1987 Mercedes-Benz 300D Service Manual

• 1,081 PDF pages in 72 separately named article files, indexed primarily to the 1987 Mercedes-Benz 300D. Related articles also identify 190D/190 Series, 260E, 300TD, 300SDL, 300E/300 Series, 420SEL, and 500/560 Series applications.
• Diesel engine material identifies 602.911, 602.961, 603.960, and 603.961 applications and covers cylinder-head service, timing-chain replacement, valve timing, camshaft and hydraulic tappet inspection, prechamber work, piston/rod and bearing service, lubrication, cooling, injection-pump timing, and turbocharger testing.
• Drivetrain sections address W4A020 and W4A040 diagnosis, non-190 automatic-transmission removal, fluid service and control adjustments, axle-shaft and CV-joint repair, differential disassembly, pinion-depth setup, bearing preload, backlash, and pinion-seal replacement.
• Brake and chassis articles cover four-wheel disc-brake repair, Bosch ABS tester diagnosis, hydraulic-unit and wheel-speed-sensor service, power-steering pump and gear overhaul, front strut and wheel-bearing work, 5-link rear suspension repair, and alignment checks.
• Automatic climate-control coverage includes pushbutton panels, Bosch/Kammerer logic, the auxiliary coolant pump and heater valve, vacuum actuator tests, sensor and compressor cut-out diagnosis, test-box procedures, and HVAC wiring/vacuum diagrams.
• Electrical information pairs a 300D/300TD component locator with full-vehicle grid drawings and system circuits for starting/charging, cooling fan, electronic diesel controls, ABS, SRS, power accessories, wipers, and climate control.
• This is a Mitchell Repair Information Company article-print compilation, not a single Mercedes-Benz factory workshop manual. Eight all-makes Motorist Assurance Program inspection-guideline PDFs account for 479 pages of the set.

Coverage and File Structure

The files are organized by subject rather than as one continuous manual. The main header is 1987 Mercedes-Benz 300D, but each article has its own application list. The diesel engine chapter names the 190D, 300D, 300TD, and 300SDL; shared-system articles broaden the list where common hardware is discussed.

Coverage outside 1987 is selective. VIN, maintenance, service-indicator, ABS, and SRS articles include certain earlier or later years, but they do not provide complete 1983-1987 repair coverage. General sections address troubleshooting, injector waveforms, overhaul practice, cooling service, alignment theory, and diagram use. The eight uniform inspection publications cover major vehicle systems for all makes and models; they are inspection standards rather than Mercedes-only repair chapters.

Diesel Engine and Drivetrain Repair

The engine article separates the 602.911 non-turbo 2.5L, 602.961 turbo 2.5L, 603.960 turbo 3.0L, and 603.961 turbo 3.0L configurations. It documents cylinder-head removal and installation, the tightening sequence and multi-stage angle method, timing-chain replacement, camshaft timing checks, hydraulic tappet inspection, valve spring and guide work, combustion prechamber service, piston and connecting-rod installation, crankshaft and rod-bearing checks, front and rear oil seals, oil-pump service, and water-pump replacement. Related tables provide torque specifications, capacities, wear limits, clearances, and dimensional data.

Engine/transmission assembly removal is shown for the 190D and 300SDL applications. Procedures not covered there are referred to a separate all-piston-engine overhaul reference; its cleaning, inspection, machining, and reconditioning material is not specific to the 602/603 diesel engines. Dedicated tool references include Chain Press 000 589 57 43 00, Dial Indicator Holder 363 589 02 21 00, ABS Test Adapter 126 589 09 21 00, and SRS Tester 126 589 10 21 00.

For the diesel cars, the transmission tables identify 722.317/W4A040 for the 300D and 300TD and 722.321/W4A040 for the 300SDL; W4A020 applications are also listed for the 190D range. The material covers operating-pressure diagnosis, shift complaints, transmission removal, fluid service, linkage and control-pressure-cable adjustment, modulating-pressure checks, vacuum-control setup, and neutral-safety-switch adjustment. It does not contain a full internal automatic-transmission overhaul. The drive-axle article goes deeper, with axle and CV-joint work, differential disassembly and reassembly, limited-slip components, shim selection, pinion depth, preload, and ring-gear backlash.

Climate Control, Electrical Systems, and Chassis Diagnosis

The automatic climate-control article distinguishes 300E control-panel operation from the other covered systems and separates Bosch from Kammerer panel behavior. Diagnostic sections cover functional checks, vacuum doors and switchover valves, temperature sensors, the evaporator temperature regulator, auxiliary fan control, compressor cut-out logic, and electrical testing with Adapter Cable 124 589 16 63 00 and Socket Test Box 124 589 00 21 00. Although the 260E appears in the article heading, the publication states that model-specific A/C-heater information for the 260E is unavailable.

Useful drawings include the cylinder-head tightening sequence, timing-chain layout, Mercedes drive-axle and axle-shaft exploded views, the 300E/300D/300TD automatic A/C-heater diagram, the 300/260 Series ABS wiring diagram, the Electronic Diesel System schematic, and the 300D/300TD/300SDL vacuum-hose diagram. Separate electrical files add component locations and engine-compartment, fuse-block, underdash, instrument-cluster, passenger-compartment, and rear-compartment grids.

Several repair traps are called out clearly. Overtightening the drive-pinion flange nut crushes the collapsible spacer and requires spacer replacement. Hammering ABS speed rings can demagnetize them and corrupt the wheel-speed signal. SRS work requires system isolation and the specified tester; self-powered test equipment or static at the slip-ring contacts can create an accidental-deployment hazard.

Refrigerant recovery, ABS hydraulic work, SRS service, spring compression, and lifting require the equipment and precautions specified in the relevant article. The set suits technicians, independent repair shops, and experienced owners who understand the distinction between Mercedes-specific procedures and general industry guidance.