207D 209D

307D 309D
407D 409D
Operating
Instructions

J
Mercedes-Benz

Mercedes-Benz
service

......

207D 209-D
307D ~ 309D
Operating
Instructions 407D 409D
Printed in Germany
We reserve the rig ht to modify the technical details as given in the data and ill us-
trations 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 essent ial quest ions concerning operation, service
and maintenance.
In some sections you will in addition find instru ct ions for the
economic operation of your vehicle. By comply ing with these
instructions you can assist in effectively reduci ng the fuel con-
sumption (energy consumption).
To ensure continuous operational reliability and roadworthi -
ness, we strongly recommend that service and maintenance
work listed in the Maintenance Booklet be carried out on time.
For this purpose, an exte nsive network of MERCEDES-BENZ
service stations is at your disposa l.
Before operati ng the vehicle for the first time, please refer to the
sect ions entitl ed

"Components" and "Operation"

Several vehicle types whose principal components are identi-

cal are dea lt with in these Ope rating Instruc tions.
Besides this important optional extras are included. Your ve-
hicle may the refo re differ from some of the descript ions and
illustrations.

We wish yo u good motoring!

Daimler-Benz Aktiengesellschaft

3
Conten ts

Page Page
Components 6 4 The vehicle, service and ma intenanc e 43
11 Door control front . 6 41 Engine 45
12 Driver's seat adjustme nt 7
13 Seat be lt . 7 4 11 011,incl liltur ch,inno 45
1.4 Instruments - su mmary . 6 412 lnsprn llnq unct smv1c:u1u,11,dn11110, 46
1.5 Indicator lights and switches 10 413 nornovt1I nnd in&t lllullon ol <.yllnclPr hcild cove r 47
16 Light switch .... 12 414 AdJU.Jt1nuv»lvn CIP tr IIICtJ .. .. .. .. 47
17 Combination switch .. 12
1.6 Steering lock 13
19 Tachograph 13
110 Radio 14 4.2 f uel ay111,un 46
1.11 Heating and ventilation 16
1.12 Headlight beam contro l 16 421 l11t1 ljH{;lllll'I 46
1 13 Interior light 16 422 H1•11ln11111
lho luol llih r 46
1.14 Interior mirror . . . 16 4 23 , d111u
1111 '"t'
1 ov 1.. m
1111 . . ..... 49
1.15 Seat lock - assistan t driver's seat . 19
1.16 Head rest .. 20
117 Door control - cargo space 20
1 16 Engine cover 22 4.3 Coollny •v• tt1,u 50
1.19 Engine compartment flap . 23
431 1>uu11inQtooh111ttuul llllinq syslmn with coolant 50
432 <.10:11111,g
1111cooll11qhmt hottting systems 51
433 V 111111 51
2 Operation 24
2.1 Preparallons for driving 24
22 Starting and shu tting off the eng ine 29 44 C.lulc h 53
2.3 Hand brake operation 30
24 Starting the vehicle and shifting gears 30 44 1 Hyth ult• aoc11ons01 c1u1,h and brake
25 Breaking-in .. 33 flV!I IPII I , '"" ku1u llutd lovol .' ... .... . 53
2.6 Driving and braki ng 34
2.7 Trailer .. 37
26 Wi nter operation .. 36
4.5 To111•ml11lun .. .. .... 54
451 M11 u, ,, 111•,1111111011 .. .... . . 54
3 Fuels , coolants, lubricants, etc. 40 4 5 1 1 011 hwol chm. k tout 011 t.:h,rngo ... .... ... 54
4512 Cl11u11111u IJroutrw, 54
3 1 Diesel fuels 40 452 Ml I trnlOUl•lliC lri,trl:UrnS510fl 54
32 Engine oils 41 4521 011tovl'i c ""' k 55
33 Coolants 42 4522 0,1 HIIII flllPI < hanqn 55

4
Page
Pago Page
43
4 II Rear axle 57 4 . 1:1 Preparing the vehicle for storage . 71
45
OIi level check and oi l change 57 4 , 13 Preparing the vehicle for service after storage 72
45
46
47 ~ Troubleshooting 73
47 4 , Steering 58
,, 1 Engine and fuel sys tem ... .... . .. 73
•1 7 I Checking the steering linkage 58 ~;> Clutch. 74
,1 ( 'l. Chec king steering free play .. 58 53 Steering 75
,1 7 3 Checking oil level 59 Brake system .
48 !J4 76
" ( ·1 Checking the toe- in 59 5 !> Electrica l system 77
48 56 Supp lementary heater . 78
48 57 Shutt ing off the engine when the vacuum system is faulty 79
49 58 Tow-s tarting and tow ing the vehicle . ....... . 80
4 II Wheels and tires 60
481 Spa re wheel locat ion 60 6 Technical data . 82
48? Wheel change 61
50 6 1 Data cards/identifica1 ion plates 82
62 Weights 84
50
51
63 Main dimensions 84
Brake system 62 64 Engine ..... . ... ... . 85
51
,1 11
65 Cooling sys tem 86
Checking the brake lines . 62 66 Clutch . 86
,1.112 Checking brake lining thickness 62 67 Transmiss ion . ___ .. . .. . _ 86
~, 'I 3 Hydraulic sections of clu tch and brake 68 Steering system 87
53 systems - checking fluid level 64 69 Front ax le .. 87
Bleeding the brake system 65 610 Rear axle . 88
6.11 Brake system .. 89
53 612 Electr ica l system ....... •. . . . .... ....... .. . 90
410 Electrical system 66
7 Tightening torques ..... ..... . . .. . .. . ....... . . . .... . . 97
54 ·1 10 1 Three-phase alternator 66
., 10 7 Fuses 66
54 4 103 Checking the headlighl alignmenl . 68 8 Capacities - summary 98
54 1104 Headlight bu lb rep lace ment 68
54 ·I 10 5 Battery care . . .... ... .... ... ..•. . 69
54 9 Service and maintenance jobs - summary 100
55
55
4 11 Vehicle cleaning and care 70 Tire pressure chart

5
1 Components 1.1 Door control front

Hinged door

Door control, outside Door and window contro l, inside

1 Locked 1 Door latch unlocked
2 Unlocked 2 Door latch locked
To open the door, 3 Opening lever, door
press in door lock cylinder <1 Window crank

6
I 'J Driver's seat adjustment
• ,I, 111dord
version
I tcight of seat, front portion
,' I orward and rearward
I tc ,ght of seat, rear portion
,1 Sca t back
1.3 Seat belt (example)
Make Bremshey Fastening:
1 Seat load 1. Pull belt with tongue (1) over shoulder
2 Seat load scale and lap. The belt must not be twisted
3 Height of seat , front and rear but must be tight.
4 Seat back
2. Press tongue (1) into buckle (2) and
5 Forward and rearward
allow to engage audibly.
6 Seat lock
Lever moved to tho right = locked Unfastening:
Lever moved to tho left = released
1. Depress red button in buckle (3).
2. Return tongue (1) to initial pos ition.
Note :
The inertia reel of the seat belt stops the
belt unwinding further in case of vehicle
decelera tion in any direction and if the belt
is pulled out quickly.
7
 1.4 Instruments - summary

Ventilation and defrost ing nozzles for side windows 10 Plug socke t
(page 16)
11 Rmho (page 14)
2 Light switch (page 12)
12 Ashtmy
3 Coo lant temperature gauge
13 E11g1no
cove r
4 Indicator lig hts (page 10)
14 Clock
5 Speedometer or tachograph (page 13)
15 Stec , 1ng lock (page 13)
6 Selector lever position indica tor - MB automatic trans-
mission or fuel gauge (page 31) 16 Horn

7 Idle speed co ntrol (page 29) 17 Fuol gaugo or operat ing hours indica tor

8 Switche s (page 10) 18 Co111

ti11
1i1l1on switch (page 12)

9 Heating and vent ilation (page 16) 19 Pull knot,, engine co mpartment flap (page 23)

l
9
 1.5 Indicator lights and switches

•,wile 11,,,,.111cl1ndicat or lights.

Th e fo llow ing sym bo ls have b ee n c hosen to fac ilitate id entification of tht> 111ct1v1ch1.il

Indicator lights

Hig h bea m 6 Cl 1i111w l11dh,,tm hqhl (page 36)

2 Preglow ing 7 Brnk1• lh11ct,11Hll>ruko pad wear (page 34)
3 Turn sign al indicator light - tractor 8 011 JIIIH,'11111' lll191n0
4 Tu rn signal ind ica tor light - trailer 9 I l<'dl«'cl 1<'111WlllCIOW

5 Rotary flas hing beacon 10 Supph11111111

t111yheater (page 16)

Switche s

11 Blowe r, hig h speed - low speed (page 16) 15 Supp lt>11

H•11
t,11y heater (page 16)
12 Heated rea r window 16 Haz,ucl wi1111111qfl,1sher swi t ch wit h ind icator light
13 Rotary flas hing b eaco n 17 Light •,w1tc 11(pogo 12)
14 Interior light - b us

10

L
11
1
1.6 Light switch 1.7 Combina tion switch

0 Off-position 1 Low beam li Windshield washer/head lig ht washer

1 Parking lights
2 Headlights
3 Standing lights, right
4 Standing lights, left
A As pos ition 1 or 2 plus fog lights
B As pos ition 1 or 2 plus rear fog light
with ind icator light
2 High beam
3 Headlight flasher
4 Turn signal lig hts, right
5 Turn signa l lights , left
Note:
Switch ing on turn signal lights
Up to point of resistance= bnef fln~.11111q Check wiper blades regularly for soil ing
Beyond point of resistance (engagmwnl)
= cont inuous flashin g
Noto: When the windsh ield washer sys-
h•m 1sact uated, the windshield wipers are
r1lsoswitche d on.
1110 head light washer (optional) is o nly
orwrated when the vehicle lights are
,;witched on .
r1mt ctnmage.
7 Windshield wiper
Position "O" = off
Position "I"= intermittent wip ing
Position "II"= low speed
Position "Ill" = high speed

12
 I It looring lock 1.9 Tachograph (uxiunp lo)

0
;;;
0
"'
(!)

1sher II I ht> key can be removed only in this 1 Time group knoll
· sys- pos1llon. 2 Speedomet er
rsare I ho steering is locked when the key is 3 Speed warni ng ltqht
w1lh clrawn. 4 Clock function co ntrol light
• ,It •t'rtng unlocked 5 Tachog raph funcllon control light
only I 'tt'q lowing and driving position The control light comes on if no dia-
; are • ,I, 11t1ng position gram chart is inserted or if the tacho-
graph is def ect1vo.
:,iling Brief lightin g up of the control light
while the tachog raph is opened or
closed proves the co ntrol light to be in
good working ardor

13
 1.10 Radio

1 On-Off/Volume control
2 Tone control
3 Push button s for band selcc tton and tuning of preset sta-
tions
4 Manual tuni ng co ntrol
5 Cassette release
6 r ast forwnrcl
7 Fast rt•wind
8 Ca'iSoll t' slot
Radio with push buttons for band selection and tuning of preset 9 Wavo llancJ11 1ellc.i tor
stations

j1

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

I
I 14
 11nl' con trol
1111I 1111Voh I lw rad io will th en switch over from radio recep tion to tape play-
I iack. The cassette wi ll be released auto maticall y as soon as the
111111
k1111ll(1) c lockw ise to sw itch on radio and to incr ease
lapo reaches its end.
v11h11111•
I ho qreen co ntrol light w ill come on.
,et sta- Io piny the other side of the tape, turn casse tte upside down and
1111111 101nscrt it into cassette slot.
ll1111l11v,.,(2) to alter the tone . lo manua lly eject the cassette, push release bar (5). When t he
c.issette is ejected, the unit wil l swi tch over to radio recep tion
111111111
l11111ng 11
ul omat ically .
1 1111
I ch•s1redwave band by pushing the respective button (3). I 'ush button 6 or 7 for fast forward or rewi nd of the tape. Briefly
I 111w11v11l>and selec ted is ind icated by wave band indicator (9) touching the counteracting button wil l stop the winding pro-
1111cl11!,lll!d statio n is tuned in by turn ing the man ual tuning cess.
~11f1lo (4) f or good reception, accurate manual tuning is impor-
t 1111
1111111•·,nl stat ions of var ious wave bands pull out preset button
( II 1111111•sto p, tune in station w ith manual tuning knob (4) and Serv ice and Maintenance
1111 .i, prnsct butto n in again to the stop.
Since deposi ts on the pick-up head are inevitable after extend -
ed opera tion, the cassette shou ld be c leaned wit h a cleaning
I 1111,
I 1i,1yback
cassette if the qua lity of the sound rep roduc tion dec lines . After
f 111
1v 11•,1•brand C 60 or C 90 cassettes. Push cassette into approx. 500 operating hours the unit should be inspected by a
l fl ,1•111•
slot as far as it w ill go with the full reel on the right side. special ist.

15
1.11 Heating and ventilation
Control levers are infinitely variable Adj ust ing examp les:

Blower switch: press upper end = low speed When defros tin g windows
center position =off 1 - press lowe r end
press lower end = high speed 2 right
3 right
2 Ventilating or defrosting windshield
4 - left
Lever position : left = closed
right = open 8 - turn nozzles towards side wi ndow and
ope n them
3 Contro l valve for heater
Lever position: left - cold For full heati ng capaci ty
right =warm 1 = press lower end
2 right
4 Ventilating or heating footwell
3 nght
Lever position: left = closed 4 - right
right - open
5 Supplementary heater For full ventllal1011
switch: press upper end - on 1 - press lowl'r encl
press lower end = off 2 - nght
3 = left
6 Ventilation and defrosting nozzles - windshield 4 = right
7 Ventilatio n and heating nozzles - footw ell
8 Ventilatio n and defrosting nozzles, adjustable
The nozzles can be opened and close d with the lever
in the nozzles.

Supplementary heater
The supp lementary heater can be operated with the engine on
or off.
Switching on supplementary heate r: Swit ching off supple mentary heater:
Actuate toggle switc h. The indicator light on the inst rument Actu ate togg le switch . The indica tor light goes out. The heate r
panel comes on. The heater will come on after approx . con tinues to opera te for about 2 minutes and th en switch es off
2 minutes. autom atically .

16
,eater
1esoff

17
1.12 Headlight beam control 1.13 Interior light (examp le) 1.14 Interior mirror

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

2~1

0 Normal position Position 1: On Operating lever

I Vehicle with maximum load Position 2: Off 1 Normal pos ition
(with evenly spread load) Position 3: Light is switched on ,IIH I oll :> Dimming positio n
Vehicle with maximum load by the door contact
(with large part of load shifted to rear
axle)

18
t I nnt lock - assistant driver's seat

I lt1locking right Unlockin g left

r >porate lever, tilt seat forward or Operate lever, ti lt seal forward or back-
l>ilc:kward unti l lock engages . ward until lock engages.

19
1.16 Headrest (examp le) 1.17 Door control - cargo space

IE
Height and inclination of headrest can be Rear door
adjusted.
Door control, outside (example) Door con trol, inside

Unlocked 1 Door latch unlocked

To open the door , press
in door lock cyl inder
2 Locked
2 Door latch locked
3 Opening lever of 1st door
4 Lock of 2nd door
r o open, swing handle up.

20
no
-
.,
-- -N N
0
5 ............ __ 21
g
:::J ~

fl 1111111 le 90°
,111q Opening angle 180" Opening ang le 270 °

I , " klnq hook 1 Locking hook Door lock

, 1111111 ctoor 90 ° and engage locking 2 Door strap
111111k
Disengage lockin g hook, swing door strap
I I 1111p inward.
I ... 1,,11lock ing hook before closing Open door 180° and 0ngage locking hoo k.
1111·door. Prior to closing the door, engage door
strap. Attach locking hook .
Disengage locking hook, swing door strap
inward .
Open door 270 °. Engage lock.
To unlock, pull forward latch in the door
lock.
Prio r to closing the doo r, engage door
strap. Fasten locking hook.

21
 1.18 Engine cover

1~ 3

•
Slid ing door Open ing the eng ine cover
Door control, outside Door control, inside Clamp

1 Locked 1 Door latch unlocked Noto

2 Unlocked 2 Door latch locke d Prior lo the detachment of the eng ine
covor, remove driver's seat.
To open the door , press in door lock cy lin- 3 Opening lever, door
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
 I I U r 11ul11t1
<-<>mpartmentflap

engine compartme nt flap

11111111h11 Closing the engine compa rtment flap
l· 1101>
I 1111 Lift securing device

·ngine

23

1 Fuel tan k - cargo 1ruck (exa mple)
1 Fuel tank - de livery van
24
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:,hP 1
Prior to starting the engine
- Fuel reserve
- Vehicle lighting, turn signal a11ct•,lop l1ql1ts
- Oil level in engine
After having started the engino
- Engine oil pressur e
- Steering free play
- Tachograph for proper function
Fuel reserve
Turn steering lock to driving position Chec k ruel level, rep lenish if necessary.
Prior to filling the fuel tank , shut off ong 1ne and supp lementary heater.
Always keep the fuel tank vent c lean Do not 111 1 ruel tank to the brim because of heat
expansion.
For summer and winter operation vehicle diesel fuels, refer to "Fuels, coolants, lu bricants,
etc." .
 V•hlt:le lighting, turn signal and stop lights

'" " llqlit111qsystem inc luding the stop lights must be checked daily for good condition
I , lo,,111lenses . If bulbs have to be rep laced, observe the specifi ed voltages. Refer to
1111
Ir l111lcaldata".

, hazard
OIi ievei In engine

V1l11oIP has to be on level ground w hen oil leve l in oi l sump is c hec ked . Oil level to be
t111111wll ere betwee n the lower and the upper mark on the oil dip stick . Oil level should not
, , , ,•I'd the upper mark .
, ,11111011
Use only engine oi ls of specified SAE grades (viscosity ranges ). Refer to "Fuels,
t • ", 1.111t
s,
lubricants , etc .".
Engin e compartme nt flap opene d
1 Oil dips tick
2 Oil filler nec k

leering free play

M,1111ml
steering
· ,li ould the re be any free play in the steering, have the steerin g system adjusted at a
Mt HCEDES-BENZ serv ice station immediately .
I , 1wPr steeri ng
1111 • wheels mus t 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
,111v1c e statio n.

of heat I unction test - tachograph

,ricants , I li t>indicator light must not come on. Brief lig hting while opening or closing the tachp-
111c1phindicates that the light is in good wo rking order . 1 Tacho graph funct io n co ntrol lig ht

25
 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

Eng,ne compartment flap opened

1 Filler hole - coolant
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 coo lanttemperature
is above 194° F (90° C).
After having added coolant, seal coo lant 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 qua lity) 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, lubri can ts. etc.".

Power steering - oil level

Engine compartment flap opened
1 Power steering oil reservoir The oil reservoir is filled correctly if the oil level reaches the mark in the oi l reservoir.

26
 Hydraulic clutch control and hydraulic brake system - fluid level

The trans lucent 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 suffic iently . If brake flu id needs to be replenished , have the hydrau lic system
inspected.

Soiling of air cleaner

or leaks
If the complete red field is visible in the service indicator , actuate push button to
disengage the colored field. Clean or renew filter element.

Eng ine compartment flap o p ened

1 Brake fluid reservoir

Batteries - fluid level

iss than I he batteries are located below the driver's and assistant driver's seats.
ierature
I he electrolyte level in each cell must be app rox. 15 mm (0.6 in) above the upper edge of
the plates. Only replen ish with distilled water. During the hot season, chec k battery
i briefly , ••lectrolyte level more frequently.

content
all year

:rvoir. ·------
Service indicator for pape r air cleaner
1 Inspection g lass for co lore d field
2 Push butt on

27
 Windshield washer system - fluid level

The winds hield wash er reservoir ts .tr.coss1ble after opening th e 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 11nwindingfurther if the vehic le
- is braked or acceler ated
- is cornering
- or when the belt is pulled out q111ckly
Inspect belts vis ually for damaqo nl'lww damaged seat belts.
Engine compartment flap opened
t Reservoir of windshield washer system

Inflation pressure and condition of tires

Check inflation pressur e on cold t1rt•i; 1110pressure d ifferent ial of the tires on one axle
must not exceed 0, 1 bar (1,4 psi) I flqh 'l l >l'CCIope ration or hot weathe r may increase the
tire inflation pressure as much as 1 llnr ( 14 psi) Never bleed any air as the pressure will
otherwise d rop below spec ificatio ns f or tire inflation pressure , refer to ''Tire pressure
chart".
 1111
,t111unnd shutting off the engine
)artme nt
I , I " , 111, nwasures before starting an eng ine for t he first timu, 1ll or 11has been
I rr 1111"11111clod
period. Refer to "Preparing the vehicle for sorvic 1• u tter sto rage".
II ti 111111
.·.11111
to neutra l (MB automatic transmi ssio n selector lovor pos ition "P" o r
nu
I ,u, hn11cll)rake o r service brake .

11 t 1 ,11111
I()( k key a nd turn to driving position. The c harge indica to r light and the
11w11111·11ul1catorlight will come on .
11lh1 111, •qlowing" indicatorlightgoesout, this isan indication thut llw eng ine can be
I I I 11111
·,ll'(Jrtng lock key all the way to th e right to start th e enq111e
I 11111111.iqain,
return key to the stop.
11lh• 1•111 1111
0 ,sa t operating temperature the " preglo wing" indicator hght co mes on 1 Idle speed contro l knob
1 t rlr lly 1111<1
the engine can be started immediately .
u i ,sco ld, depress accelerator halfway and turn idle spoed adjusting knob
1,11111•r11111
111 1111lo the stop. Release accelerator. At low ambient tompora tures (below
I II c ) depress both accelerator and clutch pedal fully while 5lart ing th e engine.
one axle I 1 , 1,,,•11119
lock key after th e eng ine has started, ease off the acce lerator and adjust
ease th e 111c d liy means of the idle speed adj uster knob. Check oil pressure warning ligh t
;sure will
rt 1111li·lv111lcrsta rting . Should th e oil pre ss ure warning light lwl to go out, shut off
xessure
111111,1111Pcl1,1
tely and determine ca use.

1111!1111
11111
lh e e ngine :
1111h ,,111,qlock to position "O".
o ff the engine when the vacuum system is faulty , refer to sectio n 5.7.
I , 11111111111

,1, , 1111111•
•,ltould never be shut off at a coolant temp erat ure above normal (in excess of
I ti I 11> C), e.g. after operation in mountainous areas, but should be allowed to idle for
1

I 11111111lhur1 - 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>loc<1tr.ll

1 Hand brake lever

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 sho rt per iod of time.
3. Warm up the engine smoothly at medium eng ine speeds in the lower gear ranges .
4. Demand full engine output only nflcr the operat ing 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 suffi-
cient dece leration 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.
Shifting pattern on gearshift lever (example) If even only one brake fails to work, stop immed iately.

30
 Ut1llt•111m1111on
11 1 c,11 ,,.r.ut1vely in accordance with the shifting pattern.
nward.
Ml 11111111•110ltnnsmission

,11, l 1,11
11 111 1•,rn1ss 1onfaci litates and simpl ifies the handling of the vehicle.

111111 1 In, h•d ranges, the gears are shifted automatically cond1t1onal upon driv ing
I 111 l ,, , 1•l1•r,1tor position.
h """ ilr1v1ng position only with the eng ine id ling. Relear.;c hrake only when
111II I cti 1v111g
range is selected the vehicle mig ht start off (creeping) prematurely.

MB automatic transmission
Selector lever position indicator on instrument panel
unmediate upshifting = moderate acceleration.
11•larded upsh ifting = max imum acceleration.
ed . I w1, I >111Hess accelerator beyond full throttle pressure pomt full throttle down-
accelera tion. The transmission will shift down only 11the driving speed is
111, 111111111
r ranges. 11,,111,1.l(irnum
speed of the next lower gear .
reache d
I. leII h •v1•1 positions
,) on a d ry 1,11lc>verpermits adaptat ion of the automat ic shifting process to spec ific opera t-
111cl1l
11111'1

nd if suffi - I ' 11k111qlock . The parking lock is an additional safeguard when parking the ve-
vehicle is 111It• 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
the brake p Of
11
N"
act ion is
I h, power is transmitted from the engine to the rear axle. With the brakes being
, , 11
•.ir.;ed,the vehicle can coast free ly. Engage "N" only when the vehicle is station- MB automat ic l ransm ission
11y ur moving at low speed. Selector lever positions on seat box

31
 "4" Normal positio n. All 4 gears are shifted automa tically and co nsecu tively. Position
"4" affords op timum driving characteristics under almost all operat ing conditions.
"3" Transmission sh ifts 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 sta ndstill and engine idling

Importa nt notes
When maneuvering the vehicle 1nlimited space, control driving speed by gently releasing
lhe service brake. Apply accelerator only slightly and do not pump the acce lerator peda l.
ror short stops, e.g. at a bus stop or traffic light, leave selec tor 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
wit h trai ler), select lower gear range in time.

32
'I- Position ••••li111y In
onditio n'">.
·ate up hill , 11, 1·1 v1r"hie, ope rational reliabi lity and economical operation of the veh ic le it
~arand on 111111111111 Ill.it the engine should not be run to the limit of its ou tput during t he
1ebra king 1,1 llflll
r t o mar ks

ate up hill
~arand on
1ebraki ng
l11Jl1~111(1:>00 miles).
·. Refer to
w111,111,111ual transmission
I In 11..J11lly
eep up h ill
i of the 1st
11111111admissible maximum speed of each gear (refer to marks on speed-
' I It IIOljlilph) . 180Nm
111,,11111.illc
r. O·~" ·.\nee mou nti ng bolts or wheel sec uring nuts
th vehicl e
w,11111111omat ic transmission
I 111111,·lully
I 111111 l11,1<1s(full throttle driving), high engine speeds, no k1c kdown if possib le.
releasin g t 111''" lly selecting lower speeds.
1torpeda l. I wlll 111111!railer.

gposition
19, shift to , ()(111
""' (1200 mi les) on: Increase slowly to top speed.
operatio n

Wht111I
1111111ntmg
bolts or wheel securing nuts

11111,1
1,11,vothat wheel mounting bolts or wheel securing nuts on all new vehicles be
1111111•cl .iftcr 50 km (30 miles) .
Wile,.,., r,ghten wheel mounting bolts or wheel securing nuts crossw ise .
IV• .pnc ified tightening torque .

33
 2.6 Driving and braking

Oil and fuel con sumpt ion depend largely on driving habits and ope rational con ditio ns.
Increased fuel consumption is a result of trailer operation, driv ing in the city or over short
distances , driving in mountainous areas, acce lerating and decelera ting the vehic le fre-
quently , etc . For that reason, no accura te consumption fiqures can be given.
Depending upon the operational conditions, maximum oil consumption is 1 % of th e fuel
co nsumption .
The drive wh eels must always be 1nfirm contact with tho ground (espec ially in off-t he-
road operation s). If the wheels on ono siclo of tho livonx lo aro spinning, serious damage to
the differentia l will result because the tonclon llw clllforontial gears will then be excessive.
When driving observe the gauges and contro l l1qhls on the instrumen t 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 engi ne maximum revolutions are
not exce eded in th e individual qern '\ 01 >'-PrV<' marks on speedomete r or tac hograph.
Neglig ence may cause damage to cmq1no,injec tion pump or propeller shafts.

Indicator light - brake fluid and brnko pacJwear

The indicator light comes on:
1. When the engin e 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 hydrau lic system is leaking
- if the brake lining s are worn
Have brake system checked immediately!
Test fun ction of indicato r light:
- Turn steering lock to driving position
- Depress contr ol pin on the reservoir

34
 1111111.iph Uneconom ic operation
I 11111111111,usly
check and improve your ..1..
1hlv11111
habits by mea ns of the tachograph
md it ions .
>ver short 1llno11
1111Use on ly original d iagram cards -- . ---
,hicle fre-
1.
Wl!h, rnrcct sca le. C heck funct ion da ily .
Ih• 1111110steadily
---- ---
>ft he fue l
the ve hic le is driven t he
I ,wnr 1•1th e fuel consumptio n. Brief burs t s ~--- ---
I p11t1dwill improve the average speed
111\11111\jllgibly. -- so-
n off-t he-
amageto
I Npl1111allonof sample graphs :
.40 -- - --
Kcessive.
I hu, ,111o mic dr iving-peaked graph li nes.
--- -- -
mtimeto
rravelling Ill• vd11c le was accelerated, brak ed ---- I
---
limit it. In I rw11111lruptly and reacce le rated rap id ly I I ' l

1tionsare
hograph . I • 111111111ic
d riving - rounded graph lines.
s. I tu v11h 1c le was accelera t ed t o eco nomic
11111dI he spee d of t he roll ing vehic le
w, 11111clually
red uced to zero . Eco nomic oper ation

-90 1-
~\ 1 7 ____ _j]@J_
_
- -- -U
------ --
------ --
--- --
---
--- 30 -
--
--
---
• I j \ I I I' I I I I
--
35
 Charge indi cator light

If the charge indicator light comes on wh ile the eng ine is runn ing, stop vehicle,
switc h off engin e and inspect V hel l.
Caution: Do not run engine without a V belt

Temperature gauge

Co nditio nal up on the operating concl1tio11i,1111<

1111111>10111
temperature, coo lant operating
temp eratu re in co ntin uous operntion mnqos from t~8 ?03 r (70 95° C).
Brief vehicl e ope rat ion (10 minutes at llw most) at n coo lant temperatu re of 212° F (100°C)
is perm iss ible. This temperature, howPV<!r,shoulc l not tie exceeded.

Braking

When travelling dow n long downhill qr.icl1l'll l'>, oxplo1t the engine brakin g effect by sh ift-
ing into lower gear.

Parking

App ly han d brak e when stopping or pmking a vehicle on leve l ground or on down hill
grad ients. Vehi c les equipped with MB nutornat1c transmiss ion: In addit ion to this, sh ift
selecto r lever to pos ition "P".
Safeguard a load ed vehicle or a veh 1cleparked for an exten ded per iod w ith at least one
choc k to prevent it from rolling away

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

- Sec ure empt y vehicle at front axle with a chock.
- Sec ure loade d vehic le at rear axle with a chock
When par king a vehicle at night on public roads in buil t-up area, sw itch on park ing or
sta nding light s.
Reflec tor pane ls can also be used for this purpose if perm itted by law.

36
 27 Trailer
icle,
V h1, IP with trailer coupling (ball head)
o, 1111, the trailer so it cannot roll away. Back up vehicle until the drawbar can be
ii11111111!CI in the pintle hook. Engage drawbar and lock.

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

,perating I il1111110
ca re and caution must be used when coupling the trai ler
I I h11lo 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.
11 1 , ,111t1on
when handling the drawbar - it may whip!
I lo 1111<'
must stand between tractor and trailer when the tractor is backing up!
I 11!1
1w111q
the coupling operation, check the pertinent locking device or indicator (feeler Trailer coupling
1 Plug socke t
by shift- 11111111
·..,lety button) for proper seating ofthetrailercoupling bolt. Chec k faste ning bolts of
11,11111roupling regularly for tight seat ing and tighten, if necessary Accord ing to manu-
l 11 1u1,•1's instruct ions , regularly c lean and grease tra iler coupling
11 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
downhill
1,1,111111119
units on the trailer .
his, shift
( 1111111111:
east one 11111111
, ou pling with detachable ball neck:
11111,lv
with manufacturer's instru ctions.

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 be nefit to roadworthiness, but salts do cause damage to the exposed unde r-
sections of the vehicle and to the units exposed to splash water. Thawing salts are corro-
sive. Wash the vehicle more often during tho cold scnson to remove adhering thawing
salts or deposits of salty sp lash water from undcrbocJy and painted and chromium-p lated
parts . The vehicle should be regularly inspected for corrosion . Brake, air, and oi l lines
should be checke d with particular cnre>
As preventive measure , spray vehicle uncJors1dowith wax -based preservat ive. If the ve-
hicle is used regular ly, repeat treatment w1tt1presorvntivo now and then.
Spraying age nts formerl y used such as petroleum, diesel oil, diluted used oil, etc. must
not be used any more , since they might soften or dissolve the co rrosion inh ibitor
previo usly appl ied.

Engine oils

Change the eng ine oil at the onset of tho cold seaso n.As replacement use an engine oil of
the specified SAE grades (viscosity range) Refer to "Fuels, coolants, lub ricants , etc.".

Lubrication

Chass is and brake system suffer particular ly from the infl uence 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.

38
 Coo lants

W111l11
r operat ion witho ut antifreeze is dangerous and sho uld be avoided at all costs .
/\11llhPozecan be retai ned in the cooli ng system all year round. Check its effec tive ness
,ads may Willi .i t1ydrometer prior to and freq uently during the co ld season.
d under-
lh ,,,, lo "Fuels, coolan ts, lubrican ts, etc." for bra nds of antifreeze and mixtu re ratios.
recorro-
thawing
n-p lated
I oil lines

If the ve- UIHe l fuel

~tc. must Wu,1o•r grade diesel fuel of a suffic ient fluidity is to be used during prolonged col d per iods.
inhibitor I\ ,111except 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,t
s, lubrican ts, etc.".

Jineoilof I •nora l dr iving instruct ions

ts, etc.".
111111,1•,ct off immed iately after the first few engine revo lutions! Idle the engine for a short
11111t11t .it mode rate speed . Then wann up eng ine at a moderat e speed and by driving
111,,, ,lhly in lower gea rs, avoiding high eng ine load, until the normal ope rating tempera-
'"" , ,t 1!>8to 203° F (70 to 95°C) is attained. Engine may be run atfull speed only afte r this
I• 111111•1,1ture has been reac hed.
111wil ,,,.,, use only tires whose treads afford good grip. If the drive whee ls start sp inn ing,
vsludge. t,v f(l 11••1on firm grou nd immediately .
,ints and
urewear >11,111
•,II and ice cove red roads, put cha ins on the rear wheels . Refer to manufactu rer's
111,111,llnqinstruct ions. ·

39
3 Fuels, coolants, lubricants, etc.

3.1 Diesel fuels

Diesel fuels should meet the minimum Diesel fuels at extremely low Should gasoline have to be added in case
requirements of DIN 51601 or such inter- temperatures of emorcwncy, never exceed a proport ion
natio nal specificat ions as the America n of 30 '" Pre1111urn
fuels must not be used.
ASTM D 975 No. 1-D and No. 2-D as well as At very low temperatures the flu1t11tyofd ie
W-F-800 a DF-A, DF-1,DF-2 and the British sel fuel may become insufficient chm to C,.iut1011 I he lower flash point of the
B.S. 2869 A 1, or even A 2 in cases of emer- paraffin separation . To avoid malfu11ct1u11~. supplPITltmt.try fuels increases the danger
gency . diesel fuels of a lowered c loud point wo of oxplos1om,
marketed durin g the cold season 1lw CJ 11q11w output may drop accord ing to
All branded diesel fuels commonly sold in
Central Europe meet these requirements. If winter diesel fuel is used, there will hardly tlw proportion of supp lementary fuel. For
be any malfunct ions at ambient tcmpt•1c1 tlw, w.1son, keep percen tage of fuel
Change eng ine oil as under severe lu res reac hing as low as 5° F ( 15' C) ,tcfcled lo the minimum necessi tated by the
operat ing conditi ons if diese l fuels are c1111IJ1PntIPmperature
used whose sulphur content exceeds Varying with the temp erature add II ct•r
0.5 % by weight. Marine diesel fuel, heat- lain quantity of kerose ne ' if only surnnwr
ing oil or the like must not be used. diesel fuels or less cold resistant winlt•1
1 1 ho 11'1uofkorosuno ,n road vehicles is not permitted
diesel fuels are available or 11 tem 111orn110 r:ountruJs. c q UK The refore consu lt the
When fuel is fi lled from barrels, it should be peratures d rop below 5° F (-15° C) 11ut11or1
t11
1:;1
lwforo t uch mixtures are used.
passed trough a filter, a piece of chamo is
leather or even a clean flanne l cloth, insert-
ed into the filler neck. The suct ion port of
the pump must be protected by a fine-
meshed stra iner. Always allow a gap bet-
ween the end of the suction tube and the
bottom of the barrel to prevent deposits
(dirt , sludge, water) from being suc ked up. Summer Supp lementary Winter Supplementary
Ambie nt temperat ure diesel fuel fuel diese l fuel fuel
If diesel fuel has been spilt, the affected OF (0 C) % % % %
spots can be cleaned by using a mixt ure of
25-50 % vinegar and 75-50 % water 32to 14 ( 0 to -10) 70 30 100
(depending on the degree of contamina- 14 to 5(-10to-15) 50 50 100
tion). This will help to get rid of th e offen- 5 to 8(-15to-20) 70 30
sive odor. - 4 to - 8 (-20 to -22) 50 50

40
 2 Engine oils Viscosity range
Ambien t Single -grade I
Multigrade
temperature I oils oils
1111•1111
tnbility of the various engi ne oils is
p, , 11
1lly tested in our engines. For this
The MERCEDES-BENZ facto ry or your
service station fills a new or a reco ndi- ...
"f "C
t>)

~din case
, , 011, only use engine oi ls which have tioned engine with an initial opera tion oil. HI "'
+20

,roport ion I , 11 , .. co mmended by our company. This isa high quality oil whic h was special- !i! ii!
;i, S;l
ly developed for the opera ting conditions " l:l
l:l ~
be used. Ml 111.I lJES-BENZ service statio ns have ~
11 of the
II 111
111111h
11 information on recommended
dur ing the first 500 to 1500 km (300 to
900 miles) "
_,,
'' Ii!
~
;
1edange r
If the oi l level reaches th e minimum mark "
' "
:ording to
t 1111llun!
Ii 11>11lc•1to ensure sufficient lubricat ion of
on the dipstick before the inspection
(500-1500 km [300-9 00 miles]) , the
" i
!
N

"'
0
N

f fuel. For lh 111o v1r1gparts, select engine oil visco- engine may be toppe d up with recom - fr
1 of fuel lly I' ,Al grades) according to ambient mended engine oil if no initi al operation oi l • SAE 40 o,I may be used at ambient tem pe ratu res
tedbyth e , 111 111•1.ilure. is available. continuo us ly above +86 ° F (+30° C).

1111,, ,111p
ounded engine oils must not be
I I di

>Ipermitted
:onsul t the
?d.

~mentary
uel
%

30
50

41
 3.3 Coolants

Cooling water

In the factory the coo ling water is blonclccl must l>o used to treat the coo ling water
with antifreeze (protect ion down to -20 Cl (potatile water quality).
-4"F) throughout the year Anllfroow lnlornmt1on regard ing recommended cor-
reduces the formation of scale and co rro ,o~.lon 1nh1b1torsand antifreezes may be
sion. ol>t.1111£'<
1 from any MERCEDES-BENZ
If antifreeze is not required, 1 % (10 cm 1/ Sf'IVICO stnllon
liter) of recommended corrosion inh1l>1to1

Antifreeze

Winter operation without antifreeze 1svery lwe,u .is till' antifreeze protection effect
dangerous and therefore prohibited If tho clpcrenses at a higher percentage .
antifreeze has been in the cooling system Tho efficiency of the antifreeze solution
all year, check for sufficient protection . should be checked several times during
The antifreeze solution must be draino<I tho co ld season.
from the system and renewed after a mnxi
mum period of two years. Mixing ratio
The cooling system may need degreasing, Protection to Water Antifreeze
descaling and flushing prior to the use of OF (DC) % %
antifreeze. - 4 (-20) 66 34
-22 (-30) 56 44
Do not add any more than 60 lo of anti- -40 (-40) 49 51

I I 42
 ti The vehicle, service and maintenance
lk• ,111yother tec hnical equ ipment. the
I ,11 lo• requires service and maintena nce.
ling water 0111 1ilnd frequency of the service work
I 111 net mainly on ope rating conditions
hit Ii , In turn, may vary to a considerab le
nded cor-
is may be
ES-BENZ 111 lwquen t maintenance and grease
It , 110 required under seve re operating
11ol111ons.
1 v11 1111
ve maintenance work and jobs
11111..d for the retentio n of the opera -
I 11,1 rnliability are itemized in the en-
, , 1Maintenance Boo klet.
1 , 11
,1-;kills are required for inspections
ol 111.i111t
enance work. They cannot be
11 ,111within the scope of these instruc-
1 11 II 1s recommended to have these
I• 11• •1lormed by the tra ined perso nnel
ion effect ltl It h .it your disposal in the large num-
ge. 1 , 1,1Ml 11CEDES-BENZ service stations.
3solution 1 ti .,..rvice is guaranteed by experi -
es du ring " 1111cl regular techn ical instructions
I, 1111111
1 l.ictory , by workshop equ ipment
I 11vl! P too ls.
Ml HUDES -BENZ service station
1ntifreeze 111111 ll 1PJobs carr ied out in the Main-
% be complied with . Any MERCEDES-BENZ
I 111,, . I look let.
34 111111 111,kl'r. attached to the door post
44
51 I 111 thrv .. , s door by th e MERCEDES-
BENZ service station , is a reminder of the
com ing service or maintenance work.
Should any service and maintenance job s
have to be car ried out on a do -it-yo urself
basis for organizational reasons , drai n oil,
fue l or coo lant into a tr ough or something
similar and not into th e drain or on the
ground (environm ental pollutio n). Operate
stationary engine no longe r than neces -
sary. When worki ng on the vehicle, ad here
to safety regulati ons.
Floo r jacks , lifting platforms or jack stands
may be positioned only under the front Vehicle tool kit at RH side in rear of vehicle , in case of
axle , below the rear axle ho using and/ or cargo tr ucks , belo w the assis tant driver 's seat
rear axle supp ort tubes undernea th the (examp le).
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 .
Vehic les which do not correspo nd to
standard spec ifications with respec t to
wheelbase, length of overhang, permis-
sible axle loads and special struc tures
over fro nt and rear end must not be lifted
up with a dual post lifti ng platform . In
add ition to this special regulations must
service station will advise you accor-
d ingly.
For lubrication use only high press ure
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 condi tions,
grease more frequen tly propeller shafts
and steering knuckle pins.
Lubricate special bodies and equipmen t
in compliance with manufacturer's Hl
structions.
MERCEDES-BENZspecial too ls 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 oriqinn l
spare parts required for maintenance ,mtl
repair work. Besides this bases arc proV1CI
ed all over the globe intended to ensu re
44
the rapid supp ly of MERCEDES-BENZori-
ginal spare parts.
More than 200 000 different spare parts,
even for rather old vehicle models , are
furthermore stoc ked 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 inspec tions . Each part has
l>l'on specifica lly developed, manufac-
tured or selected for and adapted to
MERCEDES-BENZvehicles.
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 proce dure in the course
of the first year of operation. Any
MERCEDES-BENZ service station will
readi ly advise you accordingly.
BENZori- 4.1 Engine

are parts, 4 1. 1 Oil and filter change

,dels, are
1tral plant 1111• filter element must be renewed at Fill engine with oil. Start engine and id le
v, ry oil change . for a short while. Observe oil pressure
N 11«•An initia l operation filter eleme nt is gauge indicator lamp. The indica tor lamp
mal effic i- must go out afte r a few seco nds. Shu t off
optimum 11lulled by the factory and must be
eng ine.
ue when pl,,ced at the time of the first oil change
?parts are 11111500 to 1500 km (300 to 900 miles). Check oil filter and oil dr ain plug for leaks.
j to most 111 hange should be performed after a Check engi ne oil level and top up oil to th e
1 part has
11111ctistance drive , while the oil is still hot upp er dipstick mark.
manufac- 1111lh1n.
lapted to
1t,•111ove dipst ick, extr act oil with oil
, •tractor 1 Oi l drain plug on engine
ES-BENZ I
installed . t111•,c
rew oil drai n plug and drain oil.
id with a I ,, 10 removing the oil filter, place oi l
,n in the t, II pan under oil filte r. Loose n, but do
icle value I 1111screw oil filter cover securing nuts.
) U repeat
111,,ttcover from oi l filter housing in order
1ecours e lh ,1 tho oil may drain. Unscrew securi ng
ion. Any 11 ,111clremove cover. Replace filter ele-
ition will 111.ind all sealing rings. Position cover
l11h•p.1yingatte ntion to proper seating of
1, 11,1•,kctan d tighten nuts. Observe tig ht-
1torque.
1111,,

11 w 111and tig hten oi l d rain plug.

Oil fitter (exampl e) Oil fitter (example)

1 Secur ing nuts 1 Filte r element
2 Fille r ho usin g

45
 4.1.2 Inspecting and servicing air cleaner
Check filter element soiling at mainte-
nance indica tor regularly
Normally weekly inspections will do; in
case of heavy dust accumulat ion, check
daily.
Inspec tion:
If the comp lete red field 1svisible in the
service indicator , actuate push button to
disengage the colored field Clean or
renew filter element.
Servicing
1. Loose n cente r bolt of the filter bowl and
Service indicator for paper air cleaner
1 Inspection glass for colored held detach it with filter element
2 Push button 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
carefu lly.
Should this c leaning 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
Air cleaner
1 Center bolt is available, a non-foaming household
2 Filter bowl detergent may be used.
46
Caution:
Filter manufacturers ' detergents have a
strong degreasing effect. Protect your
hands with rubber gloves or skin protec -
tion cream. Never apply lyes or hot
fluids.
4 Soak filter element for 10 minutes in a
cleansing solutio n of approx. 40°C
(104° F). Then swill in solution for about
5 minutes and rinse in clean water until
c lear water drops off. Shake the filter
firmly and allow to dry in a dust-fre e
room (max. temperature 60° C / 140° F)
Install element only if thorough ly dry .
5. Clean gaskets of filter element and
scal ing 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 c leaned 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 jo b:
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.
 ii I J Removal and installation of cylinder head cover

11111•,oiled cyli nde r head cove r. Ensure correct seatin g of gasket when
installing it.
ts have a I 1111111fcrankcase vent line. Disengage
1tect you r lh 111lll 11linkage. Detach oil filler neck . Un- Adhere to the tight ening torque of the
:in protec- 1uw •;ecuring nuts and remove cy linder sec uring nuts.
,s or hot d c0 ver. Chec k gasket for damage
1111 111place if necessary.
nutes in a
·ox. 40°C
1 for abou t
Nater unt il
! the filter
dust-fre e
; I 140° F).
ghly dry. Air cleane r
1 Filter element
11ent and 2 Filter bowl
~-
leaned fil-
r damage
ion lamp .
4 I 4 Adjusting valve clearance
,d on face
r 1111,tf,. elergauge , measureva lveclear- cap nut. Lock cap nut by tightening the
r element " 1 I 11•lwcen rocker arm slid ing surface s hex. nut and verify valve c learance once
hten cen - I 1h11camshaft on the cold o r hot more. For valve clearanc e, refer to
" 11111• lh e cam lobe must th en point "Technical data".
rning job s 1 w 11d(; rank engi ne at the crankshaft in
If there is no need to readjust the valve
111 111111of rotation (not at the camshaft).
cleara nce, c heck tight ness of the cap nuts
II r fl" < tal too ls for valve adjustment. and hex . nuts.
11, , , ounter hold ing wre nc h on the
lucts indi- Cautio n: Chec k con tact surfaces of the
I 11!111of the valve spring retainer to
~m which , v 111the valve from rotating. Slacken
hex. nuts. Replace hcavrly worn hex. nuts
I 110 11 valve cou nterholding the cap
11
rt /1,1111·,
1valve clearance by rotating the
toget her with cap. nuts.
Minimum height of hex. nut · 5 mm (0.2 in).
1 Roc ker arm
2 Camshaft
3 Feeler gauge
4 Spec. wrench
5 Spec. wrench
6 Spe c. wrench

47
 4.2 Fuel system

The inject ion pump is connec ted to the nozzles und cause black exhaus t smoke
engine oil cycle and requires no mainte and erratic engine ope ration.
nance .
A defective nozzle must be replaced or
It has been set at the factory for oplimum
clc,med Spec ial skills are required for th is
efficiency and most economica l fuel con
job and 11sho uld only be performed at a
sumption . An inspec tion of the inJcction
ME'RCCDESBENZ service station.
pump and the adj ustment of the start of
delivery must be performed at a New injection lines must be thoro ughly
MERCEDES-BENZ service station only cleaned prio r to installation. Blow them out
with cleaning solutio n (di esel fuel).
Dirt acc umulations in the fuel system will
result in malfunctioning of 1r1wc11011

1 Fuel prefllter (example)

4.2.1 Fuel prefilter

Regularly c heck fuel prefilter for soiling Caution: The arrow on the filter housin g
(visual insp ection). Replace, if requ ired. must point in drivi ng direct ion.

4.2.2 Replacing the fuel filter

Unsc rew sec uring screw of filter and securing screw and install a new filter.
1 Securing screw Finally bleed fuel system .
2 Fuel filte r (one-time use filter) remove filter. Replace sealing ring of

48
 4 2.3 Bleeding the fuel system

JS! smok e A, ompletely bled fuel system is impera- Actuate the primer pump until the overflow
t1v11lor the perfect operat ion of the engine. valve on the injection pump opens (rattling
lJmllir operating co nditions, continuous noise). To operate the primer pump, re-
,placed or hl1111d1ng is ensured thro ugh the overflow lease the handle first (by turning it coun-
redforthi s 111111Alter any repai rs to the fuel system or ter-clockw ise). Always screw in again after
,rmed at a 111lhn event of driving until the fuel tank is use.
on. 111nplete ly empty, the entir e system must
ho hied manually.
horoughl y
vthemou t
1el).

1 Primer pump

,r hous ing

v filter.

49
 4.3 Cooling system
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 1scon trolled by
one the rmostat.
The gradual rise of the cooling tempera-
ture abo ve the usual level indicates a fail-
ure in the coo ling system .
The cause may be lack of cooling wuter, u
1 Drain plug - radiator (example)
4.3.1 Draining coolant and filling system with coolant
Draining :
1. Remove cap of cooling water expan
sio n tank.
2. Open heater control valve.
3. Remove drain plugs.
They are located:
- at the bott om section of radiator;
- on th e right hand side of engine
After having drained the coo lant, check
whether th e drain ports are restricted by
residua l matter. Seal drain ports.
1 Drain plug - engine
50
clogged radiator, slack V-belts or a faultv
thermostat.
Check cooling and heating system fo r
leaks at regular interva ls and renew hoses ,
if required
Radiator hoses and heater hoses should
be replaced by new ones whe n they have
been in use for an extended period of time
(approx. four years).
Use on ly tested and recommended hose
material and hose clamps.
Filling with coolant:
If poss ible, replen ish coo lant only if the
coo lant temperature in the system is less
than 122° F (50° C).
Replace cap of coolant expans ion tank.
Operate engine until opera ting temper a-
ture is reached (thermostat has opened ).
Shut off eng ine and replenish coo lant.
 4 J 2 Cleaning the cooling and heating systems

( IH ning the radiator

s or a faulty
lllow out the radiato r co re from the engine until the radiator fins arc freed from foreign
I h with compr essed air or a jet of water partic les (dust, insects , etc.)
syste m for
:new hoses,

,ses shou ld
n th ey have
iriod of time

"Krikit" tester
mded hose 1 Push button

4 I I V-belts

1111qV belt ten sio n 5. Read off the V-belt tensio n at th e int er-
sect ion of the "KG" sca le and th e feel-
l\ 11
kit" tester
er ar m.
on ly if th e I 11werfeeler arm in tester. Specified value for used V-belts
;tern is less V-belt section widt h.
I '11•,1t1on tester in the middle betwee n 12,5 mm= 40-45 on "KG" sca le
I w,,pulleys. The stop must co ntact the
nsion tank. 1i1,,of the V-belt. 6. Co rrect V-belt tension, if requir ed.
g tempera- ( , ,1111nuo
usly press the pu sh button at
is opened ). Tensioning V-belts
111111angles to the V-belt until the
coo lant. 1 11 k spring can be felt or heard to Alternator V-belt:
111,1111gage. Discontinu e press ure as 1. Slacken securing screws.
ll11•1wisemeasuring data are incor-
H, I 2. Turn tension ing screw until the spec i-
fied value is achieved Tens ioning alternator V-belt (example)
11, •lully lift off tester without altering
1 Securing screws
11111,,,.lerarm positio n. 3. Retighten securing screws. 2 Tensioning screw

51
 Power steering pump V-belt: 3. Turn tensioning screw until th e spe
c itied value is achieved.
1. Slacken secu ring screws and counter
nut. Specifi ed value for new V-belts
V-belt section wid th
2. Turn tensio ning screw until the spc 12,5 mm = 50 on "KG" scale
citied value is achieved .
4 Chec k V-belt tension once more after
3. Retighten securing screws and coun running engine for 1.0-1 5 minutes
ter nut. Specifie d values for used V-belts musl
be attained.
Renewal of V-belts
Only use tested and recommended If in excep tional c ircumstances no testeri ~
V-belts. available, tighten new V-belt tem porarily
The V belt must not d eflect by more thar
1. Check V-groove faces of pulley , approx. 6 mm (0.24 in) from a stra ight linE
remove rust and dirt. when subject to thumb pressu re.
Tensioning power steering pump V belt (example)
1 Securing screws 2. Release tensi oning screw until the V Correct V-belt tension to specified valuE
2 Counter nut belt can be slipped on.
3 Tensioning screw for used V-be lts as soo n as poss ible.

52
1til the spe- 4 4 Clutch

:>ells 11111 dutch is adjusted automat ically. Ba- This adj ustment requir es special ski lls
" .idjustment of the c lutc h control and shoul d only be performed at a
le n,,, hanism is for example necessary after MERCEDES-BENZ service station.
, more after 1111pndals have been worke d on or after
5 minutes. 1111ronewal of the maste r cy linder .
-belts must

no tester is
amporarily. 4 4 I Hydraulic sections of clutch and brake systems - checking fluid level
more th an
,traig ht line 1111 lr,in slucent brake fl uid reservoi r is Functio n of the indica tor light can be
ire .
1l11d on the front LH side of the engine tested . Engine compartment flap ope ned
;ified value 11
11pmtment. Turn steeri ng lock to driv ing posit ion .
1 Brake flu id reservoir
2 Control pin
ssible. I h• Ill 11cllevel can be checked witho ut
Dep ress control pin on rese rvoir.
" w111 g off the cap . The reservoir must
lw,y•, be sufficiently filled . If brake fluid needs to be replen ished ,
check hydraulic system fo r leaks and
11, above uppe r marking (maximum
,11111
check th ickn ess of bmke linings.
I 11~1111(
)
Always sc rew on co ver of reservoir tightl y.
11,,1111lu..1torlight on the instrumen t panel
1111 . 0 1111the flu id level in the reservoir is
11,w

53

Manual transm,ss,on
1 0, 1fill er hole - oi l level
2 Oil d rain p lug
54
4.5 Transmission
4.5.1 Manual transmission
4.5.1.1 Oil level check and oil change
Prior to unscrewing the sc rew plug, c.i re
fully clean its vic inity. Change oil 1mmc 'cl1a
tely after an extended trip while 1ti5 still hot
and thin .
Clean oil drain plug .
Oil level check :The oil level in the co rrec tly
filled transmis sion reach es th e lower l'Clqu
of the filler hole in the transmission hous-
ing. Add oil through th e fill er hole, 11ro-
4.5.1.2 Cleaning breather
Clean exterior of breather on transmissio n
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-
qu ired. If the oil level is checked with th
transmission at operating temperature , d
not allow any emerg ing oil to dr ain.
Dnuning oil Unscrew oil dra in plug and o
filler plug .
r illing with oil : Pour oil through the fille
hole 1nth e transmission housing until th
level reac hes the lower edge of the fille
hole.
ca used by the pressure bui lt up in th1
transmission housing .
1ngon a vehicle with automati c transmis
sio n whose engi ne is id ling.
 il r,2 1 Oil level check
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
ed with th e 11,y means of dipstick while the engine
>erature,do
train. I .,,vo painstaking cleanness. To wipe
plug and oil , llpi;tick, do not use woolen fabric
If 11ft I hiplenish oil only through a fine-
II ·,trainer. Even minor impurities may
~h the filler u , molfunction.
ng until th e
of the filler
!I J OIi and filter change
,, ,, rnl 1mmediately after an extended
I up in th e
wl11li· 111s still hot and th in.
111111 lh<' oil from the transmission:
I! w •,ocuring screw of oil filler neck
I t It 11tI oil
ill 011lorrn torque converter:
1111 , 11,k
•,huft until the drain plug of the
111 11111vorter appears in the opening
I Ill 11,111110converter housing. Back off
111,111qDrnrn oil. Renew seal rings.
c transmi s- w 111 111<1llqhten 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 th e upper dipstick
marking. Do not fill abov e upper marking. If
the transmission is co ld (68-86°F =
20-30 °C) the maximum oil level is appro-
ximately 35 mm (1.3 in) below the dipstick
minimum marking .
Oil filler pi pe - aut omati c transmission (example )
1 Dipstick
Filter change : Remove and clean trans-
mission oil pan . Renew filter .
Check oil pan gasket for damage and
renew if required . Attac h oil pan.
Screw on oil fille r nec k with securing
screw and new seal nng s.
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. 1 Securi ng sc rew - oil filler pipe
2 Oil d rain plug - torque converter
55
 Start engine and run it at idle. Selector
lever in positio n "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"). Inspec t
oil level wh ile the eng ine is operati ng. Add
oil, if necessary. Check transmissio n and
lines for leaks.

Automatic transmission
1 Oilfi lter
2 Securing screws

56
"). Insp ect II ti Rear axle
·ating.A dd
ission and
41(I I Oil level check and oil change

11h11lo unscrewing the screw plug , care-
I 111v, le•an its vicinity . Change oil immedia -
1 iv ,11,•1 an extended trip while it is sti ll hot
fl I lhlll
ii h v,•I c heck: The rear axle is filled cor-
1 , lly 1llheoillevel reaches the lower edge
11111•
lillc r hole in the differ ential.
lcl 1,11
11,roughthe filler hole, if required .
Should the oil level llo chc•t k,icl with the
rear axle warmed up, do 1101 nllow any
emerging oil to dralll
Draining oil : Unscr ew 011clr.1111
plug and oil
filler plug .
Filling with oil : Pour OIi thr ouq h the fill er
hole in the diff crc11t1;1
I 1111111the oil level
reaches the low er Pclqo ol tile filler hole .

1 Filler hole - oil level

2 Oi l drain plug

57
 4.7 Steering
For safety reasons, perform maintenance
jobs at regular interval s.
This adjustment requi res special skills
and should only be performed al a
MERCEDES-BENZ service station.
4.7.1 Checking the steering linkage
1 Remover 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 the re 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 .
58
Power steering
In case of emergency, i.e. when the hy-
draulic syste m fails, the vehicle can con-
tinue 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 seati ng.
When the engine is not running (hydrau lic
sys tem of the steering assembly is inoper -
ative), the play verified would be inaccu-
rate (excessive).
The wheels must start moving when th e
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.
 ii 7 3 Checking oil level

M 11
1111
1steer ing 35-45 mm (1.4 1.6 111 ) 110 111the upper
edge of th e filler holo
m the hy- 1111• w hicles No oil chang e is requ 11Pd
i can co n- •,toering whee l all the way to the left.
111111
1sed effort
·transmi s- Ill ti I v1!hicles Power steer ing
•11f!ering whee l all the way to the right.
111111
Regularly ch eck the oi l loVl'l tn the power
I 111area around screw plug before steering reservoir Thn co , we t oi l level
111 , 111wingthe plug! When the steering reaches the reservoir 11 1.irk111g
11 1•1 correc tly fil led, the oi l level is No oil chan ge is requ111• d

t and un- Manual steering

ii 1 4 Checking the toe- in 1 Filler and oil level chec k plug

,t seatin g.
, 111measuremen ts on the front axle, tance between tho two po rnts which are
11,
, ,11vehicle on a pe rfectly leve l sur - loca ted behind tho lront .ixlo
1ht• tires must be inflated to equal
The differ ence in 1111•11'l
111
oment betwee n
11,,. Looseness in whee l bearings ,
the distan ce of tht• two point s before and
, 11 I 1•11t tsanddrag link ends must not be
after the wheel rotut 1rn1 Is th e amount of
I , ,111 t1 The toe-in may be checked on
toe-in .
11• 1111 ,tv or loaded ve hic le.
Vehicles with strwol1 t 110 ro<J
(hydrauli c 1111 ,1•,rne toe- in (steering in straight-
After having lom,1•111• rl the clam ping
•isinoper - It 111 position), mark meas uring points
sleeves , th e tie roct u 111l>c adjus ted in-
,e inacc u- 1 1111 11111 flange in fro nt of the ax le at
finitel y.
I, I I PIiier heig ht, using cha lk or
I i l l ti 1)1'11
Cil. Vehic les wit h offsot t111rocl
when th e Toe-in is adju sted l>y p11!,hlng one end of
1 111,
· llw dista nce betwee n these two
,x. 30 mm the tie rod out of the stPrnlfl q arm by means
e steerin g of a push er (spocint too l)
d by a 1 11111volli c le backwards or forwards
Observ e speci fied torq110 to which the Engine compa rtment flap ope ned
on . Will l'i rolntio n and measure the dis -
nut s have to be roll qhtf' 111
•d 1 Power steering o il reservo ir

59
 4.8 Wheels and tires

4.8.1 Spare wheel location

Spare whee l below cargo body 2 Hold spare wheel carrier. Comp letely
unscrew sec uring nuts on RH side.
Unscrew the securi ng screws. Remove
spare wheel from the side and unscrew 3 Lower spare wheel carrier. Unscrew
spare wheel from carrier. secur ing screw and remove spare
wheel
Spare wheel below c hassis frame encl
1. Pull off thread protection caps. Corn
pletely unscrew sec uring nuts on l H
side.

Spare wheel below cargo body

1 Sec uring screws
2 Spare wheel carrier

Spare whee l below chass is frame end (example) Spare wheel below chassis fra me end
1 Protection caps 3 Spare wheel carr ier 1 Secur ing screw
2 Secur ing nuts

60
 4 II 2 Wheel change

1 111110n: When wheels are c hanged, spe-
11i11dtire load capacities and ti re pres-
11111·,must be observed (refer to "Tire
:ompletely 1,11 •,ure chart").
~H side.
M 1lw sure the vehicle cannot roll off.
. Unscre w
)Ve spare I , 111oning the jack at front end:
I hulor the pertinent sp ring, directly in front
I th" front axle.
I , 1t1oningthe 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 whee ls are pos itioned ,
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 secur ing nuts.
Prior to positi oning th1• 111111 •1 wlleul (twin
whee ls), make sure all •;plw1 u nl 11ngsare
properly seated After hnv111qpositioned
the outer wheel , screw rr,, 11111trqhten two
to three wheel stud nut •, loql'lher with
sp herical spring wm,hu,·, Make sure
wheel is corr ec tly cc nlt •rl'<l (wheel bolts
exactly in th e ce nter ol 1111• disk whee l
holes) .
Position and tighten 11•ma111rngspherica l
spring washer s and wh!'PI stud nuts.
For the tight ening ol tlH• wh eel mounting
bo lts or securin g nul'., rl'll'r to section 2.5.
Jack - fro nt axle (exam ple)
The wheel mountrnq l>CJll s or sec uring
nuts of a c hanged wl1cc l must be
checked after 50 km (30 miles) and
retightened , if ncccs5, 1ry Thereafter
periodic inspection:. will cJo
Wheel mounti ng bolts or secur ing nuts
are to be tight enccl u osswrse.

2S934

Jac k - rear axle (exampl e)

61
 4.9 Brake system

4.9.1 Checking the brake lines

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 .
Commerc ial vehicles designed to haul
cherrncals and acids are particularly jeo -
pardized by brake line corrosion. Besides
vd11cles intended for the transportation of
comcnt, lime, animals and hide s this
c.i!Pqory inc ludes brewery vehicles and
',1n11lnr

Front wheel brake

1 Brake linings
2 Brake disk

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 th ickness is
reached, replace brake pads immediately
Check lining thickness th rough one of the
openings in the disk wheels (use a light for
visual inspection ). Rotate disk wheels if
required.
For a c loser inspect ion of the brake linings,
detac h front wheels and remove brake
pads.
This adjustme nt requires special sk ills
and shou ld only be performed at a
MERCEDES-BENZ service station.

62
 "ear wheel brake (drum brake)

lhiLkness of rear wheel brake linings must For a careful check of lhP l>r,1keshoes and
IK1 regularly c hecked
through the inspec- linings, remove the brake drums.
J to haul tion holes (inner side of wheel - brake
Jlarly jeo- Simultaneou sly make suro that the brake
1mchor plate).
1. Besides
shoes pivot freely aroum i their anchor
)rtation of lhu brake linings must be replaced as pins.
ides th is ,on as they are worn to minimum thick-
This adjustment requires spPcial skills and
icles and " !IS. sho uld only be pl'rformcd at a
Minimum thi ckness: 3 mm (0.12in) MERCEDES-BENZ SNVICO station.

Rear wheel brake

1 Inspect ion ho le - lining thickness

<elinings,
,ve brake

:ial skills
ed at a
,n.

63
 4.9.3 Hydraulic sections of clutch and brake systems - checking fluid level

The translucent brake fluid reservoir 1~ Depress con trol pin on reservoir .
located on th e front LH side of the cngin<'
II llrake fluid needs to be replen ished,
compart ment.
check hydraulic system for leaks and
The fluid level can be checked without check thickness of brake linings.
sc rewing off th e cap. The reservo ir must
Always screw on cover of reservoir tightly.
always be sufficiently fill ed
U!;P only tested and recommended brake
Do not fill above upper marking (mnximum
fluicl brands for replenishmen t or renewal.
marking).
Observe boiling poin t (DOT 4).
The indicat or lig ht on the instrument parwl
Ropl,tcc t,rnke fluid once a year, most suit-
comes on if the fluid level in the rcscrvoi1'>
ably in spring
is too low.
A <;mall sticker, attac hed to th e doo r pillar
Function of the indica tor light cnn Im
Engine compartment flap opened of the driver's door by the MERCEDES-
tested
1 Brake fluid reservoir
2 Con trol pin
m N7 service station, is intended to serve
Turn stee ring lock to driving position ns a reminder when next to replace the
brake fluid

64
rel 4 U 4 Bleeding th e brake system

r. p ruse nce of air in t he system is ind i- ox 1, rcvo

- Bac k off bleed scr l'W l>y f 1p 111
l11dl>y a spr ingy , spongy fee ling of the lut io n .
>lenishe d, I , 1k 11 pedal. The brake (hydraulic system)
ea ks a nd - Continu e dep re•,•;111qt hu pPd il l to th e
111 lltt>n have to be b led immediately .
s. stop .
I,t I 11;1keflu id duri ng t he bleed ing opera -
o ir tight ly. - Retai n peda l 111thl'I po•1llh111 .imt allow
I 11 ·,o as to e nsure that t he reservo ir is
brak e flui d to flow 0111
jed brake lw •v·,filled to th ree quarters of its capa-
r renewal. llv llle ed bra ke system wit h a b leed ing - Turn in bleed sc, ..w r1111
l 1Pl1•, 1•;c br ake
t ~h ,, o r by hand in t he fo llowing o rde r: pedal.

nos t su it - 11i,111ove d u st cap from t he respective Repe at th is sequo11cc•11111

111111•lir a ke fluid
1,1111•ti screw . emitted fr om the ho•,11h lr c•u DI l)ubb les.

j oor pi llar ( , 11111cct

b leeder hose . - Remo ve blecdc, ho·,1•, !11•,
l.ill clu st cap.
RCEDES - Brake caliper
I l,11u hose end in a jar half filled wi t h - Corr ec t brakt> fluid lnVl'I 1 Bleeder screws
cfto serve l, 1, 1ku flu id .
place the Bleedin g t he hyd,1111 111 l 1111kosyste m
I 1i•pw ss bra ke pedal until resis tan ce de se rves your SP«'<l11l111t1•11tlo11b eca use it
, 111 lie felt. Reta in peda l in th is pos it ion . is of pa ramount 111111111111111,, to the road -
wort h iness of tho v.. 111c111

1 Box -typ e wrench

2 Bleeder hose

65
 4.10 Electrical system
4.10.1 Three-phase alternator
Due to major differences in the opcm t1nq
c haracte ristics of the three -phaso alt orna
tor and the DC generator , the follow1nq
points have to be observed :
1. Thet hree-p hasealternat ormu st noVPr
be discon nected from the batl<'rtP~,
wh ile the vehicle is in operat ion /\s
lon g as the engine is runnin g, no1tt10r
an alternator cable, nor a ballo ry lrn
minal may be loosened, removed or
wrongly con nected .
Supplementary heater
1 Fuse in battery box 2. Tow-sta rt the vehicle only with tho l>al
teries co nnected.
4.10.2 Fuses
All points of co nnection must be 1n pos1l1vt1
contact with each other. For return of thl'
cur rent, make sure all power consuming
units are well grounded.
Damaged cab les 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
genc ies.
66
3 Only after pos itive and negat ive cab le
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 termi-
nal lo the part to be we lded. Detach
posrtrvo and negat ive battery terminal
cl:unps
5 f1l·pw1s and inspec tions 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 rep lacing the fuse.
Prior to performi ng work on the elec trical
system, tho negative(-) battery term inals
must be disco nnected from the battery
posts. Objects liable to conduct elect ri-
city (tools) must not be put on top of the
batteries because they might ca use
short s.
 use box I

No Consumin g unit
High beam , left, hig h beam indicator light
tivecabl e
~ High beam, right
:!from the
tteries be 3 Low beam, left
l charge r.
II Low beam, right
ictric wel-
mdterm i- Parking light, left, tail light, left, instrum ent panel llqhl1111
t Detac h h Parking light , right, tail light, right
{te rmina l
I Hazard warni ng flasher switch, interior light, clor ~

the alter- u Horn, stop light switch

j by the I 111111,1, flt11ol
Turn sig nals, wi ndshield wiper , oil p ressure war11111q Fuse box on RH side below the instrumen t pane l
MERCE- 1 Loc king hand le
indicator light Turn to open
nly.
I II Blower, tempe ratur e gauge , fuel gauge
•

burnt out

electrica l
termina ls
e battery
;t electri-
op of the
it cause
1-10 Fuses

67

1 Tighten cap
2 Loosen cap
3 Aiming screw, vertical direction
4 Aiming screw, horizontal direction
1 Bulb - parkin g ligh t
2 Bulb - headlig ht
68
4.10.3 Checking the headlight alignment
Correc t headlig ht aiming is of paramount
importa nce to roadworthiness. Period ic
c hecks with a headligh t aimer sho uld
therefore be made.
Each headl ight must be checked ind1v1rl
ually. The other headligh t and tho othor
exterio r lights must be c overed up for this
process.
Loaded vehicle :
The brig ht/ dark borderline of the low
beam is determ ined by subtracting 10cm
(4 in) from the headlight horizon tal cent or
line (dista nce between headlight conter
and groun d) wit h a vehicle positioned 111
4.10.4 Headlight bulb replacement
Turn left and detach ca p of headlight
co wling. Disconn ect electr ical co nnector,
unloc k bulb ho lder from its bayonet lock
by depressing and turni ng it cou nter
c loc kwise . Remove two-fil ament bulb with
socket. Do not touc h the new bul b with
moist or oi ly fingers but use tissue paper.
Install the lamp in such a way as to ensure
the insertio n of the two bulb socke t guid e
such .i way that the headlights are 10 m
(32 .8 ft) from tho aimi ng screen.
Unloaclorl v11 tw:10
(I oncl<•c
l with I drivor or 75 kg= 165 lbs).
On votlic.los !' quipped with headlight
111•;1111c:rntlrol,
turn beam control knob to
1111t1al
positio n
I ht> l>r1qhl/cli1rk borde rline of the low
lwi1rt11•,cll'lt•rnincd by subtracting 30 cm
(12 in) from the.'headligh t ho rizontal ce n-
t11 rll110(<1 1•,t.mc.cbetwee n headlight ce n-
tor 11ml qro uncl) wrth a vehicl e position ed
in •,11<.t,ii wuy that the headligh ts are 10 m
(32 1111)horn the aiming screen .
luq:; into the notches on the reflector neck .
Put on lnmp holder and depress and turn it
c lockwiso for engage ment. Connect the
elcctrrcu l connector, position cap and fas-
ton by turning to the right.
Then check headlig ht adjustment.
For bulb spec ifica tions refer to "Techn ical
data".
 4.10.5 Battery care
re 10 m Ut>an batteries only with the plug s
11.rewed in. No gasoline, benzol, kero-
one or similar sho uld be used for clean-
65 lbs). 111y Lightly coat terminals with acid-
proof grease, particularly c lamp under-
~adlight 1de. Vent holes in the pl ugs and/or cell
knob to vuntilation hoses must not be plugged. No
111u tal objects should be placed on the
he low tmtteries (danger of short ci rcu it). Battery
J 30 cm vl!!ual inspect io ns must never be per-
tal cen - formed with naked lights beca use the for-
1htcen- matron of oxy- hydrogen gas might create
,itioned lho danger of an explosion . Only use
1re 10 m
, IPc tric lights.
Ch ec king th e electro lyte sp ecific g ravi ty
I ho elec trolyte level in eac h cell should be 1 Hydrom ete r
1pprox. 15 mm (0.6 ft) above the plate

)r neck.
d turn it
ect the
mdfas-

chn ical

69
 4.11 Vehicle cleaning and care
Use an amp le supply of water to wash the
vehicle. Do not was h it in strong sunlight.
Use dry clea ning gaso line (not automotive
fuel) to remove grease stains. Do not app ly
c rude oil or grease to the syntheti c resin
fi nish since suc h agents will qui ckly de-
str oy the protective film on th e fini sh.
Do not c lean lenses of turn signal and tail
lights with nitro thinner but use c leaning
gasol ine.
For c leani ng steering wh eel, gea rshift le-
ver, soiled upho lstery and floor co vering in
the cab , use only warm water with dish
was hing detergen t or washing powder for
de licate fabri cs. Do not use sco uring
agent s. Use dry cleaning gaso line to
remove greas e stains in th e uph olstery.
Clean seat belt webbing with luk ewarm
70
.J~---~
wate r and soap. Do not applyanyc hem1cal co1rod I'd •,pob clrrrnnaled as soon as pos-
clea ning agen ts. Do not dry the wch b111
q al s1l> l t1 1{1•pn11prnnlwor k and apply under-
tempe ratures above 176° F (80° C) or 111 ',t'i II
di rect sunlight. Never bleach or ro clyu ll w
f't11lor 111 111•c .. ~;!,illY welding prior to the
web bing .
.ip pllc.111011ol co rrosion inhib itor.
App ly some talcum to window w<>alht•1
str ips and door rubb er seals I 1111 11•;., ol ; 11•rosols, such as kerose ne
<1 10!,1•1rnl o1 1c1l tile like, should be discon -
Have the chassis thorou ghly cleanecl .irnl lir uuid lr1lo1mnlion on tested and recom-
inspected prior to th e performnnc!' of 11H•11<IP< I rn1lr co rros ion co mpounds ca n
major maint enance work . IJp ol>lo1 111t><I from any MERCEDES-BENZ
After c leaning the vehic le, especially 11 li!'IVI< (l •,lil liOll
steam c leaners or grease solvent•; wt•1P 1l1o1kt1l10!H", must never be painted or
used, lubricate c hassis according lo llw c IP.illl'cl with gnso line, benzo l, kerosen e
Maintenance Book let. or 11 111w111I oils. Clean hoses on ly with
wall i1 I IP <;uro not to app ly any sprays or
All vehicle components are exposrct lo
q1Pas!' to the brake hoses when spray ing
mecha nica l action (flying stones, gravel)
and c hemica l reaction s (melting snow, rn lulH1c,11ingthe vehic le.
thawing salts). Have damage repaired and
 4.12 Preparing the vehicle for storage

Thoroughly c lean the interio r and exte - life, however, is limited, no matter how well
,naspos- l)atte ries are serviced .
ly under- rior of the vehicle and park it in a dry
and airy garage. Dnve vehic le every 3 month s for approx. 1
Grease all lubricating po ints in accord- hour. If this cannot be do ne, run engine at
)r to the ance with specifica tio ns in the Main- modera te speed for approx. 1 hour. Ope-
tenance Book let. rate supp lementary heater and air co ndi -
Increase tire pressu re by app rox. 2 bar tioning system for app rox. 10 minutes.
,erosene
above the specified level to prevent flat
1 disco n-
spots on the tires. Engine, fuel system etc. can also be
j recom-
Cover up tires to protec t against sun preserved for extended periods . Every
1nds can
rays. MERCEDES-BENZ service station wi ll
:S- BENZ
Fill up fuel tank complete ly. readily advise you.
Check coo lant for antifreeze content. If
1inted or the vehicle is operated with out anti- Change engine oil and filter acco rding to
:erosene freeze in the coo lant (e. g. in trop ical Maintenance Book let speci ficat ions.
,nly with zones). it will do to add 1 % anticorro- Should the 500- 1500 km/300 - 900 miles
;prays or sion oi l. inspect ion have not been carried out yet
spraying Chec k paintwork for damage and re- use initial operation oil.
pair.

71
4.13 Preparing the vehicle for service after storage
The follow ing po ints 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 .
72
Shou ld the engine have been prcservo(I, Choe k coolanl lovul und antifreeze effect.
perform special depreservution I u11c:llo11tosl PIC'ctrlcal system.
measures. Every MERCCDrS 111NZ
Sl.irl P11ql110 ,11HI check oi l pressure. ln-
service station will you accordingly
'ipP< I IHm1", 111H I Imes for crac ks and
Check oil levels in engine, steerinq qcm, tonks C.IHHk llrnke oHic iency.
transmission and live axles.
 S Troubleshooting
e effect. eliminate the cause of the malfunct ion .
!he following suggest ions will help you to
< ope with roadside failur es. It is th eir pur- fh ese recommenda tions can not be con-
iure. In- pose to enable you to driv e your ve hicle to side red exhaust ive.
ks and 1 MERCEDES-BENZ service stat ion where

5.1 Engine and fuel system

For details
refer
Cause Correc tive ac tion to section

Fngine will not start Fuel tank almosl nr 11111nlo 1, ly 2 .1

empty Fill up and bleed the system 4.2.3
Fuel line, fuel t,mk • 111111
,,
or precle aner c:loqu• d Clean and bleed the system 4.2.3
Fuel filter c logqP.d Renew filter element, 4.2.2
bleed the system 4.2.3
Fuel syst em leaki1111 Seal the fuel lines ,
bleed the system 4.2.3

Ambient temperal1111I 11•!1,w Observe winter operatio n 2.8

+ 32° F (0° C) instruc tions 3 .1

llnrd starting or engine stalling Fuel filter clogg<'d Renew filter element , 4.2.2
bleed the system 4.2.3
Vent in fuel tank clouoi d Clean the vent
Overflow valve in thu 11111,111111
pump does not hold 111 11
developed proS!iw o Workshop responsibility

73
 For deta ils
refer
Cause Co,roc.t1vom.11011 to section

Lack of power Unsu itab le fuel Dra1111111cl r<'plact• l>y llranded fue l 3. 1
Observo w111ll'r01w1.11to11instruct ions 2.8
Lac k of fuel 111',J)t'cl hH •I ftllt 1 1 4.2.1
Full- load stop is not reached l\clJw,I 11111 lo.id •,lop, cons ul! worksho p -
Insufficient ai r supp lied
at high engine sp eeds St•1v11" 11111<111clc>nrtf'f or renew 4.1.2

Black exhaust smoke Air cleaner dirty CIPilll CH rwu,w 4.1.2

Faulty injectio n nozzles Wo1k•,l10p 1w,ptm•,1l>lhty
Sta rt of del ivery maladju sted Worki,hop 1P1,pwP,il>lllly
Excess ive qua ntity of fuel injected WCllk11hop tfl •,pott•,lliilt l y

Engine overheats Not enough c oolant
Faulty thermos tat
V-belts loo se o r broke n
Coo ling system clogge d
Exterior of radiato r so iled
l\clcl cooll111I, < hock w•, lom for leaks 2.1
noplm u ll1t111110•, l11I
f{ot1qhlf111m 1111111w V Lwlls 4.3.3
Workhhop 10•,po111,llullly
Clea 11oxlurlor ot 1,111111101 4.3 .2

5.2 Clutch

Clutch slips Clutch fac ings wo rn or covered

wi th grease or oil Work1;hop rt••;pon'i il >tllly

Clutch dragging Air in th e hydrau lic syste m Workshop rp1,po11'-iil>1hty

Insuff ic ient release travel of slave
cy linder Workshop responsibility

Fluid level in hyd raulic system

too low Check sys tem for leaks, rep lenish 4.4.1

74
de tails For de tails
r 5.3 Steering refer
ecti on Cause f r,111 ll'wcIll lion to sec tion

.1 Hard steering Ste ering kmu kh,s n111 Ii ii ,111 Iii ii I 11lulc, 1lc
.8 No oil in SICPrlltq I' 11 l ltl'< k sys tem for leaks , add flui d 4.7.3
.2.1

Hard steering Low fluid level 111 • y•,11111 c.lwc k system fo r leaks, add fl uid 4 .7.3
.1.2 lpower steering) V- belt s loose or 1>101<,11 I l ul 1ghten o r renew V-be lts 4.3.3
Air in hydraulic &y ,It 111 Chuc k system for leaks , add fl uid 4.7.3

1.2 Power steering Air in the hydruullt , V I<111 Chec k syste m for leaks,
r• ttles when being turned acld flu id 4.7 .3
Low fluid leve l in :;y IP111 Chec k system for leaks ,
.tdd fluid 4.7.3

f>oor center ing Steering knu ck le'> 11111h 111111 li t ti Lub ricate
Excess ive free piny Worksho p res pons ibility
3.3 Tires und erin flate<I Inflate to correc t pressure
Incorrect to e-in Correct 4.7.4
3.2 Maladj usted front wtu ut
bear ings Workshop responsi bi lity
Low fluid level in sy•,10111 Che c k syste m fo r leaks , add fl uid 4.7 .3
Ai r in th e hy draulic 'iV ,lr 111 Check system fo r leaks , ad d fl uid 4.7 .3

75
5.4 Brake system For details
refer
Cause C CHIP( IIVI' 1f tlUII to section

Uneven braking action Worn tires I~' h,11tq1•

Tires underinflated
Oi l on brake lining s
Uneven brake lining wear
Faulty hydraulic system
lo, 011Ptl prn-;surc
11111,111•
llolt111Jtu.i~t••,, c ll'illl llli&ko cJrum
(wwk•,111111111•,po11,,ll> ltlll es)
111111101>1nku•1
(w1uk•,ho111P·,pom,lli 11ily)
Wrn kuhnp I o•,prnt•a 1>11il y

No or insufficient Vacuum brake booster

braking effect defective Work~.h11p 1p•,po11sll1illly
No brake fluid in hydr auli c system C.,lw,•k hyd1,1ul1c •,y•,lt'lfl 4.9.1
Im lcJ1k•. 11<1<1 IJ111kufluid, 4.9.3
llltJl'd oy•,lt>III 4.9.4
Air in hydraulic system Acid l ir 1kc1f1111d, 4.9.3
l>IOf'd flV ,It •111 4.9.4
Worn lining , grease on lining lh•l1110,wwk•,lmp rt•i;po nsibilit y

The braking effect cannot

be controlled Faulty w heel brake cylinder Wm I •,hop w·,po11i;1h1llty

Hand brake not releasing Ha nd brake cable stuck Wrn ko,l1op I o•,pons 1l>iltly

76
 For details
etails 5.5 Electrical system refer
Call 0 , , \tit l1vonc.t1on to section
ction

Starter will not crank the engine Battery II ,1 ( .lt.llCJO 4.10.5

Battery I 111lly ll1•pli1Ce 4.10.5
Battery lc1111l11 ,1 lo 1 I If II 11I ii l -lP.tn terminals, coa t with acid-
proo f grease, tighten firmly 4.10.5
Cables loo •, or I ,, ,11y I tqhten or replace
Starter ct,,10 t111c Workshop respons ibility

Charging contro l light fails to come Burnt-out 1111111 llop lace

on (with engine inoperative) Open c irc uit• 111
wlJlllU l 1qhten or replace connect ions

Charging control fails to go out 1 ltv1 Workshop responsi bility

(with engine operating) I !<•tighten or renew V-belts 4.3.3
1.1
1.3
1.4 Preglow indicator light
1.3 will not come on Burnt -out 111111> l~eplace
1.4 Interrupt cc I pr oglt ,w
circuit Workshop responsib ility
Glow pluq( 'l) l,111lly Replace glow plug(s)
Battery low Recharge battery 4.10.5

77
 For detail s
5.6 Supplementary heater refer
Cause Corrective action to sect ion

Heater will not ignite ,
control unit shuts off
automatically
Glow plug burnt out
Glow plug is grounded or
carbon-fou led
Ambient temperat ure below
320 F (OOC)
Fuel pump will not feed
Workshop respons ibility
Workshop respons ibility
Comply with measures required
lor winter operation 2.8
Workshop responsibil ity

Heater motor will not start Battery flat Charge 4.10.5

Fuse defective Roncw ruse 4.10.2
Commutator or carbon brushes worn wo, kshop responsibility

System overheats Outlet openings in passenger

compartme nt have been blocked Glenn

78
oils
5.7 Shutting off the engine when the vac1111111v It 111I ln111ty

Open engine cover and push down stop

lever on inject ion pump until the engine
stops .

.5
.2

1 Stop lever at onjection pump (example)

79
 5.8 Tow-starting and towing the vehicle
Towing
For towing , leave engin e runn111q
, 11po :,
sible, to allow th e power stcN 111qJo t,,,
come effec tive and to supply vrn 1111111lo
the brake system.
In case of engine damage
Vehicles with manual transmi ssion
Towing distance up to 100 km (60 n11lus)
1 Towing eye front
There are no restrictions for tow111qtho
veh icle.
Towing distance more than 100 km (GO
miles)
Remove propeller shaft of the live oxlo
Vehicles with automatic MB tran sm1s~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 spee d or
40 km/h (25 mph) .
For a towing distance of more than 50 km
(30 miles), remove prope ller shaft of the
live axle.
80
In c11nc, of tmn smlssion damage
ll1•111ov111Hop1•
ll111•,hill! of the live axle.
In <11111,ol "''" 11xlodamage
I ill 11·.11
,1•h•
111
1:11R1 of lronl nxle damage
I 111110111
.,~lo
I\ 1>01Jlll'Ctctow11vehicle whose dr iving
wl111PI">hi1v1• cl11q into soft or mudd y
111rn111<l, •,l1011lctllt' towed out with utmos t
< ,111',l'',JH·Lially whon the veh icle is load-
, •ct
I ho vfllrn le111n1i,tnot be pulled out jerki ly
m t1t 1111 t111<Jlo espec ially sideways -
l>nc.,1wa,tilt' c h.1ssis of the vehic le might
l>P cl,llllilOt'CJNever pull out a vehic le to-
qcthc1 with tho tru,Jer.
A useful piece of advice: using the rear
coup li ng jaw, pull the vehic le out back -
ward along its orig inal track, if possible .
 Tow-starting

Manual transmi ss ion:

Turn steering lock to driving position .
The preglowing indicator light mu st
have gone out.
Dec lutch , e ngage 2nd or 3rd gear, tow -
start ve hic le, engage clutch slowly and
Movt• c;elt < ''" 1, v,,1111111U1ur,",' •
actuate acce lerator until the engine starts
fi rin g .
Au t omatic MB transmissio n : u 111111
If the enq1110 ,I 111 111111(1 .,,.lrn.lo r
,t po 1111
lever to lht> 11111111 1, 111111111<11.i!P
ly
Turn steering lock to t he driving position. (position "N ")
The preglowing indicator light must have
gone out. Caution : 5ho11ld lht 1 11 11111 I.ill lo fire 1 Towing eye rear
within a IPW ,, , 1111<1 , 11111 111111•ulral
Move selector lever to neutral (pos ition .ii t11w ,I """ll w tum
again and 11'111
"N"). Tow-start ve hic le. For approx. 2

19
ly
st
j-

ly

lt
)-

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 . 1
For safety reasons th is card must 1101IJIJkt<pl 111 l •, ltw key numbe r for t he
ll11JVPlih 11•1111•,
o rder ing of rep lacement keys.
Card No. 2
This ca rd (without key number) is kopl 111lt1tt Mnl11t,,r11111,
11 IJooklct

Please q uote t he co mplet e chassis 11111111>01

,111111111qh11• 111m11Jor when order ing spare
parts o r inq uiri ng for technical detnll·,

82
,e

ire

1 Chassis number } . . 1 I 111111,N I I II fl Ill I/It Body number on right side front cab
2 Identificat ion plate in nght entranc e post

83
6.2 Weights kg (lb)
207 D 207 D 301 D :10, I> ao7 u
209 D 207 0 1 209 D 309 D :u1c1I> aoc1I> 407 D 409 D

Permissible front axle load .. ... ..... 1 350 1 500 1 500 1 at,O 1 ',<JO I ,00 1 /00 1 700
(2980) (3310) (3310) (2 '1110) (3 3 10) (3 3 1<1) ('I /~0) (3 750)

Permissible rear axle load .... .. ..... 1 400 1 400 1 680 2 0:10 ~· () l(J :• •' 1() 1?00 3200
(3090) 3090) (3 700) ('1 '1110) (•1•1110) (•11170) (! ObO) (7 050)

Gross vehicle weight ............... 2 550 2650 280 0 3 ?00 ,1~·oo I {100 '1 GOO 4600
(5620) (5840) (6170) (7 O!iO) (l (If 10) (l '~'()) ( 10 1"0) (10140)
1 Only van

6.3 Main dimensions mm (in)

207 D 207 D 207 D
209 D 209 D 209 D
307 D 307 D 307 D 401 U 40/ I>
309 D 309 D 309 D 409 n 40 11 D

Wheelbase ........................ 3050 3350 3700 33Ml ~I/00

(120.1) (131.9) (145.7) ( 131.fl) (1'1!, 7)
Min. turning circle ...... . ........... 10.9 m 11.8 m 12.7 m 11.8 Ill 12.7 111
(35.7 ft) (38 .7 ft) (41.7 ft) (38 7 11 ) (41.111)
Track, front ..... . . . .... . . . ... approx. 1600 1 600 1 600 1GOO 1 (iQQ
(63.0) (63 .0) (63.0) (630) ((i30)
Track, rear ..... ....... . ... .. . approx . 1 610 1 610 1 610 1580 1 'j8Q
(63 .4) (63.4) (63.4) (62 2) (G2 2)

84
6.4 Engine 2070 2090
3070 3090
4070 4090
I 11111111 6 16 617
Mod, I 6 16.9 6 17.9
Muthod 1110111, 1l1t111 Diesel fo u r st roke
Cy lind, 1 c1111111•111,1,1 4 cyl inders 5 cyl inders
ve rti cal in line
Bor e 90 .9 mm (3.58 in)
Stroke 92 .4 mm (3.6 in)
Total pisto11 di ,pl ,, , 1111
111 2399 cm3 2998 Cm3
(146.4 cu. in) (183.0 cu. in)
Compre sslo11 r 1111 11111111~ 21
Min . cornp1,1· 10111,11 11111
(engine WIIIIIII cl llP) 16.7 bar (242 p si)
Devel op!!d lu)r I pow, 1
accordinq to l )IN' 53 kW 65 kW
(72 H P) (88 HP)
Max . torquu 111N111 tllJ II ) 137 (99) 172 (124)
at 2400/min
Idle speed 750/ min 700/mi n
Injection 01d1 1 1-3-4-2 1-2-4-5-3
Ejection IHIJU',111,111ii 11,1 111111
11n:, los
New no u lo•t 115-123 bar (1 664 - 1 778 psi)
Used nou los at least 100 bar (1 450 p si)

• The specified output measured according to DIN

Start of (l!'IIV• 1y (ll l 24° befo re TDC
70 020 is actually available at the clutch for the pro-
pulsion of the vehicle since all power requirements Valve arrarH1t>1111•111 Ove rh ead, pe r cy linder
for the aux iliary units are ded ucted. int ake an d 1 ex haust valve

85
 Valve clearance intako lJ I lll 111111
(ll (11)41Ill)
{ 11~11 11111
1 (tllll?h1)
with e ngine co ld exhitu·,1
Valve c learance
wit h engine warm
(140° ± 59° F) in1t1kP II1 , 1 111111(1111111j 111)
{ O I i 11111111111 1 1 111)
(60°± 15° C) exh,wi,1
Lub ricatio n system I Oil! 11I I ll llllil 1lh111
Oil pump .. ..... . ... .. . f 11 II l'fl) 11111111
•
Oil filte r ........ . •..... •. •. I' I" I 11111
1111W11111
I
Oi l pressure
Idle speed . ........ . ... . . •• 11I 1 111l, IJ 11 (7 I 11•,I)

6.5 Cooling system Cooli ng sys t em . . . . . . . . . . . •

Temperature control . . . . . . . • •
Coolant temperat ure .... •.. • .

Design .. .. .... . ..... .... •.•• ,111 Jlol pl 11• dry, li1h 11
6.6 Clutch
Clutch control . . . . . . . . . . . . . • llydr 11111
1

Desig n . .. .....•......... ..• hy11111111111,11 111111•,11w,s 1o n

6.7 Transmission
c,l/1U 1/1 I',
Model . ..... ...... . .... • .. •. f II I
Number of gears . . . . . . . . . . • . . .
Gear ratios . ... ... . ... ...... ••.
IPVlll ,t -t, Iii{
I lpll111111I
MIi ru11<1111111i 1•1miss1o n W4 A0 18
l1111
'I .'ll I .
1 fo11W11fd I It VIII ,IJ
1-,111111/i,1 1,'/ 1,rn :111.1;
11 VOi ,t - l., •11 111

' At ambi ent temp eratur es co ntinu ously below -4 ,0° F

(-20° C) add 0.0 5 mm (0.001 2 in) to valve clearance.

86
6.8 Steering system Do ,11111 Mo111u,1
I steering L 1.5 Z
Mod,JI /GO2
Optional.
f'owor steeri ng LS 2 A
7655

Powor ,,11, 111111pu11111(filv1 V belt, narrow type 12.5 x 900

6.9 Front axle Vehicle 2070/2090

Design Rigid knuck le yoke axle VL 0/ 1 C-1 .3
Model 730.4
Opt ional:
Rigid knuc kle yoke axle VL 0/2 C-1.5 1
730.4

Vehicle 3070/309 0
Design Rigid knuck le yoke axle VL 0/2 C-1.5
Model 730.4

Vehicle 4070/409 0
Design Rigid knuck le yoke axle VL 0/3C-1.7
Model 730.4
Toe-in
(measurocl 011 1111wl1t11 I II 1111111) straight tie rod O± 0.5 mm (0 ± 0.012 in)
offset tie rod O± 2 mm (0 ± 0.08 in)
Camber 10
Kingpin inc 111111111111 50
Caster 2° 30'
When camber, caste r and kingpin
inclination data are quoted in degrees
of angle, a tolera nce of ± 20' must not
1 Van standa rd version be exceeded

87
6.10 Rear axle Vehicle ............... ..
Des ign . . .... . .. .... .. . 11 ,~It 111 0/1 • 1.7
Mode l . .. .... . .. ..... •..
Rear axle ratios . . . . . . . . .

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

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

Design ........ ... .. .. ... . 111 0/?. 2.2
Model . .. .. .... ..... ......... .
Rear axle ratios ......... .•..

Vehic le cargo tru c k . . . . . . . .

Design .. . . . .. ... ... ... .•.. 11 ,~h 111 0/3 3.3
Model .... ... . . ........... .
Rear axle ratio s. . . . . . . . . . . .

Vehi c le Van . . . . . . . . . . . . . . . . . . 110/ I>

Design .. . ... .... .. ..... •.•.• I lyp Old OilII l~h· 111 0/3 ·3.3
Model . .. ... . ......... .......•. l•I I '•ii
Rear axle ratios. . . . . . . . . . . • • . I ti Ii
r lpl 11111,1
1- [, 111

Vehic le . .. ... . . .... . .... ....•. ,1011 II

Design ...... . .......... . . ..• I lyp1111I ll' II It• 11. 111 0/3 ·3.3
Model . ...... .. .... ... . ..... . 7 I I ',;.>
Rear axle ratios .......... .... . 1- ,1'I
( lpllllll ,1
1 - •, 331
6.11 Brake system

Cargo trucks and vans:

1st circuit = front wheel brake (disk
brake)
2nd circui t = rear wheel brake (drum
brake)

Cargo bus for perso nnel transpo rtation:

1st circu it = fro nt wheel brake (disk
brakes , lower pistons of
brake calipers) and rear
wheel brake (drum brake)
2nd circuit = front wheel brake (disk
brake, upper piston s of
brake calipers)

89
6.12 Electrical system Alternator
Design .. ... ..... .... . . .• . .•. 11111I pit I ,I
Output . .... . ... . . .... ...•. l•I V/ ,,, A
Alternator drive ........ ... . V Ii, II I ,' t, Ii I O I ',

Starter motor
Design ........ . . .... .. .. .
Output .. . ..... . . . ...... ... .

Batteries, Engine 616 . . . . . . . . I,' V 1,1iAll

t >pll111111I
I,' V 1111
Ali 111
•' )( I I
V I olo Ah or ~ X 12 V 88 Ah
Engine 617 ..... .... .. I:• V 1111
Ali
CIt,11111111
!' x I!' V 1111
Ah

90
Lamps (DIN 72601) Incandescent lamps

110.,<11111111 A 12 V 45/ 40 W
Op tional:
H 4/12 V 60/55 W

HL 12 V 4 W

Turn s1u11 ,1
Stop hqlil P2 5-1/ 12V2 1 W
Rear loq 111111 :}
Tail liqhl i; 1111111111
1 G 12V10W
Vn11 G 12 V 5 W

Licenso plriti 1tgl1I L 12 V 5 W (Festoo n bulbs)

Interior liqhl K 12 V 10 W (Festoon bu lbs)

lnstrumonl lloh1111
l
Maximum •.pt Id w 111111111
1111111 H 12 V 2 W
Indicator hqlll

Hazard w11111l11 1 II, 11111111th111111

ll11ht
llluminall on 111111,1o,( 011trc,I· W 5- 12 V 1.2 W Glass- base lamp
Indicato r 1111111
11111 11 liJ 1 1111111
FuSC'l • 8 A, 16 A, 25 A DIN 72 581

91
Key to wiring diagram (Position 1 to 7)

Wire color code Light switch, rear fog light, I uu ll uht 11

license plate light, tail light,
bl = blue right, parking light, right 111 l11qlit1hl , h•lt
br = brown I I I II I Ii thl I ICJhl
el = ivory E1 Rear fog light
ge =yellow E2 License plate light
gn =green E3 Lice nse plate light
gr =grey E4 Tail light, righ t I 11111 11
lunnl llyhts, hazard
Ii = violet E5 Parking light , right wcu 11111u llnaher system
rs = pink F6 Fuse
rt = red
01 Light switch I I I 111·
sw = blac k
X1 Trailer plug soc ket 11t 111111•,11111111
indicator light ,
ws = white l rnll1·1
I :i 11.1.·.11dwarning flash er
Example: ,1•111111111
11111
1
Wire designation 1.5 gr/ rt ;, , 1111111111.it
ron switc h
Cross section of wire 1.5 = 1.5 mm2 Parking light, left, tail light, loft, l I I I 1l 11dwarning flas her switch
Basic color gr = grey trailer plug socket
Identif ication color rt = red
E6 Parking light, left
E7
F5
Tail light, left
Fuse
I, I 011 c•rnll1111monitoring
I 11111
1111111
• 111
!1
X1 Trailer pl ug sock et
Starter control , power supply 11', 111111 •,1q11a
l indicator light ,
l1ru Im
A1 Steering lock I Iii 111111 •,lqnal, front, right ,
G1 Battery 12 V 1111 ·,rclo
G2
H1
Alternator
Preglowing indicator light
GJ Headlights 117 I 11111
1111 I 11111
•;iqnal , front, right
·,1qnal, rear, right
H2 Charge indicator light E8 Headl ight, left ll 'l I 111
n •;rqnal, rear, left
K1 Relay E9 Headligh t, right 111o I 11 111•,1qnal, front, left
M1 Starter F1-F4 Fuses 1111 111111 •,iqnal, front, left,
R1 Glow plugs H3 High beam indi cator liqhl Oil •,!(Ip
S1 Battery master switch S2 Comb ination switc h X1 I 1.rllPr plug soc ket

92
 sv./blEc
1 lsw/bl g, ~
•w1w1
1,.5ge
tws-50

f],~+
t 1•w
I ' ,.,.,,... 1
1~
r I
,bl
g•
.
- -
4 !Jllf!:¥.
l' 1I ~·, •'vi I X8
l
IX/2

• ,1;·t'I
l 1 I
2,5
~ It ) &:,8~ I h,
[!:SJ:
~. ii}. •!HI <>
I 11 rt Xl r, E4f
! r•
ES

1
L
~- =2.S~•w~---'•~w ~- ~ 12
~4___
14
lbl I II
'fl 104
JI 32
46
33
~- -i--i----t- -- -1b r
l32
40 41
4d
r
_j

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

w/-;;rs=--=-- ------- --- - -~-- - - -69
11
0 "1- -ls w/g, ws
5P,~h"fg, 41
!i1).1 f. t~ r P",
FS
8A u
" r.1s2
1
WL ~t -tt
l
tul f f l ~
4\41,5gr

l +- ~ 1sw/gnws
I WtlJI 1-=f:= :::::=~~~::;:: =F~\ 5;)s
w~/h~== =;-;;~===i-
lsw/ws - 69
lsw/gn

1 1 1,5 \5 \5
I JO -,SP,
\5
SW
gr gr
SW
bl
ws
ws ws g•
SW
ws Yv!
.J~ ,

~
S3

L
49

j \~ \5f
I
X/6 X/7

I 1

r T Jl
,k"' JJ,., "'~
g,
EJ •E7~ ! X1 H3t ~ ,l f g,
41_._
I
lb, ;
\5f'
! 63
1 T
ES E~~ E11
i
l
\5
T
,.~ ~.
l
rt
i 1
31 r
HS
J-- ,t,r-----1 T , 1

42
•r 43
04
44
,3,
45
33
46
br
J..
\5,_br 1..5.._br tr l!f ,,
1/1 J..
r r 63:5 r 'r si
'>O 59 68 2
L
ill ...L
ill j
(sj l. ..L -[1)- _je

93
Key to wiring diagram (Position 8 to 18)

0 Windshield wiper, windshield

washer
~ Backup light 1,1 I !nilly Im !waled rea r
w111ctow
E12 Backup light, left 11;• I It• 11t•d tt'ilr window
M2 Wi ndshield wiper motor E13 Backup light, right 11'.I I lout,•d 11'.tr window
M3 Wi ndshi eld washer motor F10 Fuse
K3 Switch , winds hield wiper, S6 Backup light sw itch
intermittent wiping
S2 Combi natio n switc h
~ Speedometer, tachograph , ctor k ! I
11, Ill nkc, llutd, olt pressure

E14 Lighting for heatc, 1111

I I It lh ,1trn light, brake flu id
0 Stop light
P3
control
Speedometer
111U l11dh.,,trn light, oil pressure
I,, n,,111v
B1 Stop light sw itch r ,I()
P4 Tachog raph ',w11<II, liruke fluid
F8 Fuse 11 • ,w11<h, 011pressure
P5 Clock I
H12 Stop light, left
H13 Stop light , right
H14 Horn
S4 Switch, horn B Door contact switch,
interior lights , plug socket
X1 Trailer plug socket
E15 Interior light
III J
c 1,11,111111·11tights

F7 Fuse I I ii < l11111u11co

tight, front , left
~ Heater blower H15
S7
Interior light
Switch, interior light
Ll7
I I II
< t,,,11.i
ncc light, front , right
< .1n,11,111
cc light, rear, left
M4 Heater blower motor S8 Door contact switch I I 'l < .1,•u1.incclight, rea r, right
S5 Heater blower switch S9 Switch, interior light
X2 Plug socket

EJ Fuel, coolant
~ Heated rear window I 1111 llr t1ktt pnd wear
B2 Send ing unit for fuel gauge
B3 Se nding unit for coo lant B4 Sw itch for heated rca, ' II. • ,witch, brake pad wear, left
temperature gauge window '- I ,I • iw1tch, brake pad wear,
P1 Fuel gauge H16 Indicator light for hcillt •ct liq ht
P2 Coolant temperature gauge rear window XI I 1,1llnrplug sock et

94
 32 -1g,-/gn rl-isa

~F8
Ij1~1° 3~
r+
8A
f----1swlott
lsw '" t 1,,,,,
,, 111gr1gn rt ~rt
M lrt m
I'} J 1 1

r1
~t B1 {/) 1 gr 1 gr

r I' II I In 1~ !' 1
'·r.~'I L,,, ~
lsw
rt
P\ij58

trr~..
tx/3
1sw
rt

1srn
rt
• •
H12 t ~
t H13
1
br
.L
1rt

1
sw

br
.L 1
.1:
.~
)I~~,
I I ~ ~ ~ ~ ~
104 106
(IIJI I IT} .L -ill]- .L J

95
Key to wiring diagram of
automatic transmission I 111 11)1'•1
1 11 "f 30
II (~\
3,?~
0

';;--f)
'IIIIK
1 I I I I I I I
1 Speedometer lighting
2
3
4
Relay
Fuse box (standard equipment)
Starter
-4 ;
I+,.
J :c
5 Selector lever position indicator
6 Transmissio n
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 switc h
10 Send ing unit, selector
1,w / hl
lever position indicator

1
br
gr ......4-+-4----+----t- +- --

T1
br
1
br
1
br
1
br
1
br
1
br
1
br
II
br

~*µ
L
·:_rl
' ,~ \ I ~~ --: _ J
m

96
7 Tightening torques in Nm (lb ft)

Engine I 111111•• , .,

Cylinder head cover 1 , 1I u lll I rrn 11 p1111ql J t >oil 80 (57 8)

Oil pan to crankcase
M 6 . ....... . ... . .... ... ...... . .. 11 (7 1111

M 8 .... ..... ............... . ... . 30 ( 'I 71 II cuu • a Ift

Oil drain plug - oil pan ........... . 35 -45 (25 3 I I 40-50 (28.9- 36 .1)
80 (57.8)
Oil filter cap .. ....... .... . . ...... . 20!144)
Hose clamp ..................... . (, (4 IJ

Whonla
Transmiss ion
Wt11, I 111111111ting bolts or securing
Manual transmission 111110 1 c11 k wheels .............. 160-180(115.7-130.2)
Oil dra in plug . .. .. . ....... .... ... 70 ± 15 (50 6 l IO 0)

Automat ic transmissio n
1!!!!1111\j
Oil pan ......................... . 7 ( 1)
J 111111111 11111lo steering gear L 1.5Z .. 360 (260.4)
Oil filter ........................ . 4 (~ 8) LS2A .. 360 (260.4)
Oil drain plug - torque converter . . . 14 +2(101114) ( I 11111111111
•,lceve to tie rod ....... . 45-55 (32.5-39 8)
Securing sc rew - oil filler pipe ..... . 35 I 7 (~!J 3 I , I) ,11111111lstie rod ... ........
1 c1111i . 90- 100 (65.1- 72 .3)

--
'.,,,

97
8 Capacities - summary Components and lubri ca nts m ust matc h Therefore, only tos tccJ and rec ommended
brands must be used . MERCEDES-BrN7 !l<'rvtCO <;lntiom, will rencJ1ly give you all th e
required information .

Mode l Capacities c a. I lH)I, < oo l,1111,1111111<

lilll
01 lllllktl lh11cl
max . 6.5 I
(13.8 / 11.5 US / Imp. pi s.)
616 616 .9 m in. 5.0 I
Engine w ith (10.6/8 .8 US/ Imp. pts.) V1<;cosity ranges
+ fnq11111oil
oil filter max . 6.5 I rln ler to "Section 3.2"
(13.8/ 11.5 US/ Imp . pts.)
617 61 7.9 min. 5.0 I
(10.6/8.8 US/ Imp . pts.)

Manua l transmission G 1/ 18-5 r 711 .1

2.3 I
(4.9/4.1 US/ Imp . pts.)
Auto11111t11, t11111•,111l•1•,lo11
flurcl (A 11) typ1JA ~i11tl1x
A
71 Auto111atlcIr 111•,1111i,•1to11
MB automatic transmission 720 .1 flurcl (A11 ) 1Jux1011
II
(14.8 / 12.3 US / Imp . pis.)
1.5 I
HL0 / 1-1 .7
\ 741.406 (US/Imp . pts. )
1.8 I Hypo icl Ill'• 11oil SAE 90, 85 W/ 90
Rear axle HL 0/2 - 2.2 741.404
(3.8/3.2 US / Imp . pts.)
1.8 I
HL 0/3 - 3.3 741 .52
(3.8/ 3.2 US/ Imp . pts.)

98
 Model ( 111111
, 1111
• I II Fuel, coo lant, lub ricant
or brake fluid
Clutch and brake systems - o II Brake fluid
hyd raulic sections ( I I\/ I 9 II R/111111
pl!l )
t-
Grease nipples on chassis
and body Multipurpose grease

Battery term inals Bosc h Ft 40 v 1

Fuel tank 70 I
( 11.1(,/ 1(i jl 11',l lillp U.tl~) Diesel fuel

Engine 616
--+-616.9 10 ', I
22 ~'/ I O(i II ,1h11p phl
Cooling system Coolant
Engine 617 617.9 10 I
(?.1 111t (J I l'l/ 111111
pl :,, 'i
Windshield washer system and 71 Water with MB windshield
headlight washer system L ( 1'1 8/ 12 3 II Jl111p pi s ) wash ing agent

99
9 Service and maintenance jobs - summary
(For details refer to Maintenance Booklet)

Under severe
operating conditions
Under nonnal
operating cond ition s
after 500 - 1 500 km
Oil c hongo on uruts

0
'

-~
..
Automa tic
~
Inspection
after 500 - 1 500 km
(300 - 900 miles) (300 - 900 mile s) • • •
Operating Fuel Mileage Opo1111
111u
hours throughput hours
(h) liters km (miles) (h)

Service
Service
70
140
800
1 600
7 000
14 000
(4000 )
(8000 )
140
280
••
Maintenance 200 2400 20000 (12 000) 400 •
Service 270 3 200 27 000 (16000 ) 540 •
Service 340 3000 340 00 (20000 ) 680 •
Maintenance 400 4800 40000 (24 000) 800 • • • •
Service 470 5600 470 00 (28000 ) 940 •
Service 540 6400 54000 (32000 ) 1 080 •
Maintenance 600 7200 60000 (3600 0) 1200 •
Service 670 8 000 67 00 0 (40000 ) 1 340 •
••
Service 740 8800 74 00 0 (44000 ) 1 480
Maintenance
etc.
800 9600 80000 (48 000) 1600 • • •
0 Change oil and fille r at least tw ice a year .

100
Tire pressure chart

Tire pressure in bar (I> I)

Rear axle
(I( I Axle loads kg (lb)

Tires rn , 0 I II I I pl
(jJ I UIII 11 Ill
1400 1680 2030 22 10 3200
(?. (3090) (3 700) (4480) (4870) (7050)

175R 14C/N 6 37 40
(t,Jdl (56.9)

185 R 14C/N 8 3 ?.' .. 4.5 4.5

(4 ·') fl 11 (64) (64)

205 R 14 C/N 8 (I 4.5

(41 (64)

215 R 14 C/N 8 2fli

(3 IJ
,
I II)
45
(64)
4.5
(64)
4.5
(64)
4.5
(64)

Summer tires, top speocl 140 km/II (fl 1111 l,J

Winter tires, top speod I ?.OI 111/11( ,,. 1111
It]
Your MERCEDES·BI Nl o ,vi I I ti y 11111Ht h I 11111t1onon winter tires.

Caution:

(ll lite! tO •I 11
6115841096
Order No. 6550 6092 02
Englische Ausgabe A/1

Daimler-Benz
AGStuttgart-Untertuerkheim
Zentralkundendienst