Mercedes-Benz 190D 190DB 190SL Service & Repair Manual

Service Manual Models 180 to 220 SE MERCEDES-BENZ OF NORTH AMERICA l INC. Mercedes-Benz service ;·::J;l"~~·X::ii· .:. .. . " .... "~

.: '1 ·1·, SM 1201 REPRINTED IN USA Publhhed by the Daimler-Benz Aktiengeselfschafr, Srutlgart-Unlertuerkheim, Export- Service. RepreduttiDn Dr trcnsletion, in whole Dr in parr, not permitted without wriHen authori~ation.

PREFACE This manual was developed as a supplementary manual to the Workshop Manual Model 190 to extend the coverage to Models 180, 1800, 180b, 180c, 180D, 180Db, 180Dc, 190D, 190Db, 1905L, 2200, 219, 220S and 220SE. The individual repair procedures are described in detail only if they do not correspond ta those of Model 190. When there is no difference, reference is made to the basic Model 190 Workshop Manual. This means that for a complete description of various repair procedures, both manuals, the Workshop Manual Model 190 and the Workshop Manual 180 to 220SE, must be available. Not covered are the side-valve engine of model 180, diesel engines OM 636 OM 621 of models 180D, 180Db, 180Dc, 190D and 190Db, the fuel injection system of Model 220SE, the hydraulic-automatic transmission, and the daublejointed rear axle of model 180 and 180D. These units are covered in other workshop manuals. The entire contents of this Workshop Manual are arranged by groups. The group index serves to locate any particular group. Each group is preceded by a comprehensive listing of its contents. Mercedes-Benz of North America, lnc., recommends thor repairs to, and maintenance of, Mercedes-Benz automobiles performed only by Mercedes- Benz trained personnel at authorized Mercedes-Benz repair stations. The information contained in this special publication was originally issued by Daimler-Benz AG in conjunction with supplementary service literature only to its authorized dealers. The various repair and maintenance procedures outlined herein are procedures to be used by trained Mercedes- Benz service and repair station personnel. Supplementory service literature is no longer available for this publication . . Mercedes-Benz of North America, Inc., assumes no liability for any damage to person or property occasioned by the utilization of this publication to effect maintenance or repair work on Mercedes-Benz autamobiles. Reprinted by MERCEDES-BENZ OF NORTH AMERICA, INC. v

Location of Model Plate, Engine, Chassis, and Body Numbers Apart from exceptions listed below, the location of the Model Plate and the Plates giving the En- gine, Chassis, and Body Numbers and the Type of Car Finish, is, for Models 180 to 220SE, the same as on Model 190. On Models 180 and 180 D the Engine Number Plate is located on top of the timing gear cover. On Model 190 Sl, the Chassis Number Plate and the Plate giving the Type of Car Finish are located at the top of the fire wall behind the battery. On Model 220a there is as yet no plate indicating the type of Car Finish. To ensure prompt and correct execution of your orders and attention to your inquiries/ please let us have the following details: 1. Complete Chassis Number 2. Complete Engine Number 3. Complete Body Number 4. Mileage covered location of Unit Numbers In your inquiries and orders referring to specific car units such as front axle/ steering gear, transmission/ and rear axle, please quote the Unit Numbers as well. For Models 180 to 220 SE these Numbers can be found in the some place as on Model 190. VI - -~

Group Index General Engine and Engine Suspension Clutch Transmission Pedals Co~trol System Springs and Shock Absorbers Front Axle Rear Axle Wheels and Tires, Adjustment of Wheels Propeller Shaft Brakes Steering Assembly Fuel System Exhaust System Radiator Electrical System Body ,::' ..- ---:;_. ,.,.. ' -.~'-" _- --~

Acceleration curves Acceleration test Accelerator pedal adjustment Acid level and acid density of battery Adjustment curve, distributor Air filters Air intake silencer Angle of closure, distributor contacts Anti-freeze salutians Axle positioning distance Balancing of crankshaft af wheels with tires fitted Boll cup connector of steering assembly of steering wheel shift system Bose bore in crankcase Battery acid level and acid density general removal and installation Bearing assembly for steering wheel shift system removal and installation repair Bearing bushing for helical gear for idling gear shaft Bearing play of camshaft of connecting rod of crankshaft Blower toggle switch Body number, location Brake cable center, replacement rear, replacement Brake drums, reconditioning Brake lever of pistol-grip hand brake Bra ke lines, checking Brake linings, replacement and conditioning Brake master cylinder disassembly and reassembly with fluid reservoir attoched removal and installation Brake shoes adjustment disassembly and reassembly of automatic adjustment front, removal and installation rear, removal and installation ~/S ~/1 30-3 54-111l 15-23/2 09-S/1, 5/2, S/3 09-5/1 01-315 50-3 40-3/2 03-S/10 40-3/1 46-4 26-712, 26-214 03-S/3 54-1111 54-11/1 54-1111 26-1211 26-14 18-1/3 18-1/3 05-5/3 03-514 03-5/3 B2-17 VI 42-20 42-20 42-12 42-1B 42-13 42-11/1 42-4 42-3/2 42-3/1 42-10/1 42-1011 42-8 42-9 Index Brake system bleeding and flushing-out checking description trouble-shooting hints Brakes adjustment with mechanical adjustment Bulbs Cable harness from generator to regulator for reversing light switch for steering tube Comber front wheels, adjustment rear wheels, adjustment Camshaft bearing measurements bearing play checking the adjustment grinding grinding dimensions re-bedding removal and installation Car radio Carburetor altitude adjustment description disassembly and reassembly idle odjustment linkage adjustment measurement and adjustment of injection amount removal and installation technical specifications trouble-shooting hints Coster Caster adjustment Center tie-rod Chain Chain guide in cylinder head Chain tensianer, self-bleeding removal and installation testing Change-over switch for clearance light Charging of battery Charging light, removal and installation Chcssis number, location 42-2 42-2 42-0 42-16 42-20 42-20 S4-0/1 54-S 54-5 54-5 40--3/2 4~3/3 05-5/4 05-5/3 01-317 05-5/3 05-5/4 05-5/4 01-4/23 B2-20/1 07-0/54 07-011 07-3/1 01-3122 01-3122 Ol-31B 01--417 07-0110, 0/14, 0124, 0/32, 0/51 01-3/14 4~3/2 33--412 M-9 01-4/53 01-4/31 01-4/30 05-5/4 B2-17 54-11/1 15--15 VI VII

' .. ~':- 03-5/3 30--611 54---012 82-17 54-18 01-3/5 Check plates for crankshaft Choke control, removal and installation Circuit diagrams Clearance light change-over switch Clock, removal and installation Closure angle, distributor contacts Clutch adjustment data 25-1 disassembly, checking, and reassembly 25-4/1 removal and installation 25-1 Clutch actuating mechanism 26-1/2, 29-111 Clutch, driven plate 25-5 Clutch face of flywheel grinding 03-5/8 Clutch housing 26---413 Clutch pedal free ploy adjustment 29-3/1 removal and installation 29-4/1 Clutch pedal shaft 26-112, 29-5/1 Clutch pressure plote 25-012 '" r, ',;::' Clutch springs 25-4/2 Clutch throw-out bearing 25--6 Compound cross-draft carburetor 07......{)133 Compound downdraft carburetor 07"""{)125 Compression chamber 01-313, 01-5/3 Compression measurement 01-3/3 Compression ratio 01-313, 01-513 Connecting rods 01-4/50 reconditioning and re-bushinq 03-5/4 Control arm 33-512 Control lever 01-4/19 Control linkage adjustment 01-3/3B removal and installation 01-4/19 Control shaft 31}-1/1 Cooling system capacity cleaning of engine Cooling water anti-freeze preparations and corrosion inhibitors circu lotion temperature thermometer thermostat Countershaft of transmission Counterweight on crankshaft Crankcase bose bore cleaning, pressure-testing, surfoce-grinding disassembly and reassembly Crankshaft annular grooved bearing balancing grease seal grinding locating bearing overhaul stages re-bedding removol and installation with counterweight and flywheel Cylinder bores boring and honing overhaul stages VIII 00-112, 115, lIB 51}-3 21}-5/1 51}-3 50--0 50--614 54-1112 50--6/1 26-5/2 01-4147 03-5/3 01-5/1 01-4/50 01-4152 03-5110 01-4/52 03-5/1 03-5/3 01-5/1, 03-5/1 03-5/3 01-4/49 01-512 01-5/2 Cylinder cover Cylinder head gaskets machining and pressure-testing removal and installation tightening and final tightening of cylinder head screws 01-4151 . (}k- 4127 01;_512 01-4123 01-4133 Dimmer resistance for instrument lighting 54-1B Disk wheels 4~/l Distributor 15-23/1 15-2312 01-4/36 01-4/35 adjustment curve bearing removal ond installation Distributor contocts, measurement and adjustment of gaps and angles of closure 01-3/5 Distributor drive 01-4140 18-111 07-0115 07......{)/l removal and installation repair Double downdraft carburetor Downdraft corburetors Drive for oil pump, distributor, revolution counter, and injection pump 01-4/40, 18-111 Drive shaft for transmission 26-513 Driven plate of clutch 25-5 Dry oir filter 09-5/1 Electrical system ossemblies and instruments cor body engine End ploy of camshaft of crankshaft Engine cooling system disassembly and reassembly idle adjustment lubrication removal and installation together with transmission side views testing and repairing testing on roller test stand tune-up Engine broce, front Engine number, location Engine suspension front rear Exhaust-gas test values Exhaust manifold and intake pipe removal and installation replacement of damper spring replacement of heater valve and shaft replacement of heating spiral Exhaust system 54......{)/1 82-1 15-111 05-513 03-5/3 21}-5/1 01-4/1 01-3m 18-511 01-111 01-412 01-5/1 01-3133 01-3/1 22-2 VI 22-1/1 24......{)/1 01-3/32 01-4/20 14-5 14-5 14-5 49-1 I ....d

Fan distance between fan and radiator 50--1 removal and installation 01-4/33 Fan belt tension, checking and adjustment 50-5/1 Flash signal 82-3 Flash signal mechanisms for flash signal, removal and installation 54-18 for upper beam flash signal system, removal and installation Flash signal switch for upper beam Flash signal system Flash stroboscope values at engine speed Flywheel grinding clutch face removal and installation replacement of ring gear .stotic balancing Fog lights, adjustment Foot dimmer switch Front axle half Fuel consumption curves partial load Fuel distributor fittings, removal and installation Fuel feed pump checking 47-8 disassembly and repair 09-514 dust-proof version 01-4143 measurement and adjustment of pressure 01-3/8 removal and installation 01-4143 47-9 Fuel gage r fault tracing hints removal and installation Fuel injection system, removal and control lever control linkage fuel distributor fittings injection pump injection valves venturi control unit Fuel level in carburetor engines, measurement and adjustment Fuel level indicator removal and installation testing Fuel pass filter checking and repair disassembly and reassembly removal and installation Front axle number, location Front axle support, checking Front springs color code harder, for bod rood conditions removal and installation test values Front wheel bearings Fuel consumption according to German Standard for overage high-way travel rated test 54-18 54-18 54-18 01-3/5 01-3/6 03-5/8 01-4152 03-517 03-5/11 82-211 54-14 33-5/1 33--4/1 33--411 VI 33-8 32-0/1 32-7113 32-712 32-5 32-7112 33-4/1 DIN 70030 00--113,1/6,1/9 00-1/3,1/6,1/9 00--1/3,1/6,1/9 00-4/1 00-412 00-4/2 01-41l7 47-4 54-1112 installation 01-4/19 01-4/19 01-4/17 01-4/15 01-4/17 01-4/19 01-3/8 47-311 47-3/1 47--611 testing trouble shooting hints Generator and regulator, description Glow plug checking Glow plug starter and stop switch 3O-llf1, 15-33/1 15-30/1 Fuel tonk checking and repair fuel level indicator removal and installation testing removal and installation Fuse box, connections at Gasoline injection system see injection system Gear shift mechanism, adjustment Generator disassembly and reassembly mounting (support) removal and installation servicing hints test values Glow plug system Grease seal front, for crankshaft front, for crankshaft, removal 'and installation Ground lead at distributor Guide pin, shift tube Guide sprocket Hand broke ratchet and broke lever Headlight lower beam flash signal system Headlight upper beam flash signal switch Headlights adjustment removal and installation replacement of bulbs Heater blower motor switch Helical gear for distributor drive transmission Horn Horn assembly Idle adjustment Idle adjustment knob and coble Idle adjustment screw Idle mixture adjustment screw Idling gear shaft for distributor drive Ignition coil Ignition control knob Ignition lead, testing Ignition lead connector, testing 47-5 47-311 47-311 47-111 54-0/13 26-3 15-13/1 15-11 15-11 15-12 15-17 15-17 15-17 15-10 15-31 15-32 01-4149 01-4152 01-4/36 26-1211 05-517 42-18 42-18 54-18 54-18 82-2 82-1 82-1 82-17 18-1/1 26-5/3 54-18 54-18 01-3/22 30-10 01-3122 01-3122 01-4/40 15-22 30-8 15-24 15-24 IX

Ignition setting by means of flash stroboscope by means of timing light Ignition switch Ignition system, description Ignition vocuurn control Injection amount in carburetor engines, measurement and adjustment Injection pump adjustment removal and installotion Injection pump drive removo! and installation repair Injection system adjustment of control linkage checking idle adjustment readjustment of speed build-up trouble-shooting hints Injection valves Instrument cluster Instrument lighting push-pull switch ond dimmer resistance Insulating flange of carburetor Intake pipe vacuum meosuring Intake pipe and exhoust manifold removal and installaton replacement of domper spring replacement of heoter valve and shaft replacement of heating spiral Interference suppression for radio Jointing disk of steering coupling License plote lighting locating bearing of crankshaft lower becm flash signal system Machining of cylinder heod Main shaft of transmission Maximum speed test Measuring runs Misalignment of rear axle Mixing ratio, anti·freeze solution Model plate, location Needle bearings Ochme number compensntcr Oil both air filter Oil copocity engine water pump 01-3/5 01-315 15--21 15--21 01-3/7 01-3/8 01-3/35 01---4115 01---.4140 18-113 01-3/38 01-3/38 01-3138 01-3138 01-3/38 01---.4/17 54-1111 54-11/1 54-18 01---.4/9 01-3131 01-3131 01---.4120 14-5 14-5 14-5 82-21 46--13 82-17 03-5/3 54-18 01-5/2 26--5/2 ~/1 ~4/1 40-3/2 50-3 VI 26--14 30-8 09-5/3 00-112, 115, 1/8 ~1!2. 115, 1/8 x portial load fuel consumption curves Portition plate, cronkcose Pistol-grip hand brake, ratchet and brake lever Piston pin bushing dimensions Piston pin ploy Piston rings Pistons fitting, together with rings, into cylinders 03-5/5 removal and instollotion 01-4/50 Pivot bearing for steering relay arm 46--11 Pivot point distance 40-312 Plate valve of radiatar 50-1 Power brake Oil consumption test run Oil filter disassembly. cleaning, and reassembly removol and installation Oil pan Oil pressure gage Oil pump removal and installation repair Oil pump drive removol and installation repair Oil relief valve cleaning and checking in crankcase. removal and installation opening pressure Oil thrower on crankshaft Overhaul stages camshaft camshaft beoring crankcase crankshaft pistons valve guides valve seat rings removal and installation subsequent installation testing Pressure-testing of crankcase of cylinder heod Propeller shaft disossembly and reassembly removal ond installotion universal joints Pulley on crankshaft Push-pull switch For instrument lighting For windshield wipers Radiator cap removal end installation thermometer vacuum valve 18-513 01---4/43 01---4145 54-11/1 01---.4/46 18-5/1 01---.4140 18-111 18-513 01---.4/44 18-515 01---.4147 05--514 05--5/4 01-5/1 03-5/1 03-5/6 01-5/4 01-5/5 ~4/2 01-4151 42-18 03-5/5 03-517 03-5/6 42-14/3 42-15/1 42-14/2 OJ-5/1 01-5/2 41-411 41-4/1 41-4/4 01-4/47 j.';" 54-18 82-17 50-1 50-1 54-11/2 50-1

Mercedes-Benz 190D 190DB 190SL Service & Repair Manual

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