1967-1976 Mercedes-Benz W115 Service Repair Workshop Manual PDF

VEHICLE/EQUIPMENT INTRODUCTION:
The Mercedes-Benz W115 series, part of the renowned Strich Acht (Stroke Eight) generation produced from 1967 through 1976, represents the four-cylinder variant of Mercedes-Benz's compact executive sedan line. Sharing its elegant unibody platform with the six-cylinder W114 models, the W115 was fitted with fuel-efficient and remarkably durable four-cylinder diesel and gasoline engines that earned a reputation for nearly indestructible longevity. Models include the 200, 220, 220D, 240D, and the turbocharged 300D which became legendary as the first mass-produced diesel sedan with a turbocharger. These vehicles embody the Mercedes engineering ethos of the era, where vehicles were designed with generous tolerances, premium materials, and service intervals measured conservatively. The 240D in particular is celebrated as one of the most reliable cars ever built, commonly exceeding 300,000 miles with routine maintenance.

SERVICE & REPAIR SCOPE:
- Complete OM615 and OM616 diesel engine overhaul procedures
- Inline-four gasoline engine (M115) rebuild and valve adjustment
- Diesel fuel injection pump timing and nozzle servicing
- Manual transmission rebuild with overdrive repair
- Automatic transmission valve body service and band adjustment
- Diesel cold start system servicing with glow plug circuit testing
- Exhaust system manifold gasket and exhaust pipe service
- Front double wishbone suspension bushing and ball joint replacement
- Rear semi-trailing arm subframe bushing and alignment
- Brake system overhaul including booster, caliper, and wheel cylinder service
- Alternator overhaul and voltage regulator testing
- Recirculating ball power steering box adjustment and pitman arm service
- Complete body electrical wiring and harness schematic reference
- Heating and ventilation system heater core replacement
- Body structure including rust-prone areas identification
- Interior trim and instrument cluster servicing

TECHNICAL SPECIFICATIONS:
- Vehicle: Mercedes-Benz W115 series (/8 Stroke Eight)
- Model years: 1967 through 1976
- Engine options: OM615 2.0L/2.2L diesel, OM616 2.4L diesel, OM617 3.0L turbo diesel (300D), M115 2.0L/2.3L gasoline
- Valve train: SOHC inline-four (gasoline), overhead camshaft inline-four (diesel)
- Transmissions: 4-speed manual, 5-speed manual with overdrive, 4-speed automatic
- Drive layout: Front engine, rear-wheel drive
- Front suspension: Independent double wishbone with coil springs
- Rear suspension: Semi-trailing arm independent rear suspension
- Brakes: Front disc, rear disc or drum (model-dependent)
- Steering: Recirculating ball with optional power assistance
- Body: 4-door sedan, 5-door station wagon (S-115)

DIAGNOSTIC INFORMATION:
- Diesel engine will not start in cold weather: Verify glow plug relay is engaging, test each glow plug continuity with ohmmeter, bleed fuel system to remove air, verify fuel is not gelled in extreme cold
- Blue smoke from diesel exhaust: Inspect valve guide seals, check turbocharger oil seal condition on 300D, verify piston ring condition (excessive blow-by), confirm oil type and viscosity specification
- Diesel engine knocking loudly: Check fuel injection timing with timing light, inspect injection advance mechanism in pump, verify correct fuel cetane rating, test individual injector nozzle spray pattern
- Overheating gasoline engine: Inspect viscous fan clutch engagement, verify thermostat specification (80C standard), clean radiator fins, test water pump circulation by observing coolant flow in radiator neck
- Manual transmission difficult shifting: Check clutch hydraulic system for proper disengagement, inspect synchromesh ring wear on target gear, verify shift linkage adjustment and bushing condition
- Front suspension clunk over bumps: Inspect lower control arm front and rear bushings, check ball joint upper and lower play, verify stabilizer bar bushing condition, test shock absorber damping response
- Electrical system charging light on: Test alternator output voltage at B+ terminal (should be 13.5-14.5V with engine running), inspect carbon brush wear in alternator, check voltage regulator function, verify engine ground strap integrity
- Rear suspension sag on diesel models: Diesels are heavier in front; if rear sags, inspect rear coil spring fatigue, check semi-trailing arm bushing deflection, verify subframe mounting bolt torque

ILLUSTRATIONS & DIAGRAMS INCLUDED:
- Complete inline-four engine cross-sections for both diesel and gasoline variants
- Diesel fuel injection pump cross-section with governor and advance mechanism
- Complete engine bay layout showing accessory drive belt routing and tension
- Front double wishbone suspension geometry with bushing identification
- Rear semi-trailing arm suspension assembly with subframe mounting detail
- Brake hydraulic system layout with power booster cross-section
- Alternator exploded view showing brush holder and regulator wiring
- Complete vehicle electrical wiring harness diagram with circuit numbering
- Heating system ducting layout and blend door operation diagram
- Body structure with known corrosion-susceptible area identification
- Dashboard instrument cluster component identification and wiring

COMPATIBILITY:
- Mercedes-Benz W115 series (four-cylinder models): 200, 220, 220D, 240D, 300D
- Model years 1967 through 1976
- Sedan and station wagon (S-115) body styles
- All engine variants: OM615, OM616, OM617 diesel; M115 gasoline
- Manual and automatic transmission configurations
- 3867 pages of comprehensive service information
- English language edition
- PDF format, fully searchable and printable

FILE PROPERTIES:
- Format: Searchable PDF (3867 pages)
- Language: English
- Delivery: Instant digital download
- Access: Download anytime after purchase

1967-1976 Mercedes-Benz W115 Service Repair Workshop Manual PDF

VEHICLE/EQUIPMENT INTRODUCTION:
The Mercedes-Benz W115 series, part of the renowned Strich Acht (Stroke Eight) generation produced from 1967 through 1976, represents the four-cylinder variant of Mercedes-Benz's compact executive sedan line. Sharing its elegant unibody platform with the six-cylinder W114 models, the W115 was fitted with fuel-efficient and remarkably durable four-cylinder diesel and gasoline engines that earned a reputation for nearly indestructible longevity. Models include the 200, 220, 220D, 240D, and the turbocharged 300D which became legendary as the first mass-produced diesel sedan with a turbocharger. These vehicles embody the Mercedes engineering ethos of the era, where vehicles were designed with generous tolerances, premium materials, and service intervals measured conservatively. The 240D in particular is celebrated as one of the most reliable cars ever built, commonly exceeding 300,000 miles with routine maintenance.

SERVICE & REPAIR SCOPE:
- Complete OM615 and OM616 diesel engine overhaul procedures
- Inline-four gasoline engine (M115) rebuild and valve adjustment
- Diesel fuel injection pump timing and nozzle servicing
- Manual transmission rebuild with overdrive repair
- Automatic transmission valve body service and band adjustment
- Diesel cold start system servicing with glow plug circuit testing
- Exhaust system manifold gasket and exhaust pipe service
- Front double wishbone suspension bushing and ball joint replacement
- Rear semi-trailing arm subframe bushing and alignment
- Brake system overhaul including booster, caliper, and wheel cylinder service
- Alternator overhaul and voltage regulator testing
- Recirculating ball power steering box adjustment and pitman arm service
- Complete body electrical wiring and harness schematic reference
- Heating and ventilation system heater core replacement
- Body structure including rust-prone areas identification
- Interior trim and instrument cluster servicing

TECHNICAL SPECIFICATIONS:
- Vehicle: Mercedes-Benz W115 series (/8 Stroke Eight)
- Model years: 1967 through 1976
- Engine options: OM615 2.0L/2.2L diesel, OM616 2.4L diesel, OM617 3.0L turbo diesel (300D), M115 2.0L/2.3L gasoline
- Valve train: SOHC inline-four (gasoline), overhead camshaft inline-four (diesel)
- Transmissions: 4-speed manual, 5-speed manual with overdrive, 4-speed automatic
- Drive layout: Front engine, rear-wheel drive
- Front suspension: Independent double wishbone with coil springs
- Rear suspension: Semi-trailing arm independent rear suspension
- Brakes: Front disc, rear disc or drum (model-dependent)
- Steering: Recirculating ball with optional power assistance
- Body: 4-door sedan, 5-door station wagon (S-115)

DIAGNOSTIC INFORMATION:
- Diesel engine will not start in cold weather: Verify glow plug relay is engaging, test each glow plug continuity with ohmmeter, bleed fuel system to remove air, verify fuel is not gelled in extreme cold
- Blue smoke from diesel exhaust: Inspect valve guide seals, check turbocharger oil seal condition on 300D, verify piston ring condition (excessive blow-by), confirm oil type and viscosity specification
- Diesel engine knocking loudly: Check fuel injection timing with timing light, inspect injection advance mechanism in pump, verify correct fuel cetane rating, test individual injector nozzle spray pattern
- Overheating gasoline engine: Inspect viscous fan clutch engagement, verify thermostat specification (80C standard), clean radiator fins, test water pump circulation by observing coolant flow in radiator neck
- Manual transmission difficult shifting: Check clutch hydraulic system for proper disengagement, inspect synchromesh ring wear on target gear, verify shift linkage adjustment and bushing condition
- Front suspension clunk over bumps: Inspect lower control arm front and rear bushings, check ball joint upper and lower play, verify stabilizer bar bushing condition, test shock absorber damping response
- Electrical system charging light on: Test alternator output voltage at B+ terminal (should be 13.5-14.5V with engine running), inspect carbon brush wear in alternator, check voltage regulator function, verify engine ground strap integrity
- Rear suspension sag on diesel models: Diesels are heavier in front; if rear sags, inspect rear coil spring fatigue, check semi-trailing arm bushing deflection, verify subframe mounting bolt torque

ILLUSTRATIONS & DIAGRAMS INCLUDED:
- Complete inline-four engine cross-sections for both diesel and gasoline variants
- Diesel fuel injection pump cross-section with governor and advance mechanism
- Complete engine bay layout showing accessory drive belt routing and tension
- Front double wishbone suspension geometry with bushing identification
- Rear semi-trailing arm suspension assembly with subframe mounting detail
- Brake hydraulic system layout with power booster cross-section
- Alternator exploded view showing brush holder and regulator wiring
- Complete vehicle electrical wiring harness diagram with circuit numbering
- Heating system ducting layout and blend door operation diagram
- Body structure with known corrosion-susceptible area identification
- Dashboard instrument cluster component identification and wiring

COMPATIBILITY:
- Mercedes-Benz W115 series (four-cylinder models): 200, 220, 220D, 240D, 300D
- Model years 1967 through 1976
- Sedan and station wagon (S-115) body styles
- All engine variants: OM615, OM616, OM617 diesel; M115 gasoline
- Manual and automatic transmission configurations
- 3867 pages of comprehensive service information
- English language edition
- PDF format, fully searchable and printable

FILE PROPERTIES:
- Format: Searchable PDF (3867 pages)
- Language: English
- Delivery: Instant digital download
- Access: Download anytime after purchase