MERCEDES BENZ W124 Series 230E, 230CE, 230TE 1985-1992 Factory Workshop Manual Collection | PDF Download | carmanualsdirect

MERCEDES BENZ W124 230E Workshop Manual | PDF Download

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MERCEDES BENZ W124 Series 230E, 230CE, 230TE 1985-1992 Factory Workshop Manual Collection | PDF Download

MERCEDES BENZ W124 Series 230E, 230CE, 230TE 1985-1992 Factory Workshop Manual Collection | PDF Download

Massive Mercedes Benz Factory Manual collection for the W126 with over 3800 pages. Includes:

Mercedes Benz W124 Factory Chassis & Body Workshop Manual
Mercedes Benz W124 Air Conditioning System Factory Workshop Manual
Mercedes Benz W124 Cruise Control Factory Workshop Manual
Mercedes Benz Engine 102 (2.3 Litre 4 Cylinder Petrol) Factory Workshop Manual

Easy, step by step instructions, this manual is suitable for the home workshop mechanic or professional technician.

Models covered manufactured from 1985-1992

Mercedes Benz 230E Sedan
Mercedes Benz 230CE Coupe
Mercedes Benz 230TE Station Wagon

Engines covered:

M102 2.3 Litre 4 Cylinder

Below is a detailed list of topics covered in these Mercedes Benz Manuals:

Electrical System Engine

Removing, testing and Installing alternator
Removing and Installing poly V-belt pulley (fan assembly)
Removing, testing and Installing regulator
Removing, testing and Installing starter motor

Suspension - Shock Absorbers, springs, Torsion Bars

Removing and Installing shock absorber struts
Removing and Installing rear shock absorber
Removing and Installing front spring
Removing and Installing rear springs
Removing and Installing front torsion bar
Removing and installing rear torsion bar

Suspension Level control, and Rear Axle

Removal and Installation of rear axle complete
Removal and Installation of front and rear rubber mounts of rear axle suspension
Removal and Installation of camber strut
Removal and Installation of torque strut
Removal and Installation of tie rod, replacement of rubber mount
Removal and Installation of thrust arm
Removal and Installation of spring link, replacement of rubber mount
Removal and Installation of wheel carrier
Replacement of supporting joint on wheel carrier
Removal and Installation of rear axle shaft flange with angular ball bearing
Bleeding the ASD hydraulic system
Removal and Installation of rear axle center assembly
Replacement of radial sealing ring on bevel drive pinion
Replacement of radial sealing ring on connecting flange of rear axle shaft
Removal and Installation of rear axle shafts
Replacement of rubber cup seal on rear axle shaft
Removal and Installation of connecting flange of rear axle shaft

Front and Rear Axles

Removing and Installing front axle halves
Adjusting wheel bearing play
Removing and Installing front wheel hub
Replacing front wheel hub
Removing and Installing steering knuckle
Removing and Installing steering knuckle arm
Checking supporting joint of steering knuckle mounting
Replacing boot for supporting joint of steering knuckle mounting
Replacing supporting joint
Removing and Installing control arm
Replacing control arm mounting
Testing rear axle spring struts
Testing front axle spring struts for leaks
Testing spring actuators on front and rear axles
Testing pressure oil pump and level controller on rear axle
Removing and Installing rear axle spring struts
Removing and installing front axle spring struts
Removing and Installing spring actuators
Removing and Installing control rod/ connecting rod on level controller
Removing and Installing level controller

Chassis Alignment

General Information on chassis alignment
Checking and adjusting vehicle level at front and rear axles
Checking and adjusting control point of level control
Checking and adjusting ball point position
Checking and adjusting camber and caster at front axle
Checking and adjusting toe-in at front axle
Checking toe-out on turns
Checking camber at rear axle
Checking and adjusting toe-In at rear axle
Measuring rear axle spring link, camber strut, torque strut, thrust arm and track rod
Measuring wheel carrier
Measuring steering knuckle
Measuring lower wishbone

Propeller Shaft

Removal and installation of propeller shaft
Removal and Installation of propeller shaft front axle on 4MATIC
Balancing rear propeller shaft on vehicle
Measuring propeller shaft alignment with mechanical propeller shaft articulation angle meter
Removal and installation of propeller shaft intermediate bearing and renewing of grooved ball bearing
Renewing centering sleeve

Brake System - Hydraulics

Bleeding brake system and replacing brake fluid
Replacing brake hoses
Checking brake system for leakage using pressure tester
Removal and Installation of mechanical stop lamp switch
Removal and Installation of fixed caliper on front axle
Removal and Installation of floating caliper on front axle
Removal and Installation of fixed caliper on rear axle
Disassembly and assembly of fixed caliper
Disassembly and assembly of floating caliper
Checking and replacing brake pads
Checking, removal and Installation of brake disc on front axle
Checking, removal and Installation of brake discs on rear axle
Removal and Installation of stepped tandem master brake cylinder
Reconditioning stepped tandem master brake cylinder
Removal and Installation of parking brake pedal assembly
Removal and Installation of hand brake lever for parking brake
Removal and Install. of release knob for parking brake hand lever
Removal and Installation of front brake control cable
Removal and Installation of rear brake control cable
Removal and Installation of parking brake shoes
Adjusting parking brake

Brake System - Anti Locking brake System (ABS)

Design and function of anti-lock braking system
Important Information on repairs
Removal and Installation of hydraulic unit
Removal and Installation of ABS control unit
Removal and Installation of relays for solenoid valve and charge/return pump
Removal and Installation of overvoltage protection/ basic module
Removal and Installation of front wheel-speed sensors
Removal and Installation of rear wheel-speed sensor
Electrical test program
Test Instructions for ABS tester with fault memory

Brake System - Accelerator Skid Control (ASR)

Design and Function of Acceleration Skid Control ASR II
Removal and Installation of ASR hydraulic unit
Removal and Installation of ASR pressurizing pump
Removal and installation of accumulator
Removal and Installation of left and right rear axle speed sensors
Removal and installation of ASR control unit
Test Program - ASR II electrics
Test Program - ASR II hydraulics
Testing check valve
Checking brake booster
Removal and Installation of brake booster

Steering System

Survey of steering gears
Survey of power steering pumps
Survey of steering linkage
Checking play of steering components
Checking and adjusting friction torque of steering gear
Replacing steering gear when performing repairs to vehicle Involved In accident
Important notes regarding repair of steering gear
Removing and Installing parameter steering
Removing, installing and checking bearing cover with pitman arm shaft
Disassembling and assembling pitman arm shaft bearing cover
Removing and Installing adjusting screw
Removing, Installing and checking play compensator
Removing and Installing steering shaft bearing cover, replacing radial seal ring
Removing, installing and checking control valve
Filling and bleeding the power steering pump/ tandem pump
Disassembling and assembling power steering pump/ tandem pump
Testing oil pressure of power steering pump
Adjusting steering gear In vehicle
Removing, Installing, replacing sealing ring In lower housing cover
Removing and Installing of steering gear
Removing and installing power steering pump
Filling and bleeding power steering pump
Removing and Installing drag link
Removing and Installing steering Idler arm, replacing plain rubber mount
Removing and Installing tie rod
Replacing boot for tie rod ball joint and drag link ball joint
Removing, checking and Installing jacket tube
Dismantling and assembling jacket tube
Removing and Installing the steering lock complete
Removing and Installing lock cylinder
Removing and Installing steering wheel
Removing and Installing contact spiral
Removing and Installing steering angle sensor
Removing and Installing slip ring on steering wheel

Electrical - Instrument Panel, Switches

Initial filling of battery
Treatment of battery when vehicle taken out of use
Installing separate fuse for blower motor
Overvoltage protection relay
Removing and Installing odometer
Hall sensor, road speed signal with mechanical/ electronics speedometer
Testing electronic speedometer
Testing electric oil pressure gauge
Testing gauge for economic driving
Function of fuel gauge sensor
Testing fuel gauge
Testing windscreen washer level Indicator
Removing and Installing rear dome lamp and switch
Location and Identification of fuses and unfused connections
Warning device for parking brake
Charging battery, testing state and capacity
Removing and Installing front fuse and relay box and location of auxiliary fuse boxes
Removing and Installing combination relays
Removing and Installing horns of two-tone signal system or fanfares
Removing and Installing control units of module box
Removing and Installing blower motor for module box
Removing and Installing module box
Removing and Installing combination switch
Removing and Installing switches In center console
Removing and Installing exterior light switch
Electrical connections of optional equipment
Removing and Installing clock tachometer
Removing and Installing speedometer
Removing and Installing speedometer shaft
Removing and Installing Instrument cluster
Testing operation of exterior lamp failure Indicator
Removing and Installing exterior lamp failure monitoring unit
Removing and Installing gauges
Removing and Installing function display
Testing electrical outside temperature display
Removing and Installing temperature sensor of outside temperature display
Function of electronic brightness control of Instrument lighting

Body Glass - Windshield, Back Window, Side Windows,

Removal and Installation of windshield glass
Removal and installation of back window
Removal and installation of ornamental frame back window
Removal and installation of side window in rear passenger
Removal and installation of side window in loading space (T-sedan)
Adjusting rear side window

Body Assembly - Instrument Panel, Center Console, Trim

Removal and installation of instrument panel
Removal and installation of cover for speaker
Removal and installation of cover under instrument panel
Removal and installation of center console
Removal and installation of lateral trim on center console
Removal and Installation of cover on shift lever
Removal and installation of trim on roof frame front
Removal and installation of reveal molding laterally on windshield
Removal and Installation of panel above windshield (convertible)
Removal and Installation of reveal molding at top of windshield( convertible)
Removal and installation of headlining
Removal and Installation of trim on roof frame, rear
Removal and installation of trim on rear pillar
Removal and installation of side wall trim in rear passenger compartment
Removal and installation of electrical roller blind for rear window
Removal and installation of trim on center pillar
Removal and installation of trim on rear center pillar (T-sedan)
Removal and installation of trim in rear compartment (T-sedan)
Removal and installation of trim on rear center piece

Body Assembly - Doors

Removal, installation and adjustment of driver's door
Replacing driver's door
Removal, installation and adjustment of rear door
Replacing rear door
Removal and installation of door lining on driver's door
Removal and installation of door lining on rear door
Disassembly and assembly of door lining on driver's door
Removal and installation of door lining on tailgate (T)
Removal and installation of window crank
Removal and installation of sealing strip
Removal and installation of outside sealing strip
Removal and installation of window lift (power window) on driver's door
Removal and installation of' window lift (power window) on rear door
Removal and installation of electric window lift on driver's door
Removal and installation of electric window lift on rear door
Removal and installation of crank window on driver's door
Removal and installation of crank window on rear door
Adjustment of crank window on driver's door
Removal and installation of fixed window on rear door
Removal and installation of flexible window rail on driver's door
Removal and installation of flexible window rail on rear door
Removal and installation of door holder
Removal and installation of sealing frame on driver's door or rear door
Removal and installation of inside door actuation on driver's door
Removal and installation of inside door actuation on rear door
Removal and installation of outside door handle on driver's door
Removal and installation of outside door handle on rear door
Removal and installation of door lock on driver's door
Removal and installation of door lock on rear door
Removal and installation of inside door actuation on rear door
Removal and installation of outside door handle on driver's door
Removal and installation of outside door handle on rear door
Removal and installation of door lock on driver's door
Removal and installation of door lock on rear door
Removal and installation of door lock on tailgate (T- sedan)
Functional description tailgate lock with electro mechanical closing assist (T-sedan)
Electric wiring diagram (T-sedan)
Testing and replacing microswitch (T-sedan)
Checking and replacing motor (T-sedan)
Removal and installation of tailgate (T-sedan)
Adjustment of tailgate (T-sedan)
Removal and installation of glass pane on tailgate (T -sedan)
Removal and installation of gas pressure spring on tailgate
Removal and installation of ledge grips on tailgate

Body Assembly - Sun Roof, Soft Top, Roof Rails

Removal and installation of headlining on sun roof
Removal and Installation of headlining on cabriolet
Removal and installation of tilting/sliding sun roof top panel
Adjustment of tilting/sliding sun roof top panel
Removal and Installation of gasket and holding rails on sun roof opening
Removal and installation of control cable
Removal and installation of tube
Removal and installation of tube (T -model)
Removal and installation of angular lifting arm on tilting/ sliding sunroof
Removal and installation of motor and gear unit
Checking and adjusting slip clutch for sun roof motor
Removal and installation of wind deflector on tilting/ sliding sun roof
Removal and installation of tilting/ sliding sun roof frame
Removal and installation of soft top (hydraulically control soft top)
Replacement of soft top cover
Adjustment of soft top
Removal and installation of rear window on cabriolet
Removal and installation of left and right catches
Adjustment of handle on catch
Removal and installation of roll-over bar retracted and extended switches
Removal and installation of soft top compartment open switch
Removal and installation of switch assembly on left soft top mount
Removal and installation of soft top bow up (raised) switch
Removal, installation and adjustment of soft top compartment cover switches "closed" and "locked
Removal and installation of soft top control unit
Removal and installation of roof rail (T -model)
Removal and installation of mounts for roof rack (coupe)

Central Locking System

Function description
Checking function of control locking system
Checking electrical function of central locking system
Checking pneumatic function of supply pump
Checking electrical function of actuator
Checking pneumatic function of actuator
Checking central locking system for leaks
Checking pneumatic line for leaks
Removing and Installing actuator
Removing and Installing rear door actuator
Removing and Installing fuel filler flap actuator
Removing and installing supply pump
Function description of Infrared remote control
Checking and replacing batteries for infrared transmitter
Removing and Installing folding key on Infrared transmitter key
Removing and Installing driver door infrared remote control (IFZ) receiver unit
Removing and Installing trunk lid Infrared remote control (IFZ) receiver unit
Removing and installing Infrared remote control unit (IFZ)
Removing and Installing RCL control module (N54) and IR DAS control module
Electric wiring diagrams
Function diagrams

Electrical System - Body- Dome Lamps, Trunk Lamp, Heated Rear Screen, Antenna, Wiper Motor

Removing and Installing dome lamp control unit and rear dome lamp
Function of dome lamp control unit
Function of daytime driving lamp
Retro fitting daytime driving lamp control
Removing and Installing trunk lamp switch
Function of city driving lamp
Testing city driving lamp
Function of tilting/sliding roof, wiring diagrams
Convenience control tilting/sliding roof
Wiring diagram heated rear screen
Function of automatic antenna
Function of headlamp wash/wipe system
Convenience control power windows
Removing and Installing rubber of wiper blade
Removing and Installing wiper motor
Removing and Installing wiper linkage
Removing and Installing rubber seal below wiper gear
Removing and Installing tall gate wiper motor
Function of heated windscreen washer nozzle
Function of heated windscreen washer system
Function of seat heaters
Outside rear-view mirror with electrically heated mirror glass
Power windows
Removing and Installing power seat adjustment switch
Front power seat adjustment
Testing voltage-coded switch for power seat adjustment with memory
Function of anti-theft warning system
Testing anti-theft warning system

Electrical System - Exterior Lighting System, Entertainment System

Adjusting front lighting
Removing and Installing bulbs of headlamp unit
Removing and Installing bulb for ashtray Illumination
Removing and Installing lens of headlamp unit
Removing and Installing headlamp reflector
Removing and Installing fog lamp reflector or high beam headlamp reflector
Testing headlamp range control
Removing and Installing headlamp unit
Removing and Installing tail lamp
Removing and Installing tog lamp
Removing and Installing bulb of fog lamp
Removing and Installing license plate lamp
Function of center high-mounted stop lamp
Light warning buzzer
Operating radio
Removing and Installing radio
Removing and Installing CO player with changer
Removing and Installing receiver and amplifier
Mechanically releasing and removing magazine
Removing and Installing amplifier of sound system
Removing and Installing amplifier of active bass speakers
Removing and Installing speakers In Instrument panel
Removing and Installing speakers In rear
Removing and Installing speakers In front doors
Removing and Installing speakers In rear doors
Removing and Installing antenna
Removing and Installing telescope of automatic antenna

Body Assembly- Front and Rear Bumpers. Radiator Cowl, Mercedes Star

Removal and installation of front fender
Removal and installation of front bumper
Removal and Installation of molding on front bumper
Disassembly and assembly of front and rear bumpers
Removal and installation of rear bumper
Removal and Installation of molding on rear bumper
Removal and installation of engine hood
Adjustment of engine hood
Removal and installation of engine hood hinge
Removal and installation of control cable for engine hood
Removal and Installation of radiator cowling
Removal and installation of radiator grille
Removal and installation of trim strips on radiator grille
Removal and installation of Mercedes star
Removal and installation of trunk lid
Attachment of model designation on trunk lid
Removal and installation of hinge lever on trunk lid and soft top compartment cover
Adjustment of trunk lid
Removal, Installation and adjustment of soft top compartment cover (convertible)
Removal and installation of trim on side wall
Removal and installation of protective strip on side wall
Removal and installation of trim on frame side member (coupe)
Removal and installation of water deflector on front wall pillar and on roof
Removal and installation of sectional sealing strip on roof frame (coupe)
Removal and installation of outside mirror
Removal and installation of electrically adjustable outside mirror

Body Assembly- Head Restraints, Drivers Seat, Rear Seat, Seat Coverings

Removal and installation of adjusting rail for head restraint
Removal and Installation of guide rail for head restraint
Removal and installation of driver's seat
Removal and installation of front passenger seat
Layout and operation of backrest lock (coupe)
Removal and installation of vacuum element of driver's or front passenger seat (coupe)
Removal and installation of vacuum switch on driver's backrest( coupe)
Removal and installation of gear unit for backrest adjustment
Removal and Installation of driver's seat height adjustment
Function diagram of backrest lock (coupe)
Eliminating noises from front seats
Removal and installation of armrest with lifting mechanism on driver's seat (coupe)
Removal and installation of rear seat and rear seat backrest
Modification of rear seat backrest mounting (coupe)
Removal and installation of folding armrest for rear seat (coupe)
Removal and installation of driver's seat cushion cover
Removal and installation of driver's backrest cover
Removal and installation of tensioning member on driver's or front passenger backrest
Removal and installation of front belt tensioner
Removal and installation of complete seat belt extender
Removal and installation of seat belt extender rack

SRS System - Airbags, Belt Tensioners, Seat Belts

Description of operation of airbag with belt tensioner
Safety regulations for airbags and belt tensioners
Removing and Installing control unit for airbag and belt tensioners
Renewal regulations for seat belts
Removing and installing seat belt with belt tensioner
Removing and Installing belt buckle
Removing and Installing reserve power source for airbag and belt tensioner
Removing and Installing voltage transformer for airbag and belt tensioner
Removing and installing airbag unit In steering wheel
Removing and Installing passenger airbag unit
Test program for airbag and belt tensioner
Test program for belt tensioner (without airbag)

Climate Controlled Air Conditioning System Shop Manual

Instructions for use of service manual
Engine and vehicle identification
Vehicle identification number locations
Removal and Installation of heat exchanger
Checking oil level in A/C compressor
Removal and installation of A/C compressor
Removal and installation of speed sensor on A/C compressor
Replacing shaft seal on A/C compressor
Removal and installation of electromagnetic clutch, removal, installation and checking of solenoid coil
Removal and installation of series resistor for auxiliary fan
Removal and installation of condenser
Removal and installation of fluid reservoir
Testing, removal and installation of pressure switch for A/C compressor in fluid reservoir
Testing, removal and installation of pressure switch for auxiliary fan in fluid reservoir
Testing, removal and Installation of evaporator temperature sensor
Testing, removal and installation of outside air temperature sensor
Removal and installation of expansion valve
Removal and installation of evaporator
Removal and installation of blower motor
Removal and installation of air conditioner/ automatic temperature control unit
Removal and replacement of auxiliary fan
Testing, removal and Installation of switch for air conditioner/ automatic temperature control
Testing, removal and installation of switch for fresh air/ recirculated air
Removal and installation of switch-over valve for fresh air/ recirculated air flap
Removal and installation of vacuum elements
Testing, removal and installation of speed sensor on starter ring gear
Description of function of automatic climate control
Checking functions of automatic climate control
Checking regulating quality and heating output
Testing the automatic climate control with the impulse counter
Checking electric components of the automatic climate control
Checking compressor cut off and remedial measures
Electric circuit diagrams
Checking refrigerating capacity (short test)
Checking refrigerating capacity and suction/high pressure
Checking flap control vacuum system for leaks
Removal and installation of heat exchanger
Removal and installation of mono valve
Removal and installation of heating water circulating pump
Automatic climate control unit
Removal and installation of aspirator blower (M9) for temperature sensor interior air
Removal and installation, testing of temperature sensor interior air
Removal and installation, testing of temperature sensor heat exchanger
Removal and installation, testing of temperature sensor evaporator
Removal and installation, testing of temperature sensor outside air
Removal and installation, testing of fresh/recirculated air switch
Removal and installation of switch over valve block
Removal and installation of vacuum elements
Removal and installation of electronic blower regulator

Cruise Control Shop Manual

Functional Description
Pushbutton Switch
Cruise Control Amplifier
Road Speed Sensor
Cruise Control Actuator
Hints for troubleshooting
Testing with Adapter
Test Program Survey
Testing reference resistor
Removal and Installation of Cruise Control Actuator
Removal and Installation of pushbutton switch
Removal and Installation of sensor
Adjusting Connecting rod to control cable
Removal and Installation of cruise control amplifier
Removal and Installation of cruise control reference resistor
Removal and Installation of switch on clutch pedal
Installation of relay against partial load shaking
Installation of relay against deceleration shaking
Layout of connectors
Wiring Diagrams

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Language: English

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