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