Mercedes-Benz 209 D, 207 D, 307 D, 409 D, 309 D Operating Instructions Manual

207 D 209 D
307 D 309 D
407 D 409 D

Operating Instructions

J

Mercedes-Benz

Mercedes-Benz

service

......

207 D 209-D

~

307 D

309 D

Operating Instructions

407 D 409 D

Printed in Germany

We reserve the right to modify the technical details as given in the data and ill us­trations of these Operating Instructions (s.e.e.o.).

Reprinting, translation and copying, even of excerpts, is not permitted without

our prior author ization in writing.

ZKD/ 1.83.3/ Ru

These Operating Instructions are designed to provide clear
answers to essential questions concerning operation, service
and maintenance.

In some sections you will in addition find instructions for the
economic operation of your vehicle. By comply ing with these
instructions you can assist in effectively reducing the fuel con­sumption (energy consumption).

To ensure continuous operational reliability and roadworthi­ness, we strongly recommend that service and maintenance
work listed in the Maintenance Booklet be carried out on time.

For this purpose, an extensive network of MERCEDES-BENZ
service stations is at your disposa l.

Before operating the vehicle for the first time, please refer to the
sections entitled

"Components" and "Operation"

Several vehicle types whose principal components are identi­cal are dealt with in these Operating Instructions.

Besides this important optional extras are included. Your ve­hicle may therefore differ from some of the descript ions and
illustrations.

We wish you good motoring!

Daimler-Benz Aktiengesellschaft

3

Contents

Components

Door control front .

11

Driver's seat adjustme nt

1 2

Seat belt .

1 3

Instruments - summary .

1.4
Indicator lights and switches

1.5

Light switch ....

1 6

Combination switch ..

1 7

Steering lock

1.6

Tachograph

1 9

Radio

110

Heating and ventilation

1.11

Headlight beam contro l

1.12

Interior light

1 13

1.14

Interior mirror . . .

1.15

Seat lock - assistan t driver's seat .
Headrest ..

1.16

Door control - cargo space

117

Engine cover

1 16

Engine compartment flap .

1.19

2 Operation

2.1

Preparallons for driving

22

Starting and shutting off the engine

2.3

Hand brake operation
Starting the vehicle and shifting gears

24

Breaking-in ..

25

Driving and braking

2.6
Trailer ..

2.7
Winter operation ..

26

3 Fuels, coolants, lubricants, etc.

Diesel fuels

3 1

Engine oils

32

Coolants

33

Page

10
12
12
13
13
14
16
16
16
16
19

20
20
22
23

24
24

29
30
30
33
34
37
36

40
40

41
42

Page

4

6
6

7
7
6

The vehicle, service and ma intenanc e

4 1 Engine
4 1 1 011 ,incl liltur ch,inno

412 lnsprn llnq unct smv1c:u1u ,11, dn11110,

413

nornovt1I nnd in&t lllullon ol <. yllnclPr hcild cove r

414

AdJU.Jt1nu v»lvn CIP tr IIICtJ

4.2 f

uel ay111,un

l11t1ljH{;lllll'I

421

H1•11ln 11111 lho luol llih r

422
4 23

1111 , d111u '"t' 1111 1 ov 1 .. m . . .....

4.3

Coollny •v• tt1,u

431

1>uu11inQ tooh111t tuul llllinq syslmn with coolant

432

<. 10:11111,g 1111 cooll11q hmt hottting systems

V 111111

433

C.lulc

44
4 4 1

4.5
451

4 5 1 1
4512
452
4521
4522

h

Hyth ult•

flV!I IPII I

M11 u, ,, 111•,1111111011

011 hwol chm. k tout 011 t.:h,rngo

Cl11u11111u IJroutrw,

Ml I trnlOUl•lliC lri,trl:UrnS510fl

011 tovl'i

0,1 HIIII flllPI < hanqn

aoc11ons 01 c1u1, h and brake

, '"" ku1u llutd lovol . ' ... ..... 53

To111•ml11lun

c ""' k

.... .. . .

.. .. ....

.. .... ..

... .... ...

54
54
55
55

50
51
51

53

54
54

54

43
45
45

46
47
47

46
46

46
49

50

4

Page

43

45
45

46

47
47

48
48

48

49

50
50

51
51

53

53

54

54
54
54
54

55

55

4 II

Rear axle

OIi level check and oi l change

4 ,

Steering

Checking the steering linkage

•1 7 I

,1 ( 'l.

Checking steering free play ..

,1 7 3

Checking oil level
Checking the toe-in

" ( ·1

4 II

Wheels and tires

481

Spare wheel location

Wheel change

48?

Brake system

,1 11

Checking the brake lines .
Checking brake lining thickness

,1.112

~, 'I 3

Hydraulic sections of clu tch and brake
systems - checking fluid level
Bleeding the brake system

Electrical system

410

·1 10 1

Three-phase alternator

., 10 7

Fuses

Checking the headlighl alignmenl .

4 103

1104

Headlight bulb replace ment

Battery care . . .... ... .... ... ..•. .

·I 10 5

4 11

Vehicle cleaning and care

Pago

57
57

58
58

58
59
59

60
60

61

62
62

62

64

65

66
66

66
68
68

69

70

4.1:1 Preparing the vehicle for storage .

4,13 Preparing the vehicle for service after storage

~

Troubleshooting

,, 1

Engine and fuel system ... .... . . .

Clutch.

~;>

Steering

53

Brake system .

!J 4

Electrica l system

5 !>

Supp lementary heater .

56

Shutt ing off the engine when the vacuum system is faulty

5 7

Tow-starting and tow ing the vehicle . ....... .

58

6 Technical data .

6 1

Data cards/identifica1 ion plates
Weights

62

Main dimensions

63

Engine ..... . ... ... .

64

Cooling system

65

Clutch .

6 6

Transmiss ion . ___ .. . .. . _

67

Steering system

68

Front ax le ..

69

Rear axle .

610

Brake system ..

6.11

Electrical system ....... •. . . . .... ....... .. .

612

7 Tightening torques ..... ..... . . .. . .. . ....... . . . .... . .

8 Capacities - summary

9 Service and maintenance jobs - summary

Tire pressure chart

Page

71

72

73
73

74

75

76

77

78

79

80

82
82

84
84

85
86
86
86

87
87

88

89

90

97

98

100

5

1 Components

1.1 Door control front

Hinged door

Door control, outside
1 Locked

2 Unlocked

To open the door,
press in door lock cylinder

Door and window contro l, inside

1 Door latch unlocked
2 Door latch locked
3 Opening lever, door

<1 Window crank

6

I 'J Driver's seat adjustment

1.3 Seat belt (example)

• ,I, 111dord version
I tcight of seat, front portion

,' I orward and rearward

I tc,ght of seat, rear portion

,1 Scat back

Make Bremshey

1 Seat load

2 Seat load scale
3 Height of seat, front and rear
4 Seat back
5 Forward and rearward
6 Seat lock

Lever moved to tho right = locked

Lever moved to tho left

= released

Fastening:

1. Pull belt with tongue (1) over shoulder

and lap. The belt must not be twisted

but must be tight.

2. Press tongue

(1) into buckle (2) and

allow to engage audibly.

Unfastening:

1. Depress red button in buckle (3).

2. Return tongue

(1) to initial position.

Note:
The inertia reel of the seat belt stops the

belt unwinding further in case of vehicle
deceleration in any direction and if the belt
is pulled out quickly.

7

1.4 Instruments - summary

Ventilation and defrost ing nozzles for side windows
(page 16)

2 Light switch (page 12)

3 Coolant temperature gauge

4 Indicator lights (page 10)

5 Speedometer or tachograph (page 13)

6 Selector lever position indicator - MB automatic trans-

mission or fuel gauge (page
7 Idle speed control (page 29)
8 Switche s (page 10)

9 Heating and ventilation (page 16)

31)

10 Plug socke t
11 Rmho (page 14)

12 Ashtmy

13 E 11g1no cover

14 Clock

15 Stec, 1ng lock (page 13)

16 Horn
17 Fuol gaugo or operating hours indica tor
18 Co111ti111i1l1on switch (page 12)
19 Pull knot,, engine co mpartment flap (page 23)

8

l

9

1.5 Indicator lights and switches

The following sym bols have been chosen to facilitate identification of tht> 111ct1v1ch1.il •,wile 11,,,, .111cl 1ndicator lights.

Indicator lights

High bea m

2 Preglow ing

3 Turn signal indicator light - tractor

4 Turn signal indicator light - trailer

5 Rotary flas hing beacon

Switches

11 Blowe r, hig h speed - low speed (page 16)

12 Heated rear window

13 Rotary flashing beaco n
14 Interior light - bus

10

6 Cl1i111w l11dh ,,tm hqhl (page 36)

7 Brnk1• lh11ct ,11Hl l>ruko pad wear (page 34)

8 011 JIIIH,'11111' lll191n0

9 I l<'dl«'cl 1<'111 WlllCIOW

10 Supph11111111t111y heater (page 16)

15 Supp lt>11H•11t,11y heater (page 16)

16 Haz,ucl wi1111111q fl,1sher switch with indicator light

17 Light •,w1tc 11 (pogo 12)

L

11

1

1.6 Light switch

0 Off-position

1 Parking lights

2 Headlights
3 Standing lights, right
4 Standing lights, left
A As pos ition

B As position

with indicator light

1 or 2 plus fog lights
1 or 2 plus rear fog light

1.7 Combination switch

1 Low beam

2 High beam
3 Headlight flasher
4 Turn signal lights, right
5 Turn signal lights, left

Note:

Switch ing on turn signal lights

Up to point of resistance= bnef
Beyond point of resistance (engagmwnl)

= cont inuous flashin g

fln~.11111q

li Windshield washer/head light washer

Noto: When the windshield washer sys­h•m 1s actuated, the windshield wipers are
r1lso switched on.

1110 headlight washer (optional) is only

orwrated when the vehicle lights are
,;witched on.

Check wiper blades regularly for soil ing
r1mt ctnmage.

7 Windshield wiper

Position
Position "I"= intermittent wiping
Position "II"= low speed
Position "Ill" = high speed

"O" = off

12

0

;;;

0

"'

(!)

I

It looring lock

1.9 Tachograph (uxiunp lo)

1sher

· sys­rsare

only

; are

:,iling

II I ht> key can be removed only in this

pos1llon.

I ho steering is locked when the key is

w1lhclrawn.

• ,It •t'rtng unlocked
I 'tt'qlowing and driving position

• ,I, 11t1ng position

1 Time group knoll

2 Speedomet er
3 Speed warning ltqht
4 Clock function control light
5 Tachograph funcllon control light

The control light comes on if no dia­gram chart is inserted or if the tacho­graph is defect1vo.

Brief lighting up of the control light
while the tachograph is opened or
closed proves the control light to be in

good working ardor

13

j1

I

1.10 Radio

Radio with push buttons for band selection and tuning of preset
stations

Radio with push buttons for band selection and tuning of preset
stations and with built-in cassette player

1 On-Off/Volume control

2 Tone control

3 Push buttons for band selcctton and tuning of preset sta-

tions

4 Manual tuni ng control

5 Cassette release

6 r ast forwnrcl

Fast rt•wind

7
8 Ca'iSollt' slot
9 Wavo llancJ 111ellc.itor

I

I

14

,et sta-

1111Voh 11nl' con trol

1111 I

111111 k1111ll (1) clockw ise to switch on radio and to increase

v11h11111• I ho qreen co ntrol light will come on.

1111111
ll1111 l11v,.,

111111111 l11111ng

1 1111 I c h•s1red wave band by pushing the respective button (3).

I 111 w11v11 l>and selected is indicated by wave band indicator (9)

(2) to alter the tone .

1111 cl11!,lll!d statio n is tuned in by turn ing the manual tuning

~11f1lo

(4) f or good reception, accurate manual tuning is impor-

t 1111

1111111•·,nl stat ions of various wave bands pull out preset button

( II 111 1111• stop, tune in station with manual tuning knob (4) and

.i, prnsct butto n in again to the stop.

1111

I 1111, I 1i,1yback

f 1111v 11•,1• brand C 60 or C 90 cassettes. Push cassette into

fl ,1•111• slot as far as it will go with the full reel on the right side.

l

I lw radio will then switch over from radio recep tion to tape play-

I iack. The cassette will be released auto maticall y as soon as the

lapo reaches its end.

Io piny the other side of the tape, turn casse tte upside down and

101nscrt it into cassette slot.

lo manually eject the cassette, push release bar (5). When the

c .issette is ejected, the unit will switch over to radio recep tion

11ulomat ically .

I 'ush button 6 or 7 for fast forward or rewi nd of the tape. Briefly

touching the counteracting button will stop the winding pro­cess.

Service and Maintenance

Since deposi ts on the pick-up head are inevitable after extend ­ed operation, the cassette shou ld be cleaned wit h a cleaning
cassette if the qua lity of the sound reproduc tion declines. After
approx. 500 operating hours the unit should be inspected by a
special ist.

15

1.11 Heating and ventilation

Control levers are infinitely variable

Adjusting examples:

Blower switch: press upper end

center position
press lower end

2 Ventilating or defrosting windshield

Lever position : left = closed

right = open

= low speed
=off
= high speed

3 Contro l valve for heater

Lever position: left

right =warm

4 Ventilating or heating footwell

Lever position: left

right

- cold

= closed

- open

5 Supplementary heater

switch:

6 Ventilation and defrosting nozzles - windshield
7 Ventilation and heating nozzles - footwell
8 Ventilation and defrosting nozzles, adjustable

The nozzles can be opened and close d with the lever
in the nozzles.

Supplementary heater

The supplementary heater can be operated with the engine on
or off.

Switching on supplementary heater:
Actuate toggle switch. The indicator light on the instrument
panel comes on. The heater will come on after approx .

2 minutes.

press upper end
press lower end

- on
= off

When defrosting windows

1 - press lowe r end

2 right
3 right
4 - left

8 - turn nozzles towards side window and

open them

For full heating capacity

1 = press lower end

2 right

3 nght

4 - right

For full ventllal1011

1 - press lowl'r encl

2 - nght

3 = left

4

= right

Switching off supplementary heater:
Actuate togg le switch. The indicator light goes out. The heater
continues to operate for about 2 minutes and then switch es off
automatically .

16

,eater
1es off

17

1.12 Headlight beam control

.·.·--.·.· +·· ·fa#%· .... ··<·)y} {&&::

1.13 Interior light (examp le)

1.14 Interior mirror

2~1

0 Normal position
I Vehicle with maximum load

(with evenly spread load)
Vehicle with maximum load
(with large part of load shifted to rear

axle)

18

Position 1 : On
Position 2: Off
Position 3: Light is switched on

by the door contact

,IIH I oll

Operating lever

1 Normal position

:> Dimming position

t I nnt lock - assistant driver's seat

I lt1locking right

r >porate lever, tilt seat forward or

l>ilc:kward until lock engages.

Unlocking left
Operate lever, tilt seal forward or back­ward until lock engages.

19

1.16 Headrest (examp le)

1.17 Door control - cargo space

IE

Height and inclination of headrest can be

adjusted.

20

Rear door

Door control, outside (example)

Unlocked
To open the door, press
in door lock cylinder

2 Locked

Door control, inside

1 Door latch unlocked

2 Door latch locked

3 Opening lever of 1st door

4 Lock of 2nd door

ro open, swing handle up.

no

-

-- -N

5

:::J ~

.,

N

............ __ 21

0

g

fl 1111111 ,111qle 90°

I , " klnq hook

, 1

1111 ctoor 90° and engage locking

11

111111k

I I 1111p

I ... 1,,11 locking hook before closing

1111· door.

Opening angle

1 Locking hook

2 Door strap

Disengage locking hook, swing door strap
inward.

Open door

Prior to closing the door, engage door
strap. Attach locking hook.

180"

180° and 0ngage locking hook.

Opening angle 270 °

Door lock

Disengage locking hook, swing door strap
inward.

Open door 270 °. Engage lock.
To unlock, pull forward latch in the door
lock.
Prior to closing the doo r, engage door
strap. Fasten locking hook.

21

1~ 3

1.18 Engine cover

•

Sliding door

Door control, outside

1 Locked
2 Unlocked
To open the door, press in door lock cylin-

der, grab hand le and push door rearward

to the stop.
To close the door, grab handle and push

door forward until the door lock engages.

22

Door control, inside
1 Door latch unlocked

2 Door latch locke d
3 Opening lever, door

Opening the engine cover

Clamp

Noto
Prior lo the detachment of the engine
covor, remove driver's seat.

I I U r 11ul11t1 <-<>mpartment flap

·ngine

11111111h11 engine compartme nt flap

I 1111 l· 1101>

Closing the engine compa rtment flap

Lift securing device

23

1 Fuel tank - cargo 1ruck (example)

1 Fuel tank - de livery van

2 Operation

2.1 Preparations for driving

Check the following items daily

- Accessibility and completenos!i of tlw emergency equipment , e.g. first aid kit, hazard
warning triangle , fire extingui:,hP1

Prior to starting the engine

- Fuel reserve

- Vehicle lighting, turn signal

- Oil level in engine

After having started the engino

- Engine oil pressure

- Steering free play

- Tachograph for proper function

Fuel reserve

Turn steering lock to driving position Check ruel level, replenish if necessary.

Prior to filling the fuel tank, shut off ong1ne and supp lementary heater.

Always keep the fuel tank vent clean Do not

expansion.
For summer and winter operation vehicle diesel fuels, refer to "Fuels, coolants, lubricants,
etc.".

a11ct •,lop l1ql1ts

1111 ruel tank to the brim because of heat

24

, hazard

V•hlt:le lighting, turn signal and stop lights

'" " llqlit111q system including the stop lights must be checked daily for good condition

1111 I , lo,, 111 lenses. If bulbs have to be replaced, observe the specifi ed voltages. Refer to

Ir l111lcal data".

OIi ievei In engine

V1 l11o IP has to be on level ground when oil level in oi l sump is checked. Oil level to be

t111111wll ere betwee n the lower and the upper mark on the oil dipstick . Oil level should not

, , , ,•I'd the upper mark .

, ,11111011 Use only engine oils of specified SAE grades (viscosity ranges). Refer to "Fuels,

t • ",1.111ts, lubricants , etc.".

leering free play

M,1111ml steering

· ,liould the re be any free play in the steering, have the steerin g system adjusted at a
Mt HCEDES-BENZ service station immediately .

I , 1wPr steeri ng

1111• wheels must start moving when the steer ing wheel is turned approx.

30 mm (1.2 in).

II tlioy do not move, have steeri ng gear and linkage inspected by a MERCEDES-BENZ

,111v1ce statio n.

Engine compartme nt flap opene d

1 Oil dips tick

2 Oil filler nec k

of heat

,ricants,

I unction test - tachograph

I li t> indicator light must not come on. Brief lighting while opening or closing the tachp-

111c1ph indicates that the light is in good working order .

1 Tachograph functio n control light

25

Eng,ne compartment flap opened

1 Filler hole - coolant

Check at regular intervals:

(for example once a week or whenever you refuel)

- Coolant level

- Power steering - oil level

- Hydraulic clutch control and hydraulic brake system - fluid level

- Soiling of air cleaner

- Batteries - fluid level

- Windshield washer system lluid level

- Seat belts

- Inflation pressure and condillon ol lirl'S

- Engine, transmission , live axle, stmmng c;ystom, cooli ng and heating system for leaks

Coolant level

The coolant expansion tank must l>L' fillNl up to the marking in the filler neck.

If possible, replenish coolant only with the engine cold (coolant temperature less than
122° F/50°C) and the heater valves open Do not open filler cap if the coolanttemperature
is above 194° F (90° C).

After having added coolant, seal coolant expans ion tank with cap. Run engine briefly,
check coolant level and add more coolan t. if required.

Use clean and well filtered water (potable water quality) with the least possible content
of lime. Coolant blended with ant1frocue can be retained in the cooling system all year
round. Refer to "Fuels, coolants, lubricants. etc.".

Engine compartment flap opened

1 Power steering oil reservoir

26

Power steering - oil level

The oil reservoir is filled correctly if the oil level reaches the mark in the oil reservoir.

Hydraulic clutch control and hydraulic brake system - fluid level

The translucent reservoirs are located in the engine compartment , front , left.
The fluid level can be determined without unscrewing the cap. The reservoir must always

be filled sufficiently. If brake fluid needs to be replenished , have the hydraulic system
inspected.

or leaks

iss than
ierature

i briefly,

content

all year

:rvoir.

Soiling of air cleaner

If the complete red field is visible in the service indicator , actuate push button to

disengage the colored field. Clean or renew filter element.

Batteries - fluid level

I he batteries are located below the driver's and assistant driver's seats.
I he electrolyte level in each cell must be app rox. 15 mm (0.6 in) above the upper edge of

the plates. Only replenish with distilled water. During the hot season, chec k battery

••lectrolyte level more frequently.

Engine compartment flap opened

1 Brake fluid reservoir

Service indicator for pape r air cleaner

1 Inspection glass for co lored field
2 Push butt on

·-------

27

Engine compartment flap opened

t Reservoir of windshield washer system

Windshield washer system - fluid level

The winds hield washer reservoir ts .tr.coss1ble after opening the engine compa rtment
flap. Add MERCEDES-BENZ wincJ<.htclcl washer detergent to the water.

Seat belts

The inertia reel must stop tho S<'.tl boll 11nwinding further if the vehicle

- is braked or accelerated

- is cornering

- or when the belt is pulled out q111ckly
Inspect belts visually for damaqo nl'lww damaged seat belts.

Inflation pressure and condition of tires

Check inflation pressure on cold t1rt•i; 1110 pressure differential of the tires on one axle

must not exceed 0,
tire inflation pressure as much as
otherwise drop below specifications

1 bar (1,4 psi) I flqh 'll >l'CCI operation or hot weather may increase the

1 llnr ( 14 psi) Never bleed any air as the pressure will

f or tire inflation pressure , refer to ''Tire pressure

chart".

)artme nt

one axle
ease the
;sure will
xessure

1111,t111u nnd shutting off the engine

I , I " , 111, nwasures before starting an eng ine for the first timu, 1llor 11 has been

I rr 1111" 11111clod period. Refer to "Preparing the vehicle for sorvic 1• utter storage".

II

ti 11 1111 .·.11111 to neutra l (MB automatic transmi ssio n selector lovor pos ition "P" or

I nu ,u, hn11cl l)rake or service brake .

11 t 1 ,11111 I()( k key and turn to driving position. The charge indica tor light and the

11 w11111· 11ul1cator light will come on .

11 lh1 111, •qlowing" indicatorlightgoesout, this isan indication thut

I I 11111 ·,ll'(Jrtng lock key all the way to the right to start the enq111e

I

I 11111111.iqain, return key to the stop.

11 lh• 1•11111110 ,sa t operating temperature the "preglo wing" indicator hght comes on 1 Idle speed contro l knob

1 t rlr lly 1111<1 the engine can be started immediately .

1, 1111 1 •r 11111 u

111 1111 lo the stop. Release accelerator. At low ambient tompora tures (below

i ,sco ld, depress accelerator halfway and turn idle spoed adjusting knob

I II c ) depress both accelerator and clutch pedal fully while 5lart ing the engine.

I 1 , 1, ,, •11119 lock key after th e engine has started, ease off the acce lerator and adjust

liy means of the idle speed adjuster knob. Check oil pressure warning ligh t

111 c d

rt 1111li·lv 111lcr starting . Should the oil pressure warning light lwl to go out, shut off

1111 11,1111Pcl1,1tely and determine cause.

1111!1111 11111 lhe engine :

1111 h ,,111,q lock to position "O".

I , 11111111111 off the engine when the vacuum system is faulty , refer to sectio n

llw engine can be

5.7.

,1, , 11 11111• •,ltould never be shut off at a coolant temp erature above normal (in excess of

1

I ti I

11 > C), e.g. after operation in mountainous areas, but should be allowed to idle for

I 111 11111lhur 1 - 2 minutes.

29

2.3 Hand brake operation

To release:
Pull lever slightly, depress button in hanc! t)mko lover and swing lever downward .

To engage:
Pull lever firmly to the last poss11>lo c<1tr.ll

1 Hand brake lever

::=: ···=·

Shifting pattern on gearshift lever (example)

30

2.4 Starting the vehicle and shifting gears

Do not set off off immediately aftc1 th1• first few engine revolutions!

1. Do not turn on heater until n c oolilnt temperature of 122° F (50° C) is reached.

:•.

2. Let the engine idle at modorato speed for a short period of time.

3. Warm up the engine smoothly at medium engine speeds in the lower gear ranges.

4. Demand full engine output only nflcr the operating temperature has been reached .
Engage reverse gear only at engine 1tllc speed and with vehicle at a standstil l.
Caution: Immediately after setting off, test brakes (service and parking brakes) on a dry

-/:

road affording good grip.

The brake is in good working order if tho brake action of the wheels is equal and if suffi­cient deceleration is obtained Your sound judgement will tell you whether the vehicle is

prepared for the road.

There must be no oil or water on the brake linings. If water has penetrated to the brake
shoes, apply service brake with light pedal force until the required brake action is

restored.
If even only one brake fails to work, stop immediately.

nward.

ed.

r ranges.

reache d

I.

,) on a dry

nd if suffi­vehicle is

the brake

act ion is

Ut1l lt•111m1111on

11 1 c,11 ,,.r.ut1vely in accordance with the shifting pattern.

Ml 1111 1111•110 ltnnsmission

,11, l1,111•,rn1ss1on faci litates and simpl ifies the handling of the vehicle.

11 111

111111 1 In, h•d ranges, the gears are shifted automatically cond1t1onal upon driv ing

111 l ,, , 1 •l1 •r,1tor position.

I

h """ ilr1v1ng position only with the engine id ling. Relear.;c hrake only when

111 II I c ti 1v111g range is selected the vehicle might start off (creeping) prematurely.

unmediate upshifting

11•larded upsh ifting

I w1, I >111Hess accelerator beyond full throttle pressure pomt full throttle down-

111 , 111111111 accelera tion. The transmission will shift down only 11 the driving speed is

11,, 111,1.l(irnum speed of the next lower gear.

le II h •v1 •1 positions

11 lc>verpermits adaptat ion of the automat ic shifting process to spec ific opera t-

1,

11111'1

111cl1l

I' 11 k111q lock . The parking lock is an additional safeguard when parking the ve-
111

It• f ngage pos ition "P" only with the vehicle stationary

f

J11111t<1I The engine can be started only with the transmi ssion shifted to position

p Of 11N"

I h, power is transmitted from the engine to the rear axle. With the brakes being
, , 11 •.ir.;ed, the vehicle can coast freely. Engage "N" only when the vehicle is station-

11y ur moving at low speed.

= moderate acceleration.

= maximum acceleration.

MB automatic transmission
Selector lever position indicator on instrument panel

MB automat ic l ransmission
Selector lever positions on seat box

31

"4" Normal positio n. All 4 gears are shifted automa tically and consecutively. Position

"4" affords op timum driving characteristics under almost all operat ing conditions.

"3" Transmission shifts up to 3rd gear only. Preferably used on moderate uphill

gradients to avoid alternate up and downshifting betwee n 3rd and 4th gear and on
moderate downhill gradients in order to take advantage of the engine braking
effect up to the maximum permissible eng ine speed in third gear. Refer to marks
on speedometer or tachograph .

"2" Transmission shifts up to 2nd gear only. Preferably used on moderate uphill

gradients to avoid alternate up and downshifting between 2nd and 3rd gear and on
moderate downhill gradients in order to take advantage of the engine braking
effect up to the maximum permissible engine speed in second gear. Refer to
marks on speedometer or tachograph.

"1" Only 1st gear is at your disposal. Advantageous for the operation on steep uphill

gradien ts and as brak e downshifts within the permissible speed range of the 1st
gear on steep down hill gradients.

"R" Reverse gear. Engagement and disengagement of reverse gear only with vehic le

at standstill and engine idling

Important notes
When maneuvering the vehicle 1n limited space, control driving speed by gently releasing

lhe service brake. Apply accelerator only slightly and do not pump the acce lerator pedal.
ror short stops, e.g. at a bus stop or traffic light, leave selector lever in the driving position

and control vehicle with the brake. For extended stops with the engine running, shift to
position "P" or "N". On long uphill gradients , particularly in case of heavy loads (operation
with trailer), select lower gear range

in time.

32

'I-Position

onditio n'">.

·ate uphill
~arand on
1e braking
r to marks

ate up hill
~arand on
1e braking

·. Refer to

eep uphill

i of the 1st

th vehicl e

releasin g

1torpeda l.
gposition

19, shift to

operatio n

••••li111y In

, 11 , 1·1 v1r "hie, operational reliabi lity and economical operation of the veh icle it

111111 11 1111 Ill.it the engine should not be run to the limit of its ou tput during the

llflll

1,1

l11Jl1 ~111 (1 :>00 miles).

w111, 111,111ual transmission

I In 11..J11lly

11111111 admissible maximum speed of each gear (refer to marks on speed-

' I It IIOljlilph) .

111, ,11111.illcr.

w,11111111omatic transmission

I 1111 11,·lully

I 111111 l11,1<1s (full throttle driving), high engine speeds, no k1ckdown if possib le.

t 111 ''" lly selecting lower speeds.

I wlll 111111 !railer.

, ()(111 ""' (1200 miles) on: Increase slowly to top speed.

Wht111I 1111111ntmg bolts or wheel securing nuts

11111,1 1,11,vo that wheel mounting bolts or wheel securing nuts on all new vehicles be

111•cl .iftcr 50 km (30 miles) .

1111

Wile,.,., r ,ghten wheel mounting bolts or wheel securing nuts crossw ise.

IV• .pncified tightening torque .

180Nm

O·~" ·.\nee mou nting bolts or wheel securing nuts

33

2.6 Driving and braking

Oil and fuel consumption depend largely on driving habits and operational con ditio ns.
Increased fuel consumption is a result of trailer operation, driving in the city or over short
distances , driving in mountainous areas, accelerating and decelera ting the vehicle fre­quently, etc. For that reason, no accura te consumption fiqures can be given.

Depending upon the operational conditions, maximum oil consumption is
consumption .

The drive wheels must always be 1n firm contact with tho ground (especially in off-the-

road operations). If the wheels on ono siclo of tho livonxlo aro spinning, serious damage to
the differential will result because the ton

When driving observe the gauges and contro l l1qhls on the instrument panel from time to

time. The governor on the injection pump limits the maximum engine speed. Travelling

downhill , the vehicle determines the ongino speed and the governor cannot limit it. In
such a case the driver himself must mako 'lure that the engine maximum revolutions are
not exceeded in the individual qern '\
Negligence may cause damage to cmq1no, injection pump or propeller shafts.

Indicator light - brake fluid and brnko pacJ wear

The indicator light comes on:

cl on llw clllforontial gears will then be excessive.

01 >' -PrV<' marks on speedomete r or tac hograph.

1. When the engine is started

2. When the fluid level in the reservoil Is too low.

3. When the brake pads of the front wheel brake are worn.

The fluid level can be too low:

- if the hydraulic system is leaking

- if the brake linings are worn
Have brake system checked immediately!
Test function of indicator light:

- Turn steering lock to driving position

- Depress contr ol pin on the reservoir

1 % of the fuel

34

md itions .
>vershort
,hicle fre-

1.

>f the fue l

n off-the­amageto
Kcessive.

mtimeto
rravelling
limit it. In
1tionsare
hograph .

s.

1111111.iph

I 11111111111,usly check and improve your

h lv11111 habits by means of the tachograph

1
1llno111111 Use on ly original diagram cards
Wl!h, rnrcct scale. Check funct ion da ily.

I h• 1111110 steadily the ve hicle is driven the

I ,wnr 1•1 the fuel consumptio n. Brief bursts

I p11t1d will improve the average speed

111\11111\jllgibly.

I Npl1111allon of sample graphs :

I hu, ,111omic driving-peaked graph lines.

Ill• vd11cle was accelerated, brak ed

I rw11111lruptly and reacce lerated rap idly

I • 111111111ic driving - rounded graph lines.

I tu v11h1cle was accelera ted to eco nomic

11111d I he speed of the rolling vehic le

w, 11111clually red uced to zero.

Uneconom ic operation

Economic oper ation

~ 7

\ 1 - -- -U

..1..

--.

----

~---

---

---

---

-- so-

.40 --

---

- --

-- -

---- ---

I I ' l I

-90 1-

____ _j]@J__

------

------

---

---

--- 30

---

• I j \ I I I' I I I I

--

--

--

--

- --

--

35

Charge indicator light
If the charge indicator light comes on while the engine is running, stop vehicle,

switc h off engin e and inspect V hell.

Caution: Do not run engine without a V belt

Temperature gauge

Conditio nal upon the operating concl1tio11i, 1111<1111111>10111 temperature, coo lant operating

temperature in co ntinuous operntion mnqos from t~8
Brief vehicl e operation

is perm issible. This temperature, howPV<!r, shoulcl not tie exceeded.

(10 minutes at llw most) at n coolant temperatu re of 212° F (100°C)

?03 r (70 95° C).

Braking

When travelling down long downhill qr.icl1l'll l'>, oxplo1t the engine braking effect by sh ift-

ing into lower gear.

Parking

Apply hand brak e when stopping or pmking a vehicle on level ground or on down hill
gradients. Vehicles equipped with MB nutornat1c transmiss ion: In addit ion to this, shift
selecto r lever to pos ition

Safeguard a loaded vehicle or a veh 1cle parked for an exten ded period with at least one
choc k to prevent it from rolling away

"P".

Caution! On uphi ll or downhill gradients of more than 15 %:

- Sec ure empty vehicle at front axle with a chock.

- Sec ure loaded vehicle at rear axle with a chock
When parking a vehicle at night on public roads in buil t-up area, switch on parking or

standing lights.
Reflector pane ls can also be used for this purpose if permitted by law.

36

icle,

,perating

by shift-

downhill
his, shift

east one

2 7 Trailer

V h1, IP with trailer coupling (ball head)

1111, the trailer so it cannot roll away. Back up vehicle until the drawbar can be

o,

ii11 111111!CI in the pintle hook. Engage drawbar and lock.

V1 '11, II• with trailer coupling (coupling jaw)

I il1111110 care and caution must be used when coupling the trailer
I

I h11 lo the coupling operation, the trailer must be braked and secure d by chocks und er

1111 wltt>els and its drawbar must be set to cou pling height.

1 , ,111t1on when handling the drawbar - it may whip!

11

I lo 1111<' must stand between tractor and trailer when the tractor is backing up!

I 11!11w111q the coupling operation, check the pertinent locking device or indicator (feeler

11111111 · .. ,lety button) for proper seating ofthetrailercoupling bolt. Chec k fastening bolts of
11 ,11111 roupling regularly for tight seating and tighten, if necessary Accord ing to manu-

l 11 1u1, •1 's instruct ions, regularly clean and grease trailer coupling

1

1 lion of cable: The cable should be routed so that it will yield easily during corner -

1,1111

Iii I wtlll()u t kinking or chafing. Before connecting the cable, chec k the voltage of the

1,1 ,111111119 units on the trailer .

( 1111111111:

11 111111 , oupling with detachable ball neck:

11111,lv with manufacturer's instru ctions.

Trailer coupling

1 Plug socke t

trking or

Trailer coup ling

1 Safety handle
2 Hand leve,
3 Plug socket

37

2.8 Winter operation

Corrosion inhibition

The increasing application of thawing salts for clearing snow covered or icy roads may
well be of benefit to roadworthiness, but salts do cause damage to the exposed under­sections of the vehicle and to the units exposed to splash water. Thawing salts are corro­sive. Wash the vehicle more often during tho cold scnson to remove adhering thawing
salts or deposits of salty splash water from undcrbocJy and painted and chromium-p lated
parts. The vehicle should be regularly inspected for corrosion . Brake, air, and oil lines
should be checked with particular cnre>

As preventive measure, spray vehicle uncJors1do with wax -based preservat ive. If the ve­hicle is used regularly, repeat treatment w1tt1 presorvntivo now and then.

Spraying agents formerly used such as petroleum, diesel oil, diluted used oil, etc. must
not be used any more, since they might soften or dissolve the corrosion inhibitor
previously appl ied.

Engine oils

Change the engine oil at the onset of tho cold season. As replacement use an engine oil of
the specified SAE grades (viscosity range) Refer to "Fuels, coolants, lubricants , etc.".

Lubrication

38

Chassis and brake system suffer particular ly from the influence of snow and snow sludge.

Timely and thorough cleaning and greasing, especia lly of the brake linkage join ts and

yokes, of the brake units and the trailer coup ling will contribute to avoid premature wear
and inc rease roadworthine ss.

,ads may
d under­recorro-

thawing

n-p lated

I oil lines

Coolants

W111l11r operation witho ut antifreeze is dangerous and should be avoided at all costs .
/\11llhPoze can be retained in the cooli ng system all year round. Check its effectiveness

Willi .i t1ydrometer prior to and freq uently during the cold season.

lh ,,,, lo "Fuels, coolan ts, lubrican ts, etc." for brands of antifreeze and mixture ratios.

If the ve-

~tc. must

inhibitor

Jineoilof
ts, etc.".

vsludge.
,ints and
urewear

UIHe l fuel

Wu ,1o •r grade diesel fuel of a suffic ient fluidity is to be used during prolonged col d periods.

I\ ,111 except ion, kerosene may be added to the diesel fuel if no winter diesel fuel is

,v 111,11>10 or if the amb ient tempera ture drops below +5° F (-15° C). Refer to "Fuels,

.. 1.11,ts, lubricants, etc.".

I •nora l driving instruct ions

11 1111 ,1 •,ct off immediately after the first few engine revolutions! Idle the engine for a short

.it moderate speed . Then wann up engine at a moderat e speed and by driving

11111t11t

111, ,, ,lhly in lower gears, avoiding high eng ine load, until the normal operating tempera-

'"" , ,t 1!>8 to
I• 111111•1,1ture has been reached.

111 wil ,,,.,, use only tires whose treads afford good grip. If the drive wheels start spinning,

f(l 11••1 on firm grou nd immediately .

t,v

>11 ,111•,II and ice cove red roads, put chains on the rear wheels . Refer to manufactu rer's

111 ,111,llnq instruct ions. ·

203° F (70 to 95°C) is attained. Engine may be run atfull speed only after this

39

3 Fuels, coolants, lubricants, etc.

3.1 Diesel fuels

Diesel fuels should meet the minimum
requirements of DIN 51601 or such inter­national specificat ions as the America n

ASTM D 975 No. 1-D and No. 2-D as well as

W-F-800 a DF-A, DF-1, DF-2 and the British
B.S. 2869 A 1, or even A 2 in cases of emer­gency.

All branded diesel fuels commonly sold in
Central Europe meet these requirements.

Change engine oil as under severe
operating conditions if diese l fuels are

used whose sulphur content exceeds

% by weight. Marine diesel fuel, heat-

0.5
ing oil or the like must not be used.

When fuel is filled from barrels, it should be
passed trough a filter, a piece of chamo is
leather or even a clean flannel cloth, insert­ed into the filler neck. The suct ion port of
the pump must be protected by a fine­meshed strainer. Always allow a gap bet­ween the end of the suction tube and the
bottom of the barrel to prevent deposits
(dirt, sludge, water) from being suc ked up.

If diesel fuel has been spilt, the affected
spots can be cleaned by using a mixture of

% vinegar and 75-50 % water

25-50

(depending on the degree of contamina­tion). This will help to get rid of the offen­sive odor.

Diesel fuels at extremely low
temperatures

At very low temperatures the flu1t11tyof die
sel fuel may become insufficient chm to
paraffin separation. To avoid malfu11ct1u11~.
diesel fuels of a lowered cloud point wo
marketed during the cold season

If winter diesel fuel is used, there will hardly
be any malfunct ions at ambient tcmpt•1c1
lures reaching as low as 5° F (

Varying with the temperature add

15' C)

II ct•r

lain quantity of kerosene' if only surnnwr
diesel fuels or less cold resistant winlt•1
diesel fuels are available or 11 tem
peratures drop below 5° F (-15° C)

Ambient temperature

OF

(0 C)

32to 14 ( 0 to -10)
14 to

5(-10to-15)

Summer

diesel fuel

%

70
50

Supplementary Winter

5 to 8(-15to-20)

- 4 to - 8 (-20 to -22)

Should gasoline have to be added in case
of emorcwncy, never exceed a proport ion
of 30 '" Pre1111urn fuels must not be used.

C,.iut1011 I he lower flash point of the
supplPITlt mt.try fuels increases the danger

of oxplos1om,

1 lw CJ11q11w output may drop accord ing to

tlw proportion of supplementary fuel. For

tlw, w.1son, keep percentage of fuel

,tcfcled lo the minimum necessitated by the
c1111IJ1Pnt IPmperature

1

1 ho 11'1uof korosuno ,n road vehicles is not permitted

111 orn110 r:ountruJs. c
11ut11or1t111:;1 lwforo t uch mixtures are used.

q UK The refore consult the

Supplementary

fuel

%

30
50

diesel fuel

%

100
100

70
50

fuel

%

30
50

40

~din case
,roportion

be used.

11 of the

1edanger

:ording to

f fuel. For

1 of fuel

tedbyth e

>I permitted

:onsul t the

?d.

~mentary
uel

%

2 Engine oils

1111 •1111tnbility of the various engine oils is

p, , 111lly tested in our engines. For this

, , 011, only use engine oils which have

11 , .. commended by our company.

I ,

Ml 111 .I lJES-BENZ service stations have

II 11111 information on recommended

111111h

t 1111llun!

Ii 11>11 lc•1 to ensure sufficient lubrication of
lh 111ov1r1g parts, select engine oil visco-

lly I' ,Al grades) according to ambient

, 111111•1.ilure.

1111, , ,111pounded engine oils must not be

I I d i

The MERCEDES-BENZ facto ry or your
service station fills a new or a recondi­tioned engine with an initial operation oil.
This isa high quality oil which was special­ly developed for the opera ting conditions
during the first

500 to 1500 km (300 to

900 miles)

If the oil level reaches the minimum mark
on the dipstick before the inspection

(500-1500 km [300-9 00 miles]), the

engine may be topped up with recom-

mended engine oil if no initial operation oil
is available.

Ambien t Single -grade
temperature oils oils

"f "C

I

Viscosity range

I Multigrade

... t>)

"'

HI +20

"

'

_,,

"

• SAE 40 o,I may be used at ambient temperatures

'

"

' "

"

continuo usly above +86 ° F (+30°

l:l

~

!i!

ii!

;i,

l:l

S;l

~

;

Ii!

~

i

!

C).

N

"'

0

N

fr

30
50

41

3.3 Coolants

Cooling water

In the factory the coo ling water is blonclccl
with antifreeze (protection down to

-4"F) throughout the year Anllfroow
reduces the formation of scale and corro
sion.

If antifreeze is not required, 1 % (10 cm 1/

liter) of recommended corrosion inh1l>1to1

Antifreeze

Winter operation without antifreeze 1s very
dangerous and therefore prohibited If tho
antifreeze has been in the cooling system
all year, check for sufficient protection .
The antifreeze solution must be draino<I

from the system and renewed after a mnxi
mum period of two years.

The cooling system may need degreasing,
descaling and flushing prior to the use of
antifreeze.

Do not add any more than 60 lo of anti-

-20 Cl

must l>o used to treat the coo ling water

(potatile water quality).
lnlornmt1on regarding recommended cor-

,o~.lon 1nh1b1tors and antifreezes may be

ol>t.1111£'<1 from any MERCEDES-BENZ

Sf'IVICO stnllon

lwe,u .is till' antifreeze protection effect
clpcrenses at a higher percentage .

Tho efficiency of the antifreeze solution

should be checked several times during
tho cold season.

Mixing ratio

Protection to

OF

- 4

-22

-40

(DC)

(-20)
(-30)
(-40) 49

Water

%

66
56

Antifreeze

%

34
44

51

I I 42

ti The vehicle, service and maintenance

ling water

nded cor­is may be

ES-BENZ

ion effect

ge.

3 solution

es during

1ntifreeze

%

34
44

51

lk• ,111y other tec hnical equipment. the

I

,11 lo• requires service and maintenance.

01111 ilnd frequency of the service work

net mainly on operating conditions

I 111

hit Ii, In turn, may vary to a considerab le

111 lwquen t maintenance and grease

It ,110 required under severe operating

11ol111ons.

1 v111111ve maintenance work and jobs

11111 ..

d for the retention of the opera-

I 11 ,1 rnliability are itemized in the en-

, , 1 Maintenance Booklet.

1 , 11,1 -;kills are required for inspections

ol 111.i111tenance work. They cannot be

11 ,111 within the scope of these instruc-

11 II 1s recommended to have these

1

I• 11• •1 lormed by the trained personnel

It h .it your disposal in the large num-

ltl

1 , 1,1 Ml 11CEDES-BENZ service stations.

ti ., .. rvice is guaranteed by experi-

1

" 1111cl regular technical instructions

I, 111 11111 l.ictory, by workshop equipment

I 11vl!

P tools.

Ml HUDES -BENZ service station

111111 ll1P Jobs carried out in the Main-

I 111, , . I looklet.

111111

111,kl'r. attached to the door post

I 111

thrv .. , s door by th e MERCEDES-

BENZ service station , is a reminder of the

coming service or maintenance work.

Should any service and maintenance jobs
have to be carried out on a do-it-yourself

basis for organizational reasons, drain oil,
fuel or coolant into a trough or something
similar and not into the drain or on the
ground (environmental pollution). Operate
stationary engine no longer than neces­sary. When worki ng on the vehicle, adhere
to safety regulations.

Floor jacks , lifting platforms or jack stands

may be positioned only under the front
axle, below the rear axle housing and/or

rear axle support tubes underneath the
springs.

Position two-p illar lifting platforms at the

specified frame suppo rting points. Before

lifting the vehicle, clamp it to the support
arms of the lifting platform.

Vehicles which do not correspo nd to

standard specifications with respect to

wheelbase, length of overhang, permis-

sible axle loads and special structures

over front and rear end must not be lifted

up with a dual post lifting platform. In
addition to this special regulations must

be complied with. Any MERCEDES-BENZ
service station will advise you accor­dingly.

For lubrication use only high pressure

Vehicle tool kit at RH side in rear of vehicle , in case of
cargo trucks , below the assis tant driver 's seat
(example).

43

grease guns not exceeding a maximum

pressure of approx. 400 bar (5680 psi).

Grease guns without safety devices may
damage bearings, ball joint s, seals, etc.

Carefully clean lubrication nipples prior to
the lubrication service and drain plugs
before unscrewing them .

Depending on the operating conditions,
grease more frequently propeller shafts

and steering knuckle pins.

Lubricate special bodies and equipmen t
in compliance with manufacturer's

Hl

structions.
MERCEDES-BENZ special tools rcqu1rctl

in addition to commercially available tool
kits and torque wrenches to work on the

vehicle can be obtained from the spare

parts department of any MERCED! .S
BENZ service station.

All MERCEDES-BENZ service stat1om,
store the MERCEDES-BENZ oriqinnl
spare parts required for maintenance ,mtl
repair work. Besides this bases arc proV1CI
ed all over the globe intended to ensure

the rapid supply of MERCEDES-BENZ ori­ginal spare parts.

More than 200 000 different spare parts,
even for rather old vehicle models, are
furthermore stocked in the central plant
warehouses

We quaranteo maximum operational effici-

ency and reliability as well as optimum
retention of the vehicle value when
MERCEDES BENZoriginalsparepartsare
1nstnllod, as they are subjected to most
sovero quality inspections. Each part has

l>l'on specifically developed, manufac­tured or selected for and adapted to
MERCEDES-BENZ vehicles.

ror this reason, only MERCEDES-BENZ
original spare parts should be installed.

Tho vehicle has been provided with a

standard cavity wax protection in the
works. In order to retain the vehicle value

we strongly recommend that you repeat

this preservation procedure in the course
of the first year of operation. Any
MERCEDES-BENZ service station will
readily advise you accordingly.

44

BENZori-

4.1 Engine

are parts,
,dels, are
1tral plant

mal effici-

optimum
ue when
?parts are

j to most

1 part has

manufac­lapted to

ES-BENZ

installed.

id with a
,n in the
icle value

) U repeat

1ecours e
ion. Any
ition will

4 1. 1 Oil and filter change

1111• filter element must be renewed at

v, ry oil change .

N 11«• An initial operation filter element is

11 lulled by the factory and must be

pl,,ced at the time of the first oil change

11111 500 to 1500 km (300 to 900 miles).

11 1 hange should be performed after a

11111 ctistance drive, while the oil is still hot

1111 lh1n.

1t,•111ove dipstick, extract oil with oil
, •tractor

I

t111•,crew oil drain plug and drain oil.

I ,, 10 removing the oil filter, place oil

t, II pan under oil filte r. Loosen, but do

I 1111screw oil filter cover securing nuts.

111, ,tt cover from oil filter housing in order

lh ,1 tho oil may drain. Unscrew securing

11 ,111cl remove cover. Replace filter ele-

111 .ind all sealing rings. Position cover

l11h• p.1ying attention to proper seating of

1, 11,1•,kctand tighten nuts. Observe tig ht-

1111,, 1 torque.

11 w 111 and tig hten oil drain plug.

Fill engine with oil. Start engine and idle
for a short while. Observe oil pressure
gauge indicator lamp. The indicator lamp
must go out after a few seco nds. Shu t off

engine.
Check oil filter and oil drain plug for leaks.
Check engi ne oil level and top up oil to the

upper dipstick mark.

1 Oil drain plug on engine

Oil fitter (exampl e)

1 Secur ing nuts

Oil fitter (example)

1 Filter element

2 Filler housin g

45

4.1.2 Inspecting and servicing air cleaner

Service indicator for paper air cleaner

1 Inspection glass for colored held

2 Push button

Air cleaner

1 Center bolt

2 Filter bowl

Check filter element soiling at mainte-

nance indicator regularly

Normally weekly inspections will do; in
case of heavy dust accumulat ion, check
daily.

Inspection:

If the comp lete red field 1s visible

in the

service indicator , actuate push button to
disengage the colored field Clean or
renew filter element.

Servicing

1. Loosen cente r bolt of the filter bowl and

detach it with filter element

2. Take out filter element and clean filter
bowl.

3. Cover up the inner space of the filter
element. Blow compressed air with a
maximum pressure of 5 bar

(71 psi)

along the outside in direction of the
folds. Then blow out the inner space
carefully.

Should this cleaning process prove

inadequate, the filter element can also be

washed.
To do this adhere strictly to the following

safety measures.
Use filter manufacturers' detergents

Any MERCEDES-BENZ service station
will offer you advice. If no such detergent

is available, a non-foaming household

detergent may be used.

Caution:

Filter manufacturers' detergents have a
strong degreasing effect. Protect your
hands with rubber gloves or skin protec­tion cream. Never apply lyes or hot
fluids.
4 Soak filter element for

cleansing solution of approx.

F). Then swill in solution for about

(104°

10 minutes in a

40°C

5 minutes and rinse in clean water until
clear water drops off. Shake the filter
firmly and allow to dry in a dust-free

room (max. temperature

60° C / 140° F)

Install element only if thorough ly dry.

5. Clean gaskets of filter element and
scaling faces in filter housing.

6. Prior to installation, check cleaned fil-

ter element and gaskets for damage
(cracks, holes). Use inspection lamp.
Renew damaged element.

7 Mark number of times cleaned on face

of filter element.

8. Replace filter bowl with filter element

to the filter housing and retighten cen
ter bolt.

Renew filter element after 3 cleaning job:
or after 2 years at the latest.

Caution:

Dust deposits in the air intake ducts ind
cate a leak in the intake system whicl
must be eliminated at once.

46

ii I J Removal and installation of cylinder head cover

ts have a
1tect your
:in protec­,s or hot

nutes in a

·ox. 40°C

1 for about

Nater until

! the filter

dust-free
; I 140° F).
ghly dry.
11ent and

~-

leaned fil­r damage
ion lamp.

,d on face
r element

hten cen-

rning jobs

lucts indi­~m which

11 111 •,oiled cylinder head cover.

I 1111 111f crankcase vent line. Disengage

lh111lll11 linkage. Detach oil filler neck. Un-

1uw •;ecuring nuts and remove cylinder

d c0ver. Check gasket for damage

1111 111place if necessary.

4 I 4 Adjusting valve clearance

r 1111,tf,.elergauge ,measurevalveclear-

" 1 I 11•lwcen rocker arm sliding surfaces

I 1h11 camshaft on the cold or hot

" 11111• lhe cam lobe must then point

1 w 11d (;rank engine at the crankshaft in

111 111111 of rotation (not at the camshaft).

II r

fl"< tal tools for valve adjustment.

11 , , , ounterholding wrench on the
I 1 1!111 of the valve spring retainer to

,

v 111 the valve from rotating. Slacken

0 11 valve counterholding the cap

11111

I

rt /1, 1111·,1 valve clearance by rotating the

Ensure correct seating of gasket when
installing it.

Adhere to the tightening torque of the

securing nuts.

cap nut. Lock cap nut by tightening the

hex. nut and verify valve clearance once
more. For valve clearance, refer to
"Technical data".

If there is no need to readjust the valve
clearance, check tightness of the cap nuts

and hex. nuts.

Caution: Check contact surfaces of the
hex. nuts. Replace hcavrly worn hex. nuts
together with cap. nuts.

Minimum height of hex. nut· 5 mm (0.2 in).

Air cleane r

1 Filter element

2 Filter bowl

1 Rocker arm
2 Camshaft
3 Feeler gauge

4 Spec. wrench
5 Spec. wrench
6 Spe c. wrench

47

4.2 Fuel system

1 Fuel prefllter (example)

1 Securing screw

2 Fuel filte r (one-time use filter)

The inject ion pump is connec ted to the
engine oil cycle and requires no mainte

nance.
It has been set at the factory for oplimum

efficiency and most economica l fuel con
sumption . An inspection of the inJcction
pump and the adjustment of the start of
delivery must be performed at a
MERCEDES-BENZ service station only

Dirt accumulations in the fuel system will
result in malfunctioning of

1r1wc11011

4.2.1 Fuel prefilter

Regularly check fuel prefilter for soiling

(visual inspection). Replace, if required.

4.2.2 Replacing the fuel filter

Unscrew securing screw of filter and
remove filter. Replace sealing ring of

nozzles und cause black exhaust smoke
and erratic engine operation.

A defective nozzle must be replaced or

clc,med Spec ial skills are required forth is

job and

11 should only be performed at a

ME'RCCDES BENZ service station.
New injection lines must be thoroughly

cleaned prior to installation. Blow them out
with cleaning solution (diesel fuel).

Caution: The arrow on the filter housing
must point in driving direction.

securing screw and install a new filter.

Finally bleed fuel system.

48

4 2.3 Bleeding the fuel system

JS! smoke

,placed or
redforthi s
,rmed at a
on.

horoughly
vthemou t

1el).

,r housing

A, ompletely bled fuel system is impera-

t1v11 lor the perfect operat ion of the engine.

lJmllir operating co nditions, continuous

hl1111d1ng is ensured thro ugh the overflow

111111 Alter any repairs to the fuel system or

111 lhn event of driving until the fuel tank is

111npletely empty, the entire system must

ho hied manually.

Actuate the primer pump until the overflow
valve on the injection pump opens (rattling
noise). To operate the primer pump, re­lease the handle first (by turning it coun­ter-clockw ise). Always screw in again after
use.

1 Primer pump

v filter.

49

4.3 Cooling system

1 Drain plug - radiator (example)

Caution: Keep air intake free.

Do not attach any posters, badges or other

trim in the region in front of the radiator.
The cooling temperature 1s con trolled by

one thermostat.

The gradual rise of the cooling tempera-

ture above the usual level indicates a fail­ure in the cooling system.

The cause may be lack of cooling wuter, u

clogged radiator, slack V-belts or a faultv

thermostat.

Check cooling and heating system for
leaks at regular intervals and renew hoses,

if required
Radiator hoses and heater hoses should

be replaced by new ones when they have
been in use for an extended period of time
(approx. four years).

Use only tested and recommended hose
material and hose clamps.

4.3.1 Draining coolant and filling system with coolant

Draining:

1. Remove cap of cooling water expan

sion tank.

2. Open heater control valve.

3. Remove drain plugs.
They are located:

- at the bottom section of radiator;

- on th e right hand side of engine

Filling with coolant:
If possible, replenish coolant only if the
coolant temperature in the system is less

122° F (50° C).

than
Replace cap of coolant expansion tank.

Operate engine until operating tempera­ture is reached (thermostat has opened).

Shut off engine and replenish coolant.
After having drained the coo lant, check
whether the drain ports are restricted by

residual matter. Seal drain ports.

1 Drain plug - engine

50

4 J 2 Cleaning the cooling and heating systems

s or a faulty

system for

:new hoses,

,ses should
nthey have
iriod of time

mded hose

only if the

;tern is less

nsion tank.
g tempera­is opened ).

coolant.

( IH ning the radiator

lllow out the radiator core from the engine

I h with compr essed air or a jet of water

4 I I V-belts

1111q V belt tension

l\11kit" tester
I 11wer feeler arm in tester.
I '11•,1t1on tester in the middle between

I w,, pulleys. The stop must contact the

1i1,, of the V-belt.

( , ,1111nuously press the push button at
11 1111 angles to the V-belt until the

1 11 k spring can be felt or heard to

111 ,1111gage. Discontinu e pressure as

ll11•1wise measuring data are incor-

H, I

11, •lully lift off tester without altering

1111 1,,,.ler arm position.

until the radiator fins arc freed from foreign
particles (dust, insects , etc.)

5. Read off the V-belt tensio n at the inter­section of the "KG" sca le and the feel­er arm.
Specified value for used V-belts
V-belt section widt h.

12,5 mm= 40-45 on "KG" scale

6. Correct V-belt tension, if required.
Tensioning V-belts

Alternator V-belt:

1. Slacken securing screws.

2. Turn tension ing screw until the speci­fied value is achieved

3. Retighten securing screws.

"Krikit" tester
1 Push button

Tensioning alternator V-belt (example)

1 Securing screws

2 Tensioning screw

51

Tensioning power steering pump V belt (example)

1 Securing screws
2 Counter nut
3 Tensioning screw

Power steering pump V-belt:

1. Slacken securing screws and counter
nut.

2. Turn tensioning screw until the spc

citied value is achieved .

3. Retighten securing screws and coun
ter nut.

Renewal of V-belts
Only use tested and recommended

V-belts.

1. Check V-groove faces of pulley ,

remove rust and dirt.

2. Release tensioning screw until the V

belt can be slipped on.

3. Turn tensioning screw until the spe
citied value is achieved.

Specified value for new V-belts
V-belt section width

12,5 mm = 50 on "KG" scale

4 Check V-belt tension once more after

running engine for

1.0-1 5 minutes.

Specifie d values for used V-belts musl

be attained.

If in exceptional circumstances no testeri~
available, tighten new V-belt tem porarily
The V belt must not deflect by more thar
approx. 6 mm

(0.24 in) from a straight linE

when subject to thumb pressure.

Correct V-belt tension to specified valuE

for used V-belts as soon as possible.

52

1til the spe-

4 4 Clutch

:>ells
le

, more after
5 minutes.

-belts must

no tester is

amporarily.

more than

,traight line

ire.

;ified value
ssible.

11111 d utch is adjusted automat ically. Ba-

" .idjustment of the clutc h control

n,, , hanism is for example necessary after

This adj ustment requires special skills
and shoul d only be performed at a

MERCEDES-BENZ service station.

1111 pndals have been worked on or after

1111 ronewal of the master cylinder.

4 4 I Hydraulic sections of clutch and brake systems - checking fluid level

1111 lr,inslucent brake fluid reservoir is

1l11d on the front LH side of the engine

1111pmtment.

I h• Ill 11cl level can be checked witho ut

" w111g off the cap . The reservoir must

lw ,y•, be sufficiently filled.

11, ,11111 above upper marking (maximum

I 11~1111()

11,, 1111 lu . .1tor light on the instrument panel

1111 . 0 1111 the fluid level in the reservoir is

Functio n of the indica tor light can be

tested.

Turn steering lock to driving position.
Depress control pin on reservoir.

If brake fluid needs to be replen ished,
check hydraulic system for leaks and
check thickn ess of bmke linings.

Always screw on cover of reservoir tightly.

11,w

Engine compartment flap opened
1 Brake fluid reservoir
2 Control pin

53

4.5 Transmission

4.5.1 Manual transmission

4.5.1.1 Oil level check and oil change

Manual transm,ss,on

1 0, 1 filler hole - oil level

2 Oil drain plug

54

Prior to unscrewing the screw plug, c.ire
fully clean its vicinity. Change oil 1mmc'cl1a
tely after an extended trip while 1t i5 still hot
and thin .

Clean oil drain plug .
Oil level check : The oil level in the correctly

filled transmission reaches the lower l'Clqu
of the filler hole in the transmission hous­ing. Add oil through the filler hole, 11 ro-

4.5.1.2 Cleaning breather

Clean exterior of breather on transmission

housing as otherwis e oil loss may be

4.5.2 MB automatic transmission

Engage parking brake and move selector
lever to gearshift position "P" when work-

quired. If the oil level is checked with th
transmission at operating temperature , d
not allow any emerging oil to drain.

Dnuning oil Unscrew oil drain plug and o
filler plug.

rilling with oil: Pour oil through the fille
hole 1n the transmission housing until th
level reaches the lower edge of the fille
hole.

caused by the pressure built up in th1
transmission housing.

1ng on a vehicle with automatic transmis
sion whose engine is idling.

il r, 2 1 Oil level check

ed with th e
>erature, do
train.

plug and oil

~h the filler
ng until the

of the filler

I up in the

c transmis-

111, lu has to be on level ground when oil

v 11~ checked.

t ,1 ,, lo the oil level check, allow engine to

11, Int approx. 1-2 minutes. Check oil

11 ,y means of dipstick while the engine

I .,,vo painstaking cleanness. To wipe

, llpi;tick, do not use woolen fabric

If 11ft I hiplenish oil only through a fine-

II ·,trainer. Even minor impurities may

u , molfunction.

!I J OIi and filter change

,, ,, rnl 1mmediately after an extended

wl11li · 111s still hot and thin.
11 1111 lh<' oil from the transmission:

I! w •,ocuring screw of oil filler neck

I t It 11t I oil

ill 011 lorrn torque converter:

1111 , 11,k•,huft until the drain plug of the

111 11111vorter appears in the opening

I Ill 11,111110 converter housing. Back off

11 1,111q Drnrn oil. Renew seal rings.

w 111 111<1 llqhten drain plug. Observe

ltl 11111 1 lo1q11os

The oil level in the transmi ssion fluctuates
with the oil temperature . With the trans-

mission at operating temperature (194° F

= 90° C) the oil level must be somewhere

between the lower and the upper dipstick

marking. Do not fill above upper marking. If

the transmission is cold (68-86°F =

20-30 °C) the maximum oil level is appro-

ximately 35 mm (1.3 in) below the dipstick

minimum marking .

Filter change : Remove and clean trans-

mission oil pan. Renew filter.

Check oil pan gasket for damage and

renew if required . Attach oil pan.

Screw on oil filler neck with securing

screw and new seal nngs.

Observe tightening torques

Filling with oil: First pour in 4 liters of oil

through the oil filler pipe. Secure vehicle

to prevent it from rolling away.

Oil filler pipe - aut omatic transmission (example )

1 Dipstick

1 Securing screw - oil filler pipe
2 Oil drain plug - torque converter

55

Automatic transmission

1 Oilfi lter

2 Securing screws

Start engine and run it at idle. Selector
lever in position "P".

Pour in the rest of the oil while the engine
is running. Shift all gears and return selec

tor lever to neutral position ("P"). Inspect
oil level while the engine is operating. Add
oil, if necessary. Check transmissio n and

lines for leaks.

56

"). Inspect

·ating.A dd
ission and

II ti Rear axle

41 (I I Oil level check and oil change

11h11 lo unscrewing the screw plug , care-

111v, le •an its vicinity . Change oil immedia -

I

1 iv ,11, •1 an extended trip while it is still hot

fl I lhlll

ii h v,•I check: The rear axle is filled cor-

lly 1llheoillevel reaches the lower edge

1 ,

11111• lillcr hole in the differ ential.

lcl 1,1111,rough the filler hole, if required .

Should the oil level llo
rear axle warmed up, do

chc•t k,icl with the

1101 nllow any

emerging oil to dralll
Draining oil : Unscrew 011 clr.1111 plug and oil

filler plug .

Filling with oil: Pour OIi throuqh the filler
hole in the diffcrc11t1;1I 1111111 the oil level
reaches the lower Pclqo ol tile filler hole .

1 Filler hole - oil level
2 Oil drain plug

57

4.7 Steering

1 Remover

For safety reasons, perform maintenance

jobs at regular intervals.
This adjustment requires special skills

and should only be performed al a
MERCEDES-BENZ service station.

4.7.1 Checking the steering linkage

Drag link ends and tie rod ends must be
periodically checked for excessive piny or
looseness. Lift front axle. The balls must
rest in their sockets without play Socket

4.7.2 Checking steering free play

Manual steering
Should there be any free play in the steer

ing, have the steering system adjusted at a
MERCEDES-BENZ service station imme
diately.

Power steering
Play in the steering should only be

checked when the engine is running.

Power steering

In case of emergency, i.e. when the hy­draulic system fails, the vehicle can con­tinue to be steered with increased effort

because the mechanica l power transmis-

sion is retained.

caps and seals must be tight and un-

damaged.

Check all bolts and nuts for tight seating.

When the engine is not running (hydraulic

system of the steering assembly is inoper-

ative), the play verified would be inaccu-

rate (excessive).

The wheels must start moving when the

steering wheel is turned approx. 30 mm

(1.2 in). If they do not move, have steering
gear and linkage inspected by a
MERCEDES-BENZ service station.

58

ii 7 3 Checking oil level

m the hy-

i can co n-

1sed effort

·transmi s-

t and un-

,t seatin g.

(hydrauli c

•isinoper ­,e inacc u-

when th e

,x. 30 mm

e steerin g

d by a

on.

M 1111111 steering

1111 • w hicles

111111 •,toering whee l all the way to the left.

Ill ti I v1!hicles

111111 •11f!ering wheel all the way to the right.

I 111 area around screw plug before

111 , 111wing the plug! When the steering

11 1•1 correc tly filled, the oil level is

ii 1 4 Checking the toe-in

, 111 measurements on the front axle,

11,, ,11 vehicle on a perfectly level sur-

1 ht• tires must be inflated to equal

11,,. Looseness in whee l bearings ,

, 11 I 1•11ttsanddrag link ends must not be

I , ,111t1 The toe-in may be checked on

11 • 1111,tv or loaded vehicle.

1111 ,1•,rne toe- in (steering in straight-

It 111 position), mark measuring points

1

1111 11111 flange in fro nt of the axle at

I, I I PIiier heig ht, using cha lk or

I i l l ti 1)1'11Cil.

1 111,· llw distance betwee n these two

1

vollicle backwards or forwards

1 1111

Will

l'i rolntion and measure the dis-

35-45 mm (1.4 1.6 111) 110111 the upper
edge of the filler holo
No oil chang e is requ11

Pd

Power steering
Regularly ch eck the oil loVl'l

steering reservoir Thn

tn the power

co , wet oil level

reaches the reservoir 111.irk111g

No oil chan ge is requ111•d

tance between tho two pornts which are

located behind tho lront .ixlo

The difference in 1111•11'l111oment betwee n
the distan ce of tht• two points before and
after the wheel rotut 1rn1

Is the amount of

toe-in .

Vehicles with strwol1t

110 ro<J

After having lom,1•111•rl the clamping
sleeves, the tie roct u 111

l>c adjusted in-

finitely.

Vehicles with offsot t111 rocl

Toe-in is adjusted

l>y p11!,hlng one end of

the tie rod out of the stPrnlflq arm by means

of a push er (spocint tool)
Observe speci fied torq110 to which the

nuts have to be rollqhtf'111•d

Manual steering

1 Filler and oil level chec k plug

Engine compa rtment flap ope ned

1 Power steering oil reservo ir

59

4.8 Wheels and tires

4.8.1 Spare wheel location

Spare wheel below cargo body
1 Securing screws

2 Spare wheel carrier

Spare whee l below chassis frame end (example)

1 Protection caps 3 Spare wheel carr ier

2 Secur ing nuts

Spare wheel below cargo body
Unscrew the securing screws. Remove

spare wheel from the side and unscrew
spare wheel from carrier.

Spare wheel below chassis frame encl

1. Pull off thread protection caps. Corn
pletely unscrew securing nuts on

l H

side.

Spare wheel below chassis frame end

1 Secur ing screw

2 Hold spare wheel carrier. Completely

unscrew securing nuts on RH side.

3 Lower spare wheel carrier. Unscrew

securing screw and remove spare
wheel

60

4 II 2 Wheel change

:ompletely
~H side.

. Unscrew
)Ve spare

1 111110n: When wheels are changed, spe-

11i11d tire load capacities and tire pres­11111·, must be observed (refer to "Tire

1,11 •,ure chart").

M 1lw sure the vehicle cannot roll off.

I , 111oning the jack at front end:

I hulor the pertinent spring, directly in front

I th" front axle.

I , 1t1oning the jack at rear end:

Al , ... ir axle support tube, under no cir-

11111·,tances under the differential hous-

11• I

I , nlll damage the threads on the bolts

111•11 removing or installing the disc
!It l'IS.

!1111 • disk wheels are positioned,

1111,vti rust and dirt from contact sur-

1 , " , of brake drums, rims and wheel

11, .. 1111trng bolts or securing nuts.

l'f'IY •,ome graphite paste to bolts in or-

I , to avoid "jamming" of the wheel

1 ,,11111119 bolts or wheel securing nuts.

Prior to positioning th1• 111111•1 wlleul (twin

wheels), make sure all •;plw1 u nl 11ngs are

properly seated After hnv111q positioned

the outer wheel, screw

rr, ,11111 trqhten two

to three wheel stud nut•, loql'lher with
spherical spring wm,hu,·, Make sure

wheel is correctly cc nlt •rl'<l (wheel bolts

exactly in the center ol

1111• disk wheel

holes).
Position and tighten 11•ma111rng spherica l

spring washers and wh!'PI stud nuts.
For the tightening ol

bolts or securin g nul'., rl'll'r to section

tlH• wheel mounting

2.5.

The wheel mountrnq l>CJlls or securing

nuts of a changed wl1ccl must be
checked after

50 km (30 miles) and

retightened , if ncccs5,1ry Thereafter
periodic inspection:. will cJo

Wheel mounting bolts or securing nuts
are to be tightenccl u osswrse.

Jack - fro nt axle (example)

Jack - rear axle (exampl e)

2S934

61

4.9 Brake system

4.9.1 Checking the brake lines

Front wheel brake
1 Brake linings
2 Brake disk

Inspect brake lines for leaks and qood
condition periodicall y. Brake lines must I

>t•

replaced if signs of corrosion (pittinq)
chafing, crushing etc. are visible.

Brake lines showing even minor dam11(Jl'
must be replaced .

4.9.2 Checking brake lining thickness
Front wheel brakes (disk brakes)

Minimum lining thickne ss: 2,0 mm (0 8 1n)

When minimum lining thickness is

reached, replace brake pads immediately

Check lining thickness through one of the
openings in the disk wheels (use a light for
visual inspection ). Rotate disk wheels if

required.

Commercial vehicles designed to haul
cherrncals and acids are particularly jeo­pardized by brake line corrosion. Besides
vd11cles intended for the transportation of
comcnt, lime, animals and hides this
c.i!Pqory includes brewery vehicles and
',1n11lnr

For a closer inspection of the brake linings,

detach front wheels and remove brake

pads.

This adjustme nt requires special skills
and shou ld only be performed at a
MERCEDES-BENZ service station.

62

"ear wheel brake (drum brake)

J to haul

Jlarly jeo-

1. Besides

)rtation of
ides this
icles and

<elinings,
,ve brake

:ial skills
ed at a

,n.

lhiLkness of rear wheel brake linings must

IK1 regularly checked through the inspec-

tion holes (inner side of wheel - brake
1mchor plate).

lhu brake linings must be replaced as

,on as they are worn to minimum thick-

" !IS.

Minimum thickness: 3 mm (0.12 in)

For a careful check of lhP l>r,1ke shoes and

linings, remove the brake drums.
Simultaneously make suro that the brake

shoes pivot freely aroumi their anchor
pins.

This adjustment requires spPcial skills and

should only be pl'rformcd at a

MERCEDES-BENZ

SNVICO station.

Rear wheel brake
1 Inspect ion hole - lining thickness

63

4.9.3 Hydraulic sections of clutch and brake systems - checking fluid level

Engine compartment flap opened

1 Brake fluid reservoir

2 Control pin

The translucent brake fluid reservoir 1~

located on the front LH side of the cngin<'
compart ment.

The fluid level can be checked without

screwing off the cap. The reservoir must

always be sufficiently filled

Do not fill above upper marking (mnximum
marking).

The indicator light on the instrument parwl

comes on if the fluid level in the rcscrvoi1'>
is too low.

Function of the indicator light cnn Im
tested

Turn steering lock to driving position

Depress control pin on reservoir.

II llrake fluid needs to be replenished,
check hydraulic system for leaks and
check thickness of brake linings.

Always screw on cover of reservoir tightly.
U!;P only tested and recommended brake

fluicl brands for replenishmen t or renewal.
Observe boiling poin t (DOT 4).

Ropl,tcc t,rnke fluid once a year, most suit-

in spring

ably

A <;mall sticker, attached to the door pillar
of the driver's door by the MERCEDES-

m N7 service station, is intended to serve

ns a reminder when next to replace the

brake fluid

64

rel

r.
>lenishe d,

eaks and

s.

oir tight ly.
jed brake

r renewal.

nos t suit-

joor pillar
RCEDES-

cf to serve

place the

4 U 4 Bleeding the brake system

prusence of air in the system is indi-

l11d l>y a spr ingy , spongy fee ling of the

I , 1k 11 pedal. The brake (hydraulic system)

111 lltt>n have to be bled immediately .

I, t I 11; 1ke fluid duri ng the bleed ing opera -

I 11 ·,o as to ensure that the reservo ir is

•v·, filled to th ree quarters of its capa-

lw

llv llle ed brake system wit h a bleed ing

t ~h ,, or by hand in the following order:

11i,111ove dust cap from the respective

•ti screw .

1,1111
( , 11111cct bleeder hose .
I l,11 u hose end in a jar half filled with

l,1,1ku fluid.
I 1i•pw ss bra ke pedal until resis tance

, 111 lie felt. Retain peda l in this pos ition .

- Bac k off bleed scr
lution.

- Continu e dep re•,•;111q thu pPdill to the
stop .

- Retai n peda l 111 thl'I
brak e fluid to flow 0111

- Turn in bleed sc, .. w r1111l 1Pl1•,1•;c brake
pedal.

Repeat th is sequo11cc• 11111111111• lirake fluid
emitted from the ho•,11

- Remo ve blecdc, ho·,1•, !11•,l.ill clust cap.

- Corr ec t brakt> fluid lnVl'I

Bleedin g the hyd,1111111 l1111ko system

deserves your

is of paramount 111111111111111 ,, to the road -

wort hiness of tho v .. 111c111

l'W l>y f1p111 ox

po•1llh111 .imt allow

h lrc•u DI l)ubb les.

SP«'< l11l 111t 1 •11t lo11 beca use it

1

, rcvo

Brake caliper
1 Bleeder screws

1 Box-type wrench
2 Bleeder hose

65

4.10 Electrical system

4.10.1 Three-phase alternator

Supplementary heater

1 Fuse in battery box

Due to major differences in the opcm t1nq
characteristics of the three-phaso

alt orna

tor and the DC generator, the follow1nq
points have to be observed :

1. Thet hree-phasealternat ormust noVPr

be disconnected from the batl<'rtP~,
while the vehicle is in operation /\s
long as the engine is running, no1tt10r
an alternator cable, nor a ballo ry lrn

minal may be loosened, removed or

wrongly connected .

2. Tow-start the vehicle only with tho l>al
teries connected.

4.10.2 Fuses

All points of connection must be 1n pos1l1vt1
contact with each other. For return of thl'
current, make sure all power consuming
units are well grounded.

Damaged cables must be insulated by
means of insulating tape. Faulty fuses
must be replaced instead of repaired. An
additiona l set of fuses and bulb s should
always be carr ied in the vehicle for emer
gencies.

3 Only after positive and negative cable

tor rninals have been removed from the
tc1rninal posts may the batteries be
charged by means of a rapid charger.

II I or welding jobs with the electric wel-

cf<'r, clrrectlyco nnect thegrou nd termi­nal lo the part to be welded. Detach
posrtrvo and negative battery terminal
cl:unps

5 f1l·pw1s and inspections on the alter-

nutor are to be performed by the
skilloct staff members of a MERCE-

m.S BCNZ service station only.

Bo sure lo remove the cause of a burnt out
fuso prior to replacing the fuse.

Prior to performing work on the electrical
system, tho negative(-) battery terminals
must be disconnected from the battery

posts. Objects liable to conduct electri­city (tools) must not be put on top of the
batteries because they might cause
shorts.

66

tivecabl e
:!from the
tteries be
l charger.

ictric wel­mdterm i-

t Detach

{te rminal

the alter-

j by the

MERCE-

nly.

burnt out

electrical
terminals
e battery
;t electri­op of the
it cause

use box I

No Consuming unit

High beam, left, high beam indicator light

~

High beam, right

3 Low beam, left

II Low beam, right

Parking light, left, tail light, left, instrument panel llqhl111 1

h

Parking light, right, tail light, right
Hazard warning flasher switch, interior light, clor

I

Horn, stop light switch

u

Turn signals, windshield wiper, oil pressure war11111q I
indicator light

Blower, temperature gauge, fuel gauge

I II

~

111 111 ,1, flt11ol

Fuse box on RH side below the instrumen t panel
1 Loc king hand le

Turn to open

•

1-10 Fuses

67

4.10.3 Checking the headlight alignment

1 Tighten cap
2 Loosen cap
3 Aiming screw, vertical direction

4 Aiming screw, horizontal direction

1 Bulb - parkin g light

2 Bulb - headlight

Correct headlig ht aiming is of paramount
importance to roadworthiness. Periodic
checks with a headlight aimer should
therefore be made.

Each headlight must be checked ind1v1rl
ually. The other headligh t and tho othor
exterior lights must be covered up for this
process.

Loaded vehicle :
The bright/dark borderline of the low

beam is determ ined by subtracting

10 cm

(4 in) from the headlight horizon tal cent or
line (distance between headlight conter
and ground) wit h a vehicle positioned 111

4.10.4 Headlight bulb replacement

Turn left and detach cap of headlight

cowling. Disconnect electrical connector,

unlock bulb holder from its bayonet lock

by depressing and turning it counter
clockwise. Remove two-filament bulb with
socket. Do not touc h the new bulb with

moist or oily fingers but use tissue paper.

Install the lamp in such a way as to ensure
the insertio n of the two bulb socke t guide

.i way that the headlights are 10 m

such
(32.8

ft) from tho aiming screen.

Unloaclorl v11tw:10
(I oncl<•cl with I drivor or 75 kg= 165 lbs).

On votlic.los !'quipped with headlight

111•;1111 c:rntlrol, turn beam control knob to

1111t1al positio n

I ht> l>r 1qhl/cli1rk borderline of the low

lwi1rt1 1•, cll'lt•rnincd by subtracting 30 cm
(12 in) from the.' headlight horizontal cen­t11rll110 (<11•,t.mc.c between headlight cen­tor 11ml qrouncl) wrth a vehicle position ed

•,11<.t, ii wuy that the headligh ts are 10 m

in

1111) horn the aiming screen .

(32

luq:; into the notches on the reflector neck.
Put on lnmp holder and depress and turn it
clockwiso for engagement. Connect the
elcctrrcu l connector, position cap and fas­ton by turning to the right.

Then check headlight adjustment.

For bulb specifications refer to "Technical

data".

68

re 10 m

65 lbs).

~adlight
knob to

he low

J 30 cm

tal cen­1ht cen­,itioned

1re 10 m

)r neck.
d turn it
ect the
mdfas-

4.10.5 Battery care

Ut>an batteries only with the plugs

11.rewed in. No gasoline, benzol, kero­one or similar should be used for clean-

111y Lightly coat terminals with acid-

proof grease, particularly clamp under-

1de. Vent holes in the plugs and/or cell

vuntilation hoses must not be plugged. No
111utal objects should be placed on the
tmtteries (danger of short circuit). Battery
vl!!ual inspect ions must never be per­formed with naked lights because the for­matron of oxy-hydrogen gas might create
lho danger of an explosion . Only use
, IPctric lights.

I ho electrolyte level in each cell should be

15 mm (0.6 ft) above the plate

1pprox.

Chec king the electro lyte specific gravity

1 Hydrom eter

chnical

69

4.11 Vehicle cleaning and care

Use an ample supply of water to wash the
vehicle. Do not wash it in strong sunlight.
Use dry cleaning gasoline (not automotive
fuel) to remove grease stains. Do not apply
crude oil or grease to the syntheti c resin
finish since such agents will quickly de-

stroy the protective film on th e finish.

Do not clean lenses of turn signal and tail
lights with nitro thinner but use cleaning
gasol ine.

For cleaning steering wheel, gearshift le­ver, soiled upho lstery and floor covering in
the cab, use only warm water with dish
washing detergen t or washing powder for
delicate fabrics. Do not use scouring
agents. Use dry cleaning gasoline to

remove grease stains in the upholstery.
Clean seat belt webbing with lukewarm

water and soap. Do notapplyanyc hem1cal
cleaning agents. Do not dry the wchb111q al
temperatures above 176° F (80° C) or 111
direct sunlight. Never bleach or ro clyu llw
webbing.

Apply some talcum to window w<>alht•1
strips and door rubber seals

Have the chassis thorou ghly cleanecl .irnl
inspected prior to the performnnc!' of
major maintenance work.

After cleaning the vehicle, especially 11

steam cleaners or grease solvent•; wt•1P
used, lubricate chassis according lo llw
Maintenance Booklet.

All vehicle components are exposrct lo

mechanical action (flying stones, gravel)

and chemical reaction s (melting snow,

thawing salts). Have damage repaired and

co1 rod I'd •,pob clrrrnnaled as soon as pos-

s1l>lt1 1{1 •pn11 prnnlwor k and apply under-

',t'i II

f't11lor111 111•c .. ~;!,illY welding prior to the

.ippllc.111011 ol corrosion inhib itor.

I 1111 11•;., ol ; 11 •rosols, such as kerosene
<110!,1•1 rnl o111cl tile like, should be discon ­liruuid lr1lo1mnlion on tested and recom­11H•11<IP<I rn1lr corrosion compounds can

IJp ol>lo1111t><I from any MERCEDES-BENZ

li!'IVI< (l •,lilliOll

1l1o1kt1 l10!H", must never be painted or
c IP.illl'cl with gnsoline, benzol, kerosene
or 11111w111I oils. Clean hoses only with
wall i1 I IP <;uro not to apply any sprays or
q1 Pas!' to the brake hoses when spraying
rn lulH1c,11ing the vehic le.

.J~---~

70

4.12 Preparing the vehicle for storage

,naspos­ly under-

)r to the

,erosene

1 discon-

j recom-

1nds can
:S-BENZ

1inted or
:erosene
,nly with
;prays or
spraying

Thoroughly clean the interior and exte­rior of the vehicle and park it in a dry
and airy garage.
Grease all lubricating points in accord­ance with specifications in the Main-

tenance Booklet.
Increase tire pressure by approx. 2 bar

above the specified level to prevent flat
spots on the tires.
Cover up tires to protect against sun

rays.
Fill up fuel tank completely.

Check coo lant for antifreeze content. If

the vehicle is operated without anti­freeze in the coolant (e. g. in tropical
zones). it will do to add 1

% anticorro-

sion oil.
Check paintwork for damage and re­pair.

life, however, is limited, no matter how well
l)atteries are serviced.

Dnve vehicle every 3 months for approx. 1

hour. If this cannot be done, run engine at
moderate speed for approx. 1 hour. Ope­rate supplementary heater and air condi­tioning system for approx. 10 minutes.

Engine, fuel system etc. can also be
preserved for extended periods. Every
MERCEDES-BENZ service station will
readily advise you.

Change engine oil and filter acco rding to
Maintenance Booklet specifications.
Should the 500- 1500 km/300 - 900 miles
inspection have not been carried out yet
use initial operation oil.

71

4.13 Preparing the vehicle for service after storage

The follow ing points must be observed

when a laid-up vehicle is put back into
service:

Inflate tires to specified pressure.
Renew brake fluid if it has not been re-

placed for one year or if the storage
period of the vehic le is unknown .

Should the engine have been prcservo(I,
perform special depreservution
measures. Every MERCCDrS 111 NZ
service station will you accordingly

Check oil levels in engine, steerinq qcm,
transmission and live axles.

Choe k coolanl lovul und antifreeze effect.
I u11c:llo11 tosl PIC'ctrlcal system.
Sl.irl P11ql110 ,11HI check oil pressure. ln-

'ipP< I IHm1", 111HI Imes for crac ks and

tonks

C.IHH k llrnke oHiciency.

72

S Troubleshooting

e effect.

iure. In­ks and

!he following suggest ions will help you to

< ope with roadside failures. It is their pur-

pose to enable you to drive your vehicle to

1 MERCEDES-BENZ service station where

5.1 Engine and fuel system

Fngine will not start

llnrd starting or engine stalling

Cause

Fuel tank almosl nr 11111nlo 1, ly
empty
Fuel line, fuel t,mk • 11 1111 ,,
or precle aner c:loqu• d
Fuel filter clogqP.d

Fuel system leaki1111

Ambient temperal1111 I

11 •!1,w

+ 32° F (0° C)

Fuel filter clogg<'d
Vent in fuel tank clouoi d

Overflow valve in thu 11111,

pump does not hold 11111
developed proS!iw o

111111

eliminate the cause of the malfunct ion.

fh ese recommenda tions cannot be con-

sidered exhaust ive.

Corrective action

Fill up and bleed the system
Clean and bleed the system

Renew filter element,
bleed the system
Seal the fuel lines,

bleed the system

Observe winter operatio n

instruc tions

Renew filter element ,
bleed the system

Clean the vent

Workshop responsibility

For details
refer
to section

2.1

4.2.3

4.2.3

4.2.2

4.2.3

4.2.3

2.8

3.1

4.2.2

4.2.3

73

Lack of power

Cause

Unsuitable fuel
Lack of fuel

Full-load stop is not reached
Insufficient air supp lied
at high engine speeds

For details

Co,roc.t1vo m.11011

refer
to section

Dra1111111cl r<'plact• l>y llranded fuel 3.1
Observo w111ll'r 01w1.11to11 instruct ions 2.8

111',J)t'cl hH •I ftllt

1

1 4.2.1

l\clJw,I 11111 lo.id •,lop, cons ul! worksho p -
St•1v11"

11111 <111 clc>nrtf'f or renew 4.1.2

Black exhaust smoke

Engine overheats

5.2 Clutch

Clutch slips

Clutch dragging

74

Air cleaner dirty
Faulty injectio n nozzles
Start of del ivery maladjusted
Excess ive quantity of fuel injected

Not enough coolant

Faulty thermostat
V-belts loose or broke n
Cooling system clogge d
Exterior of radiato r so iled

Clutch fac ings wo rn or covered

with grease or oil
Air in th e hydrau lic syste m

Insufficient release travel of slave
cylinder

Fluid level in hyd raulic system
too low

CIPilll CH rwu,w
Wo1k•,l10p 1w,ptm•,1l>lhty
Worki,hop 1P1,pwP,il>lllly
WCll k11hop tfl •,pott•,lliiltly

l\clcl cooll111I,

< hock w•, lom for leaks

noplm u ll1t111110•,l11I
f{ot1qhlf111 m 1111111w V Lwlls
Workhhop 10•,po111,llullly
Clea11 oxlurlor ot 1,111111101

Work1;hop rt••;pon'i il>tllly
Workshop rp1,po11'-iil>1hty
Workshop responsibility

Check sys tem for leaks, replenish

4.1.2

2.1

4.3.3

4.3.2

4.4.1

details
r
ection

.1

.8

.2.1

5.3 Steering

Hard steering

Cause

Steering kmu kh,s n111 Ii ii ,111 Iii ii
No oil in SICPrlltq I' 11

For details

f r,111 ll'wc Ill lion to sec tion

refer

I 11lulc,1lc

l ltl'< k system for leaks , add fluid

4.7.3

.1.2

1.2

3.3

3.2

Hard steering
lpower steering)

Power steering
r• ttles when being turned

f>oor center ing

Low fluid level 111 • y•,11 111
V-belt s loose or 1>101<, 11
Air in hydraulic &y

,It 111

Air in the hydruullt , V I< 111
Low fluid level

in :;y IP111

Steering knu ck le'> 11111 h 111111 li t ti
Excess ive free piny
Tires underinflate<I
Incorrect toe-in

Maladj usted front wtu ut
bearings
Low fluid level in sy•,10111

Air in the hydraulic 'iV ,lr 111

c .lwc k system for leaks, add fluid

4.7.3

I lul1ghten or renew V-be lts 4.3.3

Chuck system for leaks, add fluid 4.7.3

Check syste m for leaks,

acld fluid

4.7.3
Check system for leaks ,
.tdd fluid 4.7.3

Lubricate
Worksho p respons ibility
Inflate to correc t pressure
Correct

4.7.4

Workshop responsi bility
Check syste m for leaks, add fluid 4.7.3
Check system for leaks, add fluid

4.7.3

75

5.4 Brake system

Cause

Uneven braking action Worn tires

Tires underinflated 11111,111• lo,

Oil on brake lining s

Uneven brake lining wear

Faulty hydraulic system

C CHIP( IIVI' 1f tlUII

I~' h,11tq1•

011Ptl prn-;surc

llolt111J tu.i~t••,, c ll'illl llli&ko cJrum
(wwk•,111111111•,po11,,ll>ltllles)
111111101>1nku•1
(w1uk•,ho111P·,pom,lli 11ily)
Wrn kuhnp I o•,prnt•a 1>11ily

For details
refer
to section

No or insufficient
braking effect

The braking effect cannot
be controlled

Hand brake not releasing

76

Vacuum brake booster
defective

No brake fluid in hydr auli c system C.,lw,•k hyd1,1ul1c •,y•,lt'lfl

Air in hydraulic system Acid lir 1kc1 f1111d,

Worn lining , grease on lining lh•l1110, wwk•,lmp rt•i;po nsibilit y

Faulty wheel brake cylinder Wm I •,hop w·,po11i;1h1llty

Hand brake cable stuck Wrn ko,l 1op I o•,pons 1l>iltly

Work~.h11p 1p•,po11sll1illly
Im lcJ 1k•. 11<1<1 IJ111ku fluid,

llltJl'd oy•,lt>III
l>IOf'd flV ,It •111 4.9.4

4.9.1

4.9.3

4.9.4

4.9.3

etails
ction

5.5 Electrical system

Starter will not crank the engine

Call 0

Battery II ,1
Battery I 111lly

Battery lc1111l11 ,1 lo 1
Cables loo•, or I ,, ,11y

Starter ct,,10 t111c

, , \tit l1vonc.t1on

( .lt.llCJO
ll1•pli1Ce

I If II 11 I ii l -lP.tn terminals, coat with acid-

proo f grease, tighten firmly

I tqhten or replace

Workshop responsibility

For details
refer
to section

4.10.5

4.10.5

4.10.5

1.1

1.3

1.4

1.3

1.4

Charging contro l light fails to come
on (with engine inoperative)

Charging control fails to go out
(with engine operating)

Preglow indicator light
will not come on

Burnt-out

1111111

Open circuit• 111 wlJlllU

Burnt -out
Interrupt

111111>

cc I pr oglt ,w

circuit
Glow pluq('l) l,111lly

Battery low

1 ltv1

llop lace

l 1qhten or replace connections

Workshop responsibility

I !<•tighten or renew V-belts

l~eplace
Workshop responsib ility

Replace glow plug(s)
Recharge battery

4.3.3

4.10.5

77

5.6 Supplementary heater

Heater will not ignite,
control unit shuts off
automatically

Heater motor will not start

Cause

Glow plug burnt out
Glow plug is grounded or
carbon-fou led
Ambient temperat ure below

320 F (OOC)
Fuel pump will not feed

Battery flat
Fuse defective
Commutator or carbon brushes worn

Corrective action

Workshop respons ibility
Workshop responsibility

Comply with measures required
lor winter operation
Workshop responsibil ity

Charge

Roncw ruse

wo, kshop responsibility

For detail s
refer
to section

2.8

4.10.5

4.10.2

System overheats

78

Outlet openings in passenger
compartme nt have been blocked

Glenn

. 5

.2

oils

5.7 Shutting off the engine when the vac1111111 v It 111 I ln111ty

Open engine cover and push down stop

lever on inject ion pump until the engine
stops .

1 Stop lever at onjection pump (example)

79

1 Towing eye front

5.8 Tow-starting and towing the vehicle

Towing In c11nc, of tmnsmlssion damage

For towing , leave engin e runn111q, 11 po :, ll1•111ov111Hop1•ll111 •,hill! of the live axle.
sible, to allow the power stcN 111q Jo
come effective and to supply vrn 1111111 lo
the brake system.

In case of engine damage

Vehicles with manual transmi ssion

Towing distance up to

There are no restrictions for tow111q tho
vehicle.

Towing distance more than
miles)

Remove propeller shaft of the live oxlo

Vehicles with automatic MB transm1s~1011
Towing distance up to 50 km (30 mil<'s)

1. Move transmission selecto r lcvor to
position "N".

2. Do not exceed a towing speed or

100 km (60 n11lus)

100 km (GO

40 km/h (25 mph).

For a towing distance of more than 50 km

(30 miles), remove prope ller shaft of the

live axle.

t,,,

In < 11111, ol "''" 11xlo damage
I ill 11·.11 ,1•h•

111 1:11R1 of lronl nxle damage

I 111 110111 .,~lo

I\ 1>01Jlll'Ct ctow11 vehicle whose driving

wl111PI"> hi1v1• cl11q into soft or mudd y
111rn111<l, •,l1011lct llt' towed out with utmos t

< ,111', l'',JH·Lially whon the vehicle is load-

, •ct

I ho vfllrn le 1 11n1i,t not be pulled out jerki ly

m t1t 1111 t111<Jlo espec ially sideways ­l>nc.,1wa,
l>P
qcthc1 with tho tru,Jer.

A useful piece of advice: using the rear
coup ling jaw, pull the vehic le out back ­ward along its orig inal track, if possible .

tilt' ch.1ssis of the vehic le might

cl,llllilOt'CJ Never pull out a vehicle to-

80

19

ly
st

j-

ly

lt

)-

Tow-starting

Manual transmi ssion:
Turn steering lock to driving position .

The preglowing indicator light must
have gone out.

Declutch , engage 2nd or 3rd gear, tow ­start ve hic le, engage clutch slowly and
actuate acce lerator until the engine starts

firing.
Automatic MB transmissio n:
Turn steering lock to the driving position.

The preglowing indicator light must have
gone out.

Move selector lever to neutral (pos ition

"N"). Tow-start vehicle. For approx. 2

Movt• c;elt

< ''" 1, v,, 111 1111 U1ur, ",' •

If the enq1110 ,I 111 111111(1 u 111111 .,,.lrn.lor

lever to lht> 11111111
(position

"N ")

Caution: 5ho11ld lht 1 11 11111 I.ill lo fire
within a

IPW ,, , 1111<1 , 11111 111 111•ulral

again and 11'111

,t po 1111 1, 111111111<11.i!Ply

.ii t11w ,I """ll w tum

1 Towing eye rear

81

6 Technical data

6.1 Data cards/iden tification plate s

Data cards bearing all major vchtd(• d,1111 ,1111 011ppl1Pd w1ll11111, vt<llte,lc.
Card No.

For safety reasons this card must 1101 IJIJ kt<pl 111 ll11J VPlih 11• 1111•,l•, ltw key numbe r for the
order ing of rep lacement keys.

Card No. 2
This card (without key number) is kopl 111

Please quote the co mplet e chassis
parts or inq uiri ng for technical detnll·,

1

lt1tt Mnl11t,,r11111, 11 IJooklct

11111111>01 ,111111111qh11• 111m11Jor when order ing spare

82

,e

ire

1 Chassis number } . .

2 Identification plate

in nght entrance

1 I 111111, N

I I II fl Ill I/It

Body number on right side front cab
post

83

6.2 Weights kg (lb)

207 D 207 D 301 D
209 D

207

1

0

209 D 309 D

:10, I>

ao7 u

:u1c1 I> aoc1 I>

407 D 409 D

Permissible front axle load .. ... ..... 1 350 1 500 1 500

(2980) (3310) (3310)

Permissible rear axle load .... .. ..... 1 400

(3090) 3090)

Gross vehicle weight

...............

2 550 2650

1 400 1 680 2 0:10

(3 700)

280 0

(5620) (5840) (6170)

1

Only van

6.3 Main dimensions mm (in)

207 D 207 D 207 D

1 at,O

(2 '1110)

('1 '1110) (•1 •1110) (•11170)

3 ?00

(7 O!iO)

209 D 209 D 209 D

401 U 40/ I>

409

n 40

Wheelbase ........................

307 D 307 D 307 D
309 D 309 D 309 D

3050 3350

3700 33Ml

(120.1) (131.9) (145.7) ( 131.fl)

Min. turning circle ...... . ........... 10.9 m 11.8 m 12.7 m 11.8

(35.7

ft) (38.7 ft) (41.7 ft) (38 7 11)

Track, front ..... . . . .... . .. ... approx. 1600 1600 1600 1 GOO

(63.0) (63.0) (63.0) (630)

Track, rear ..... ....... . ... .. . approx . 1 610 1610 1 610 1580

(63.4) (63.4) (63.4) (62 2) (G2 2)

1 ',<JO

(3 3 10) (3 3 1<1) ('I /~0) (3 750)

~· () l(J :• •' 1 ()

,1 ~·oo

(l (If 10)

I ,00

1 /00

1?00

(! ObO)

I {100

(l '~'()) ( 10 1"0) (10140)

1

1 D

~I /00

'1 GOO 4600

1 700

3200
(7 050)

(1'1!, 7)

12.7 111

Ill

(41.111)

1

(iQQ

((i30)

1 'j8Q

84

6.4 Engine

• The specified output measured according to DIN
70 020 is actually available at the clutch for the pro­pulsion of the vehicle since all power requirements
for the aux iliary units are ded ucted.

I 11111111
Mod, I
Muthod 111 0111 , 1l1t111
Cylind, 1 c111 111

Bore
Stroke

Total pisto11

Compre sslo11
Min. cornp1,1· 1011 1,11 11111

(engine WIIIIIII cl llP)
Develop!!d lu)r I pow, 1

accordinq to l)IN'

Max. torquu

Idle speed
Injection 01d1 1
Ejection IHIJU',111, 111 ii 11, 1 111111 11n: ,los

New nou lo•t
Used nou los
Start of

Valve arrarH1t>1111•111

1• 111, 1,1

di ,pl ,, , 1111 111

r 111 1 11111111~

111 N111 tllJ II )

(l!'IIV• 1y (ll l

2070
3070
4070

616

616.9
Diesel four stroke

4 cyl inders 5 cyl inders

(146.4 cu. in)

vertical in line

90.9

mm (3.58 in)

92 .4 mm (3.6 in)

2399 cm3

21

16.7 bar (242 psi)

53 kW 65 kW

HP) (88 HP)

(72

137 (99) 172 (124)

750/ min

1-3-4-2

115-123 bar (1 664 - 1 778 psi)

at 2400/min

at least 100 bar (1 450 psi)

24° before TDC

Overhead, per cy linder

intake and 1 exhaust valve

2090
3090
4090

617

617.9

2998 Cm3

(183.0 cu. in)

700/mi n

1-2-4-5-3

85

Valve clearance
with engine co ld

intako

{

exhitu·,1
Valve c learance
with engine warm

(140° ± 59° F)
(60°± 15° C)

in1t1kP

{

exh,wi,1

Lub ricatio n system

Oil pump .. ..... . ... .. .

Oil filte r ........ . •..... • . • .

Oil pressure

Idle speed . ........ . ... . . ••

lJ I lll 111111 (ll (11)41 Ill)

11~11 111111 (tllll?h1)

II 1 , 1 111111 (1111111 j 111)

O I i 111111 111111 1 111)

I Oil! 11 I I ll llllil 1lh111

f 11 II l'fl) 11111111 •

I' I" I 11111 1111W 11111 I

11

I 1 111 l, IJ 11 (7 I 11•,I)

6.5 Cooling system

6.6 Clutch

6.7 Transmission

' At ambient temperatur es continu ously below -4 ,0° F

(-20° C) add 0.05 mm (0.0012 in) to valve clearance.

86

Cooli ng system . . . . . . . . . . . •

Temperature control . . . . . . . • •

Coolant temperat ure .... •.. • .

Design .. .. .... . ..... .... •.••

Clutch control . . . . . . . . . . . . . •

Desig n . .. .....•......... ..•

Model . ..... ...... . .... • .. •.

Number of gears . . . . . . . . . . • . . .

Gear ratios . ... ... . ... ...... ••.

,111 Jlol pl 11• dry, li1h 11

llydr 111111

hy111 11111111, 11 111111•,11w,s 1o n

c,l/1U 1/1 I',

f II I

IPVlll ,t -t, Iii{

I lpll111111I

MIi ru11<1111111i l11111•1miss1on W4 A0 18

'I .'ll I .

1 fo11W11fd I It VIII ,IJ

1-,111111/i,1 1,'/ 1,rn :111.1;

11 VOi ,t - l., •111

1

1

6.8 Steering system

Do ,11111

Mod,JI

Mo111u,1I steering L 1.5 Z

/GO 2
Optional.
f'owor steering

LS 2 A

7655

6.9 Front axle

1

Van standard version

,,11, 111111 pu11111 (filv1

Powor

Vehicle

Design
Model

Vehicle
Design
Model

Vehicle
Design
Model

Toe-in

(measurocl

Camber
Kingpin inc

Caster

011 1111 wl1t11 I II 1111111)

111111111111

V belt, narrow type 12.5 x 900

2070/2090

Rigid knuckle yoke axle VL 0/1 C-1.3

730.4
Optional:

Rigid knuckle yoke axle VL 0/2 C-1.5

730.4

3070/309 0

Rigid knuckle yoke axle VL 0/2 C-1.5

730.4

4070/409 0

Rigid knuck le yoke axle VL 0/3C-1.7

730.4
straight tie rod

offset tie rod

10

O ± 0.5 mm (0 ± 0.012 in)

O ± 2 mm (0 ± 0.08 in)

50

2° 30'

When camber, caste r and kingpin

inclination data are quoted in degrees

of angle, a tolerance of

be exceeded

± 20' must not

1

87

6.10 Rear axle Vehicle ............... . .

Design . . .... . .. .... .. .

Mode l . .. .... . .. ..... •..

Rear axle ratios . . . . . . . . .

11 ,~It 111 0/1 • 1.7

11 1" lo 111 1)/:.! :.! 2

Vehicle .. . . . . . ... . .... .... .

Design ........ ... .. .. ... .

Model . .. .. .... ..... ......... .

Rear axle ratios ......... .•..

Vehic le cargo truck . . . . . . . .

Design .. . . ... ... ... ... .•..

Model .... ... . ............ .

Rear axle ratios. . . . . . . . . . . .

Vehic le Van . . . . . . . . . . . . . . . . . .

Design .. . ... .... .. ..... •.•.•

Model . .. ... .......... .......•.

Rear axle ratios. . . . . . . . . . . • • .

Vehicle . .. ... .. .... . .... ....•.

Design ...... . .......... . . ..•

Model ....... .. .... ... . ..... .

Rear axle ratios .......... .... .

111 0/?. 2.2

11 ,~h 111 0/3 3.3

110 / I>

I lypOld Oil II l~h· 111 0/3 ·3.3

l•I I '•ii

I ti Ii

r lpl 11111 ,1

1- [, 111

,1011 II

I lyp1111 I ll' II It• 11. 111 0/3 ·3.3

7 I I ',;.>

1- ,1 'I

( lpllllll ,1

1- •, 331

6.11 Brake system

Cargo trucks and vans:
1st circuit

2nd circuit

Cargo bus for personnel transportation:

1st circu it

2nd circuit

= front wheel brake (disk

brake)

= rear wheel brake (drum

brake)

= front wheel brake (disk

brakes, lower pistons of
brake calipers) and rear

wheel brake (drum brake)

= front wheel brake (disk

brake, upper pistons of
brake calipers)

89

6.12 Electrical system

Alternator

Design .. ... ..... .... . . .• . .•.

Output . .... .... . . .... ...•.

Alternator drive ........ ... .

Starter motor

Design ........ .. .... .. .. .

Output .. . ..... . . . ...... ... .

11111 I pit I ,I

l•I V/ ,,, A

V Ii, II I ,' t, Ii I O I ',

90

Batteries, Engine 616 . . . . . . . .

Engine 617 ..... .... ..

I,' V 1,1i All

t >pll111111I

I,' V 1111 Ali 111

•' )( I I V I olo Ah or

I:• V 1111 Ali

C It ,111111 11

!' x I!' V 1111 Ah

~

X 12 V 88 Ah

Lamps (DIN 72601)

Incandescent lamps

110.,<11111111

Turn s1u11 ,1
Stop hqlil

Rear loq 11 1111

Tail liqhl i; 11 111 11111 1

Vn11

Licenso plriti 1tgl1I
Interior liqhl
lnstrumonl lloh1111 l

Maximum •.pt Id w 111111111 1111111
Indicator hqlll

Hazard w11111l11 1 II, 1111 1111th 111111 ll11ht
llluminall on 111 111 ,1o, ( 011trc,I·
Indicator 1111111 111 11 11 liJ 1 1111111

FuSC'l •

A 12 V 45/ 40 W

Optional:

H 4/12 V 60/55 W
HL 12 V 4 W

P2 5-1/ 12V2 1 W

: }

G 12V10W

G 12 V 5 W

L 12 V 5 W (Festoon bulbs)

K 12 V 1 0 W (Festoon bulbs)

H 12 V 2 W

W 5-12 V 1.2 W

8 A, 16 A, 25 A DIN 72 581

Glass-base lamp

91

Key to wiring diagram (Position 1 to 7)

Wire color code

bl = blue

br = brown
el = ivory
ge =yellow
gn =green
gr =grey

Ii = violet

rs = pink

rt = red
sw = black
ws = white

Example:

Wire designation 1.5 gr/rt
Cross section of wire 1.5 = 1.5 mm2
Basic color gr = grey
Identification color rt = red

Starter control , power supply

A 1 Steering lock
G1 Battery 12 V
G2 Alternator

H1 Preglowing indicator light
H2 Charge indicator light
K1 Relay
M1 Starter
R1 Glow plugs
S1 Battery master switch

Light switch, rear fog light,
license plate light, tail light,
right, parking light, right

E1 Rear fog light

E2 License plate light
E3 License plate light
E4 Tail light, right
E5 Parking light, right

F6 Fuse
01 Light switch
X1 Trailer plug socket

Parking light, left, tail light, loft,
trailer plug socket

E6 Parking light, left

E7 Tail light, left

F5 Fuse

X1 Trailer plug sock et

GJ Headlights

E8 Headlight, left

E9 Headlight, right

F1-F4 Fuses

H3 High beam indicator liqhl

S2 Comb ination switch

I uu lluht 11

111 l11qlit1hl, h•lt

I I I II I Ii thl I ICJhl

I 11111 11lunnl llyhts, hazard

wcu11111u llnaher system

I I I 11 1·
11 t 111111 •,11111111 indicator light,

lrnll1·1

I :i 11.1.·.11d warning flasher

,1•111111111111111

;, , 1111111111.itron switc h

l I I I 1l 11d warning flasher switch

011c•rnll1111 monitoring

I , I

I 111111111111•111!1

11', 111111 •,1q11al indicator light,

l1ru Im

I Iii 111111 •,lqnal, front, right,

1111 ·,rclo

117 I 11111 •;iqnal, front, right
1111 I 11111 ·,1qnal, rear, right
ll 'l I 111 n •;rqnal, rear, left
111 o I 11111 •,1qnal, front, left

1111 111111 •,iqnal, front, left,

Oil •,!(Ip

X 1 I 1.rllPr plug socket

92

1 l sw/bl g,

sv./blEc •w1w1

t

,bl . 1~ I ' ,.,.,,...

g• - - ~·, •'vi

2,5 l ,~+ 4 !Jllf!:¥.l'

f]

• ,1;·t 'I [!:SJ: ~.ii}. •!HI <>

1

L

~- =2.S~•w~---'•~w ~- ~ 12~4 ___ lbl

~

1•w

1

I

I

1

&:, 8~

11 rt

I I

'fl 104

JI 32

X8

~- -i--i----t- -- -1b r ! r • 4d

46

33

1

I

~ It )

I

14

I

1,.5getws-50

r I IX/2

l I h,

Xl r, E4f ES

l32

40 41

r

_j

~~~5swlw s- -- -- - -- - -----===;. t

5P,~h"fg, 41

FS

8A

4\41,5gr

1 1

gr gr

SW SW

1,5

\5

\5 \5

ws

ws

bl

ws

j

~

EJ •E7~ ! X1

41_._ lb, ; ! 63

I \5f'

•r 04 ,3,

42

43 44

L

ill

45

...L

H3t

br

33

J..

46

~ ES

1

T

\5,_br 1..5.._br

ill

s::::w/-;;rs=--=--

5

g•

SW

ws

L

\~ \5f

E~~ E11i

l T

\5 ,.~

tr l!f

'>O

j

(sj

l.

1/1

,,

! i1).1 f.

u

l I WtlJI

I

I

,l f

l

~.

J..

------- --- - -~-- - - -69

"1- -ls w/g, ws

110

t~ r P",

" 1 r. 1s2

WL ~t -tt

1-=f:= :::::=~~~::;:: =F~\ 5;)sw~/h~== =;-;;~===i- - 69

+- lsw/ws

~ 1sw/gnws lsw/gn

l

l

I tu JO ff l ~ -,SP,

Yv!.J~ ,

49 S3

X/6 X/7

1

g,

g,

HS

rt

31

59 63 68 2

,k"' Jl JJ,., "'~

1

i

..L

r T J-- ,t,r-----1 1 T ,

r

r r :5 r 'r si

-[1)- _je

93

Key to wiring diagram (Position 8 to 18)

Windshield wiper, windshield

0

washer

Windshield wiper motor

M2

Windshield washer motor

M3

Switch , windshield wiper,

K3

intermittent wiping
Combinatio n switc h

S2

Stop light

0

Stop light switch

B1

Fuse

F8

Stop light, left

H12
H13 Stop light , right
H14 Horn

Switch, horn

S4

Trailer plug socket

X1

Heater blower

~

Heater blower motor

M4

Heater blower switch

S5

Fuel, coolant

EJ

Send ing unit for fuel gauge

B2

Sending unit for coo lant

B3

temperature gauge
Fuel gauge

P1

Coolant temperature gauge

P2

Backup light

~

Backup light, left

E12

Backup light, right

E13
F10 Fuse

Backup light switch

S6

Speedometer, tachograph , ctor k

~

E14 Lighting for heatc,

control
Speedometer

P3

Tachog raph

P4

Clock

P5

Door contact switch,

B

interior lights, plug socket

Interior light

E15

F7 Fuse

Interior light

H15

Switch, interior light

S7

Door contact switch

S8

Switch, interior light

S9

Plug socket

X2

Heated rear window

~

Switch for heated rca,

B4

window
Indicator light for hcillt

H16

rear window

•ct

1,1

I !nilly Im !waled rear
w111ctow

11;•

I It• 11t•d tt'ilr window
I lout,•d 11'.tr window

11'.I

Ill nkc, llutd, olt pressure

! 11, I

1111 lh ,1trn light, brake fluid

I I

It

l11dh .,,trn light, oil pressure

111 U

I,,

n,,111v

r ,I()

',w11< II, liruke fluid

I 11 • ,w11< h, 011 pressure

c 1,11,111111·11 tights

I II J

< l11111u11co tight, front , left

I I ii

< t,,,11.incc light, front , right

Ll7

< .1n,11,111cc light, rear, left

I I II

< .1,•u1.incc light, rear, right

I I 'l

llrt1ktt pnd wear

I 1111

• ,witch, brake pad wear, left

' II.

• iw1tch, brake pad wear,

'- I ,I

liq ht

I 1,1llnr plug sock et

XI

94

~F8

8A

f----1swlott

lsw

~t B1

r

lsw

rt

tx/3

1sw

rt

1srn 1sw

rt rt

• •

H12t H13t

1 1

br br

.L .L

~

(IIJI

32 -1g,-/gn rl-isa

j

I 1~1° 3~

'"

t 1,,,,, ,, 111gr1gn rt r+ ~rt

M lrt m

J

I'} 1 1

{/)

I

I

' II In

1

~

'·r.~' I L,,, P\ij58

1 g r 1 gr

!' 1 r 1

~

)I~~, .1:.~ tr r~ ..

1 I I

I IT}

.L -ill]- .L

~

~

~

~

104

~

106

J

95

Key to wiring diagram of

automatic transmission

1 Speedometer lighting
2 Relay
3 Fuse box (standard equipment)
4 Starter
5 Selector lever position indicator
6 Transmission

a Starter lock-out switch
b Switch backup light
c Solenoid valve (kickdown)

d Solenoid valve (1st gear)
7 Cable connect ion
8 Backup light
9 Kickdown switch

10 Sending unit, selector

lever position indicator

1

br

gr ......4-+-4----+----t- +- --

T I

1 1 1 1 1 1 1 I

br br br br br br br br

I "f I (~\

111 11)1'•111 30 I 3,? ~

1

1

I I I I I I I ';;--f

'IIIIK -4 ;

I +,.J :c

1,w/hl

0

)

96

~*µ ·:_rl m

L ' ,~ \ I ~~ --: _ J

7 Tightening torques in Nm (lb ft)

Engine
Cylinder head cover
Oil pan to crankcase

M 6 . ....... . ... . .... ... ...... . ..

M 8 .... ..... ............... . ... .

Oil drain plug - oil pan ........... .

Oil filter cap .. ....... .... . . ...... .

Hose clamp ..................... .

Transmiss ion
Manual transmission

Oil drain plug . .. .. . ....... .... ... 70 ± 15 (50 6 l IO 0)

Automat ic transmissio n

Oil pan ......................... .

Oil filter ........................ .

Oil drain plug - torque converter . . .

Securing screw - oil filler pipe ..... .

35-45 (25 3 I I

14 +2(101114)
35 I 7 (~!J 3 I , I)

1 , 1 I u lll

11 (7 1111

30 ( 'I 71

20!144)

(, (4 IJ

7 ( 1)

4 (~ 8)

I 111111 •• , .,

I rrn 11 p1111q l J t >oil

II

cuu • a I ft

40-50 (28.9- 36.1)

Whonla

Wt11, I 111111111ting bolts or securing

11111 01 c11 k wheels .............. 160-180(115.7-130.2)

1!!!!1111\j

J 111111 111 11111 lo steering gear L 1.5Z ..

( I 11111111111 •,lceve to tie rod ....... .

1 c1111i ,11111111ls tie rod ... ........ .

LS2A ..

45-55 (32.5-39 8)

90- 100 (65.1- 72.3)

80 (57 8)

80 (57.8)

360 (260.4)
360 (260.4)

--

' ,,

.,

97

8 Capacities - summary

Components and lubri cants must match Therefore, only tostccJ and recommended
brands must be used . MERCEDES-BrN7 !l<'rvtCO <;lntiom, will rencJ1ly give you all the

required information .

616

Engine with
oil filter

617

Manua l transmission G 1/ 18-5

MB automatic transmission

HL0 / 1-1 .7

Rear axle HL 0/2 - 2.2

HL 0/3 - 3.3

98

Mode l

616 .9

+

617.9

r 711 .1

720 .1

\ 741.406

741.404

741.52

Capacities ca.

max. 6.5 I
(13.8/ 11.5 US/Imp. pis.)
min. 5.0 I
(10.6/8 .8 US/ Imp. pts.)

max. 6.5 I
(13.8/ 11.5 US/ Imp. pts.)
min. 5.0 I
(10.6/8.8 US/ Imp . pts.)

2.3 I
(4.9/4.1 US/ Imp. pts.)

71
(14.8/ 12.3 US/Imp. pis.)

1.5 I
(US/Imp . pts.)

1.8 I
(3.8/3.2 US/Imp . pts.)

1.8 I
(3.8/3.2 US/Imp. pts.)

I lH)I, < ool,1111, 1111111< lilll

01 lllllktl lh11cl

fnq11111 oil

Auto11111t11, t11111•,111l•1•,lo11

(A 11 ) typ1J A ~i11tl1x A

flurcl
Auto111atlc

flurcl

Hypo icl

Ir 111•,1111i,•1to11

(A 11 ) 1Jux1011 II

Ill'• 11 oil

V1<;cosity ranges

r lnler to "Section 3.2"

SAE 90, 85 W/90

Clutch and brake systems ­hydraulic sections

Grease nipples on chassis
and body

Battery terminals

Fuel tank

Engine 616 616.9

Cooling system

Engine 617 617.9

Windshield washer system and
headlight washer system

Model

t-

--+-

( 111111, 1111 •

o II

( I I\/ I 9 II R/111111

70 I

( 11.1 (,/ 1 (i jl 11',l lillp

10 ', I

22 ~'/IO

10 I

(?.1 111 t (J I l'l/ 111111

71

L ( 1 '1 8/ 12 3 II Jl111p pi s ) washing agent

I II

pl!l )

U.tl~)

(i II ,1h11p phl

pl:,,

Fuel, coolant, lubricant
or brake fluid

Brake fluid

Multipurpose grease

Bosch Ft 40 v 1

Diesel fuel

Coolant

Water with MB windshield

'i

99