Description
Factory Mercedes 240D Workshop Manual (1976–1985)
This official Mercedes-Benz factory workshop manual delivers complete service and repair coverage for the W123-chassis 240D — the benchmark diesel sedan of its era — giving US owners and independent technicians the same depth of guidance used by authorized dealerships.
Powertrain & Drive Coverage
| Component | Variants Covered |
|---|---|
| Petrol | N/A |
| Diesel | OM616 2.4L naturally aspirated inline-4 diesel |
| Transmissions | 4-speed manual, 4-speed automatic |
| Drive | RWD |
| Model Years | 1976–1985 |
| Badge Twins | W123 platform (shared with 230, 280E, 300D sedan/wagon/coupe variants) |
Common 240D Repairs Covered
| System | Procedures |
|---|---|
| Glow Plug System | Individual glow plug testing, replacement, and relay diagnosis — a frequent cold-start concern on OM616 engines |
| Fuel Injection Pump | Bosch diesel injection pump timing adjustment, seals, and idle speed calibration |
| Cooling System | Thermostat, water pump, and radiator hose replacement; overheating diagnosis procedures |
| Front Suspension | Ball joint inspection and replacement, front axle alignment, steering box adjustment |
Format & Delivery
PDF. Instant download; lifetime re-downloads.
Frequently Asked Questions
Why does my 240D hard-start in cold weather, and does this manual cover it?
Hard cold starts on the OM616 diesel are almost always traced back to degraded glow plugs or a failing glow plug relay. This manual includes full diagnostic steps for the glow plug pre-heat system, individual plug resistance testing, relay bench testing, and replacement torque specs — everything needed to restore reliable cold-weather starting.
Is the W123 platform shared with other Mercedes models?
Yes. The 240D rides on the W123 platform, which Mercedes-Benz also used for the 230, 250, 280E, 300D, and 300TD models sold between 1976 and 1985. While this manual is specific to the 240D and its OM616 engine, much of the chassis, suspension, braking, and body content is directly applicable to other W123 variants.
Does the manual cover the automatic transmission fitted to US-market cars?
Yes. The majority of 240D units sold in the United States were equipped with the 4-speed automatic transmission. This manual covers full automatic transmission service, valve body procedures, fluid and filter change intervals, and driveshaft/differential maintenance alongside the 4-speed manual gearbox content.
What format is the manual?
This manual is a PDF file delivered via instant download upon purchase. It is fully searchable, can be viewed on Windows, Mac, iOS, and Android devices, and individual pages may be printed for bench-side reference. No subscription or special software is required — any standard PDF reader will open it.
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