Function test of the anti-theft alarm (ATA)

83 - Climate Control System
Maintenance Jobs
• 8312 - Checking, correcting A/C refrigerant charge
• 8381 - Replacing dust filter for heating/ventilation
• 8382 - Replacing active charcoal filter
• 8383 - Replacing recirculating air filter
General, Technical Data
• Introduction - Service Manual Automatic Climate Control Model 126
• 00 index - General technical data 00
• 00-005 - Instructions for use of service manual
• 00-010 - Model and system identification
• 00-015 - Vehicle identification number locations
Section I - Heating and Ventilation
• 83-110 - Removal and installation of heat exchanger
• 83-120 - Removal and installation of heater blower
• 83-122 - Removal and installation of air jet nozzle
• 83-125 - Removal and installation of pre-resistance group
• 83-130 - Removal and installation of interior temperature sensor
• 83-135 - Removal and installation of temperature sensors for heat exchanger
• 83-137 - Removal and installation of electronic switching unit
• 83-140 - Removal and installation of cover on air intake
• 83-142 - Removal and installation of surface heat exchanger for windshield glass heater
• 83-144 - Removal and installation of thermo valve for windshield glass heater
• 83-150 - Removal and installation of venetian blind with frame in center of instrument panel
• 83-160 - Removal and installation of venetian blinds at end of instrument panel
• 83-163 - Removal and installation of vacuum reservoir
• 83-165 - Removal and installation of vacuum elements for main air flap
• 83-170 - Removal and installation of venetian blinds with frame at rear of center console
Section I - Air Conditioning
• 83-502 - Refrigerant circuit
• 83-514 - Refilling or replenishing air-conditioning system
• 83-516 - Draining of air-conditioning system
• 83-520 - Checking oil level in refrigerant compressor
• 83-522 - Removal and installation of refrigerant compressor
• 83-524 - Reconditioning of refrigerant compressor
• 83-526 - Removal and installation of electromagnetic clutch
• 83-528 - Removal and installation of condenser
• 83-530 - Removal and installation of receiver dehydrator
• 83-531 - Checking, removing and installing pressure switch in receiver dehydrator
• 83-532 - Checking, removing and installing temperature switch in receiver dehydrator
• 83-534 - Removal and installation of expansion valve
• 83-536 - Removal and installation of evaporator housing with heater box
• 83-538 - Removal and installation of evaporator
• 83-546 - Removal and installation of auxiliary fan
Section II - Automatic Climate Control
• 83-600 - Operation of automatic climate control system
• 83-601 - Manual and optical function test of automatic climate control
• 83-602 - Preparations for testing, connecting adaptor to Volt/Ohm measuring equipment
• 83-603 - Function test of total system and remedies (with adaptor)
• 83-604 - Vacuum function diagram
• 83-607 - Output test
• 83-614 - Preparations for vacuum test
• 83-615 - Testing check valve and vacuum resevoir
• 83-620 - Testing vacuum circuit I, II and III
• 83-622 - Testing vacuum circuit IV, V, and VI
• 83-624 - Testing vacuum circuit VII and VIII
• 83-625 - Removal and installation of monovalve
• 83-628 - Testing of switchover valves
• 83-630 - Removal and installation of recirculating pump
• 83-635 - Removal, installation and assembly of control unit
• 83-640 - Removal and installation of in-car temperature sensor
• 83-645 - Removal and installation of temperature sensor for heat exchanger
• 83-650 - Removal and installation of ETR-switch
• 83-660 - Removal and installation of switchover valves
• 83-665 - Removal and installation of vacuum elements
• 83-675 - Removal and installation of electronic switchgear for temperature control
• 83-676 - Removal and installation of electronic switchgear for blower control
• 83-677 - Removal and installation of heat exchanger
• 83-678 - Removal, installation and checkup of temperature switch for cold engine lock

• Supplement A - Model Year 1986, Model 126
• See Group 24 for schematics

88 - Body Panels and Bumpers
Maintenance Jobs
• 8820 - Lubricating folding side mirror
• 8821 - Lubricating hood
• 9490 - Removing and installing lower noise encapsulation panels
• 9850 - Checking body for paint damage
Fenders
• 88-100 - Removal and installation of front fender
• 88-110 - Removal and installation of trim molding below headlamp unit
Bumpers
• 88-200 - Removal and installation of front bumper
• 88-220 - Removal and installation of rear bumper
• 88-225 - Removal and installation of rear bumper trim molding
Engine hood
• 88-300 - Removal and installation of hood
• 88-302 - Hood adjustment
• 88-306 - Removal and installation of hood hinges
• 88-310 - Removal and installation of hood release cable
• 88-320 - Removal and installation of hood lock
• 88-330 - Removal and installation of hood front seal
Radiator shell
• 88-400 - Removal and installation of radiator cowling
• 88-401 - Removal and installation of radiator grille
• 88-402 - Removal and installation of trim strips on radiator grille
• 88-405 - Removal and installation of Mercedes star
Trunk lid
• 88-500 - Removal and installation of trunk lid
• 88-502 - Removal and installation of trunk lid lock
88-505 - Attaching trunk lid model designation
• 88-512 - Removal and installation of trunk lid hinge lever
General
• 88-800 - Removal and installation of lower side paneling
• 88-805 - Removal and installation of door belt line seal molding
88-850 - Removal and installation of A-pillar molding
• 88-860 - Removal and installation of rain strip
Mirrors
• 88-900 - Removal and installation of outside rear view mirror
• 88-905 - Removal and installation of electrically adjustable outside mirror
• 88-910 - Removal and installation of power mirror motor

91 - Seats and Restraints
Maintenance Jobs
• 9150 - Inspecting safety belts for damage
• 9151 - Backrest lock - check operation
Driver's seat
• 91-100 - Removal and installation of driver's seat
• 91-110 - Removal and installation of front passenger's seat
• 91-112 - Design and operation of seat backrest lock (coupe)
• 91-115 - Removal and installation of vacuum element for driver's or front passenger's seat (coupe)
• 91-119 - Removal and installation of vacuum switch for front seat backrest (coupe)
• 91-120 - Removal and installation of reclining seat fittings
• 91-150 - Checking seat backrest lock (coupe)
• 91-162 - Function diagram seat backrest lock (coupe)
• 91-165 - Removal, installation and reconditioning of drivers seat folding arm rest
• 91-167 - Removal and installation of orthopedic seat backrest padding
• 91-170 - Removal and installation of rear seat cushion and rear seat backrest
• 91-180 - Removal and installation of driver seat cushion cover (coupe)
• 91-182 - Removal and installation of driver seat backrest lining (coupe)
• 91-300 - Remedy for electrostatic charge on seats
Safety belt
• 91-500 - Removal and installation of front seat belt
• 91-505 - Removal and installation of front seat belt anchor
• 91-508 - Removal and installation of belt positioner
• 91-510 - Removal and installation of rear seat belt
• 91-550 - Seat belt inspection
SRS
• 91-600 - Functional description of airbag, emergency tensioning retractor (ETR)
• 91-610 - Disposal and handling of SRS components
• 91-620 - Removal and installation of SRS control module (up to 8/87)
• 91-622 - Removal and installation of SRS control module (09/87 on)
• 91-625 - Guidelines for seat belt replacement
• 91-630 - Removal and installation of seat belt and ETR (up to 08/87)
• 91-632 - Removal and installation of seat belt and ETR (from 09/87)
• 91-640 - R and R SRS energy accumulator
• 91-650 - R and R voltage converter for airbags and ETRS (up to 8/87)
• 91-660 - R and R airbag unit on steering wheel
• 91-680 - R and R front passenger's air bag unit
Test programs
• 91-700 - Test program, airbags and ETR (up to 8/87)
• 91-710 - Test program, airbags and ETR (from 9/87)
• 91-750 - Test program, ETR (without airbag)
welcome454 likes this.

Ross


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