This repair and tune-up manual by Glenn's Guides, covers 1951-1965 Mercedes-Benz automobiles, including the 180, 190, 200, 219, 220, 230, 250, 300 and 600 models, with fuel- and diesel-injection systems.
- Mercedes 180A, 1957-1959 | 180B, 1959-1961 | 180C, 1961-1963 | 180D, 1953-1959 | 180DB, 1959-1961
- Mercedes 190, 1959-1961 | 190C, 1961-1965 | 190D, 1958-1959 | 190DB, 1959-1960 | 190DC, 1961-1965 | 190SL, 1955-1962
- Mercedes 200D, since 1966
- Mercedes 219/220S, 1957-1959
- Mercedes 220, 1951-1954 | 220A, 1954-1957 | 220B, 1959-1965 | 220SB, 1959-1965 | 220SE, 1958-1959 | 220SEB, 1959-1965
- Mercedes 230SL, since 1963 | 230/230S, since 1966
- Mercedes 250S, since 1966 | 250SE, since 1966
- Mercedes 300D, 1957-1961 | 300SL, 1957-1963 | 300SE, 1961-1965 | 300SEB, since 1966 | 300SEL, since 1966
- Mercedes 600, since 1965
This is a comprehensive repair and tune-up manual for Mercedes products. It is for the car owner interested in making his own repairs to save money, for the professional mechanic employed exclusively in servicing this company's products, and for the sportscar enthusiast who wants to squeeze that extra ounce of performance from his engine.
This guide is organized around the familiar units of the automobile: the engine, fuel system, electrical system, and running gear.
The first chapter deals with conventional troubleshooting, without specialized equipment, to enable you to isolate the trouble before beginning any disassembly. It will help you to pinpoint the trouble so that you will know what to look for as you disassemble the unit. Therefore, it will save time when making repairs.
This guide contains comprehensive tables and specifications, wiring diagrams, and exploded views of most of the mechanical and electrical units used on Mercedes-Benz cars.
Book Excerpt: 1951-1966 Mercedes-Benz Repair and Tune-Up Guide: 180, 190, 200, 219, 220, 230, 250, 300, 600
TROUBLESHOOTING THE CARBURETOR
DIESEL SERVICE PROCEDURES
The air-fuel mixture can be measured accurately by means of a combustion analyzer. Actual gas mileage or fuel consumption can be measured by use of a gas-mileage tester.
However there are times when a mechanic will want to make some simple tests to determine the carburetor condition without hooking up elaborate equipment.
A rather simple test for the range condition is to advance the throttle to a road speed of about 30 mph (48 km./h.). Hold the palm of your hand partially over the choke bore to restrict some of the incoming air.
At this speed, a normal carburetor mixture should be somewhat on the lean side. By restricting some of the air, you will enrich the mixture and the engine should speed up slightly.
If it speeds up considerately, the mixture is too lean; if it doesn't speed up at all, the mixture is too rich. In either case, the carburetor needs to be overhauled.
CARBURETOR TROUBLESHOOTING CHART
TROUBLES AND CAUSES
1. Lean condition on range-surges
1a. Air leaks at manifold or carburetor flange
1b. Clogged bowl vent
1c. Needle valve seat orifice too small
1d. Fuel level too low in bowl
1e. Clogged air bleeds
1f. Wrong main jet or metering rod installed
1g. Clogged main jet
1h. Worn throttle shaft
1i. Insufficient fuel pump pressure or volume
1j. Manifold heat control stuck open
1k. Leaking vacuum lines or defective vacuum booster pump
Dirt and carbon formation on the nozzles are the two enemies of good injector operation. Carbon forms on the nozzle and distorts the spray pattern, which degrades the combustion process.
Particles of dirt can ruin the injector pump quickly because of the close fitting parts. To prevent entrance of dirt, fuel filters are incorporated in the system, the periodic cleaning of which is an essential part of maintenance.
Because of the accuracy required to rebuild the pump, it is generally exchanged instead of being repaired. The replacement pump must be timed to the engine.
After any repair work, it is necessary to bleed the lines to remove entrapped air.
Disconnect the injector lines at the nozzles and at the injector pump, and then remove the lines. Loosen the oil leak line cap screws a turn or two.
Remove the four 17mm. hex nuts holding the oil leak line fittings to the injector nozzles. Disconnect the oil leak line at the cross-fitting on the fuel filter, and then remove the oil leak lines and the fitting assemblies.
Remove the nozzles from the prechambers.
Subject: 1953, 1954, 1955, 1956, 1957, 1958, 1959, 1960, 1961, 1962, 1963, 1964, 1965, 1966 Mercedes-Benz 180, 190, 200, 219, 220, 230, 250, 300, 600 Repair and Tune-Up Guide. ISBN-10:
1869826329 | ISBN-13:
TABLE of CONTENTS:
CHAPTER 1 - TROUBLESHOOTING
Basic Starting Trouble Tests | Detailed Starting Trouble Tests: Cranking System; Ignition System; Fuel System | Troubleshooting Mechanical Parts of the Engine | Troubleshooting for Excesive Oil Consumption | Troubleshooting for Engine Noises | Troubleshooting for Poor Performance due to Excessive Frinction | Troubleshooting the Cooling System | Troubleshooting the Fuel System | Troubleshooting the Carburetor | Troubleshooting the Electrical System: Troubleshooting the Battery; the Cranking System; the Charging System; the Ignition System | Testing the Ignition System for Conditions Causing Power Losses | Throubleshooting the Clutch | Throubleshooting a Transmission | Troubleshooting the Rear Axle | Troubleshooting the Front-End | Troubleshooting a Hydraulic Brake System | Troubleshooting the Caliper Disc Brake System.
CHAPTER 2 - TUNING AND IDENTIFICATION
Identification | Manufacturing Dates | General Engine Specifications | Tuning | Capacities | Ignition Service Notes | Commonly Used Specifications | Road Tests.
CHAPTER 3 - THE FUEL SYSTEM
Carburetor Service Notes | Solex Carburetor Specs | Zenith Carburetor Specs | Overhauling a Solex PBIC Carburetor | Overhauling a Solex PAITA Carburetor | Overhauling a Solex 44 PHH Carburetor | Overhauling a Zenith 35/40 INAT Carburetor | Gasoline Injection Systems | Fuel Injection Service Procedures: Injection Nozzles, RandR; Injection Pump, RandR; Timing the Injection Pump; Venturi Control Unit, RandR; Idle Adjustments; Throttle Linkage; Troubleshooting | Diesel Engine Service Notes: Starting Procedure | Diesel Service Procedures: Nozzles, RandR; Diesel Injector Nozzle Spray Pressures; Injector Pump, RandR; Diesel Troubleshooting Chart.
CHAPTER 4 - THE ELECTRICAL SYSTEM
Distributor Specs | Overhauling the Starting Motor | Starter and Battery Specs | Overhauling the Generator | Alternator: Troubleshooting; Test Specs | Alternator and Regulator Specs | Chassis Wiring Diagrams | Generator and Regulator Specs | Light Bulbs.
CHAPTER 5 - THE ENGINE
Gasoline Engine Service Notes: Cylinder Head, RandR; Checking the Valve Timing; Engine Torque Specs; Tappet Adjustment; Piston and Rod Assembly; Engine Removal; Mechanical Engine Specs; Valve Specs; Oil Pan Removal | Diesel Engine Service Notes: Piston and Rod Assembly; Piston and Rod Assembly; Engine Removal; Oil Pan Removal.
CHAPTER 6 - CLUTCH, TRANSMISSION AND REAR END
Clutch Service Notes: Clutch Pedal Free Play Adjustment; Clutch and/or Transmission Removal | Hydrak (automatic) Clutch: Operation; Service Procedures; Hydrak Clutch Troubleshooting Chart | Overhauling an M-B Transmission | Automatic Transmission: Service Procedures; Auto Transmission Troubleshooting Chart | Rear Axle: Pinion Depth Adjustment; Differential Bearing Preload; Mesh Adjustment | Rear Axle Specs.
CHAPTER 7 - RUNNING GEAR
Front-End Alignment | Steering: Adjusting the Steering Gear Assembly | Power Steering: Service Notes; Troubleshooting Chart | Wheel Alignment Specs | Brakes: Automatic Adjusters; Replacing Brake Shoes; Girling Disc Brakes; Dunlop Disc Brakes; Teves Disc Brakes; Bleeding the Brakes; Pressure Regulator.
Note: This manual was originally published in 1966 by Chilton Books.