Mercedes Benz Type 600 The Grand Mercedes (1964-1981) Workshop Manual

 

 

0 Technical Data 
0-6 Jacking up Vehicle 
A. General 
B. Jacking up with the Standard Car Jack 
C. Jacking up in the Work Shop 
D. Setting up Jack-Stands

 
00 Engine 
00-0 Testing and Adjustment of Engine 
Adjustment and tightening torque values 
00-1 Removal and Installation of Engine 
00-3 Adiustment of Tappet Clearance 
00-4 Measuring and Adjustment of Dwell Angleand Breaker Point Gap 
A. Measuring of Dwell Angle or Breaker Point Gap 
B. Replacement of Breaker Points and Adjustment of Dwell Angle or Breaker Point Gap 
00-5 Adjustment of lgnition Setting 
00-7 Testing of Valve Timing 
00-10 Testing of Delivery Pressure of Fuel-Feed Pump 
00-15 Tuning of Engine 
A. Adjustment of Control Linkage 
B. Adjustment of Idle 
00-17 Starting and Warming-up Device 
00-18 Operation of the Starting Device Control Elements 
00-20 Trouble-Shooting Hints - Engine 

 

01 Engine Housing 
01-3 Removal and Installation of Cylinder Head 
Removal 
Installation 

 

03 Transmission Parts 
03-3 Removal and Installation of Vee Pulley and Vibration Damper on Crankshaft 
Removal 
Installation 
03-4 Removal and Installation of Front Radial Sealing Ring on Crankshaft 
Removal 
Installation 

 

05 Timing 
05-1 Removal and Installation of Rocker Arm 
Removal 
Installation 
05-2 Valve Stem Sealing System 
Removal 
Installation 

07 lnjection System 
07-5 Starter Mechanism 
Operation 
07-7 lnjection Valves 
Removal and Installation 
07-9 Removal and Installation of lniection Pump 
Removal
Installation 

09 Air Filter 
09-1 Air Filter 
General 
Cleaning air filter element 

13 Air Compressor and High-Pressure Oil Pump 
13-1 Removal and Installation of Air Compressor and High-Pressure Oil Pump 
Removal 

14 lnduction Manifold and Exhaust Manifold 
14-1 Removal and Installation of Exhaust Manifold 
Right exhaust manifold 
Removal 
Installation 
Left exhaust manifold 
Removal 
Installation 

15 Electrical System 
15-0 Electrical System 
Starter 
Generator with Regulator Switch 
Distributor 
Ignition Coil with Bosch Series Resistance 
Battery 
Fuse-Box Connections 
15-2 Removal and Installation of Starter 
Removal 
Installation 
15-10 Generator and Regulator Switch 
General 
Description - Internal Wiring 
Terminals 
Testing Generator in Vehicle 
Testing of Generator on Test Stand 
Energizing 
Setting up Generator on Test Stand 
Testing with Regulator 
Testing Regulating Voltage at Half EnergizingCurrent 
Determination of Rated Voltage Speed 
Testing 2/J J max. 
Testing Rated Charging Speed 
Testing without Regulator (only in emergency) 
Testing of the Individual Components 
Testing Rectifier with Ohmmeter 
Testing of Stator Winding 
Short to ground (rectifier unsoldered !) 
Short-Circuit in Windings (rectifier unsoldered !) 
Testing Energizing Coil (rotor) 
Ground-Short 
Short-Circuit in Windings 
Voltage Regulator 
15-11 Removal and Installation of Generator 
Removal 
Installation 

18 Engine Lubrication
18-1 Composite Oil-Filter Unit 
18-2 Removal and Installation of Oil Pump 
Removal 
Installation: 
18-3 Oil Relief Valve 

20 Cooling Units in Engine 
20-1 Hydraulic Fan Coupling and Water Pump 
A. General 
B. Removal and Installation 
20-3 Partial Dismantling of Water Pump 

22 Engine Suspension 
22-0 Engine Suspension 
22-1 Front Engine Suspension 
Removal 
Installation 
22-2 Rear Engine Suspension 
Removal 
Installation 

23 Finger-Tip Control Hydraulic Pump and Vee-Belt Drive 
23-0 Vee Belts 
Arrangement of Vee belts 
Vee belt tension 
Tightening torques in mkg 
23-1 Removal and Installation of Finger-Tip Control Hydraulic Pump 
Removal 
Installation 
23-2 Vee Belts 
A. Replacement of Vee Belts, Testing and Adjustment of Tension 
B. Vee Belts "a" and "e" for Left and Right Three-Phase GeneratorsRespectively 
C. Vee Belt "b" for Finger-Tip Control Hydraulic Pump and HydraulicFan Coupling -Water 
Pump 
D. Vee Belt "c" for Air Compressor and High-Pressure Oil Pump 
E. Vee belt "d", for Vehicles with Air-Conditioning Cooling System only 

27 Automatie DB Transmission 
27-0 Automatic DB Transmission 
27-1 General Description 
27-2 Maintenance Procedures 
A. Oil Level Inspection 
B. Oil Change 
C. Servicing Instructions 
27-3 Removal and Installation of Transmission 
27-9 Replacement of Valve-Body Assembly 
Removal 
Installation 

30 Control Adiustments 
30-1 Removal and Installation of Control Shaft 
Removal 
Installation 
30-2 Adiustment of Accelerator Pedal 

32 Springs and Shock Absorbers 
32-0 Springs and Shock-Absorbers 
A. Combinations of Air Springs and Shock Absorbers 
B. Air Suspension System 
C. Shock Absorbers
D. Torsion Bars 
E. Additional Rubber Buffers 
F. Tightening Torques 
32-2 Removal and Installation of Front Shock Absorber 
Removal 
Installation 
32-3 Removal and Installation of Rear Shock Absorber 
Removal 
Installation 
32-4 Shock Absorber Adiustment 
A. Connecting and Disconnecting Lines 
B. Checking of Shock Absorber Adjustment 
32-5 Checking of Shock Absorbers 
A. Oil Reserve in Shock Absorber 
B. Sight Checking 
C. Efficiency of Shock Absorber 
D. Shock Absorber Noises 
32-6 Removal and Installation of Torsion Bar on Front Axle 
Removal 
Installation 
32-7 Removal and Installation of Torsion Bar on Rear Axle 
Removal 
Installation 
32-11 Maintenance and Assembly Work on the Air Suspension System 
A. General Instructions 
B. Emergency Rubber Buffers 
C. Maintenance Work 
32-12 Trouble Shooting Hints for the Air Suspension System 
32-16 Pressure Regulator 
Removal 
Installation 

33 Front Axle 
33-0 Front Axle 
A. Front Axle Suspension 
B. Mounting of Steering Knuckle 
C. Front Wheel Bearings 
D. Control Arm 
E. Tightening Torques 
33-1 Removal and Installation of Front Axle 
Removal 
Installation 
33-7 Control Arm Suspension 
Removal of control arm 
Lower control arm 
Repair of Bearing 

35 Rear Axle 
35-0 Rear Axle 
General Instructions 
Tightening torques, mkp 
Drive pinion 
Joint flange on drive pinion 
Adjusting data of gear set 
Rear axle shaft 
Seating of brake support on axle tube
35-1 Removal and Installation of Rear Axle 
Removal 
Installation 
35-4 Removal, Repair, Sealing and Installation of Rear Axle 
Removal 
Disassembly 
Repair 
Assembly 
Installation 
35-5 Removal, Adjustment and Installation of Gear Set 
Removal 
Installation and adjustment 
35-9 Replacement of Seal Ring on Drive Pinion 
Removal 
Checking 
Installation 

40 Wheels and Adjustment of Wheels 
40-0 Wheels and Adiustment of Wheels 
General Data, Dimensions, and Tolerances 
40-4 Adiustment of Car Level 
40-2 Wheels 
A. Disk Wheel 
B. Attachment of Disk Wheel 
C. Tires 
D. Balancing of Wheels 
E. Ornamental Wheel Cover 
40-3 Adiustment of Wheels 
A. Front Wheel Camber 
B. Rear Wheel Camber 
C. Caster 
D. Front Wheel Track 
E. Control Arm Position of Front Axle 
F. Pivot Point Distance 
G. Center Position of Rear Axle 

41 Propeller Shaft 
41-0 Propeller Shaft 
General Data, Dimensions, and Tolerances 
41-1 Removal and Installation of Propeller Shaft 
Removal 
Installation 

42 Brakes 
42-0 Brakes 
A. General 
B. Disk Brake 
C. Power Brake 
42-1 Brake System 
A. General 
B. Tandem Master Cylinder 
C. Front Brake Caliper 
D. Rear Brake Caliper 
E. Parking Brake 
F. Bosch Brake Booster 
42-4 Removal and Installation of Brake Caliper 
A. Front Axle
B. Rear Axle 
42-5 Removal, Repair and Installation of Parking Brake Caliper 
Removal and Disassembly 
42-6 Replacement of Friction Pads 
A. Service Brake Front Axle 
B. Service Brake Rear Axle 
C. Parking Brake 
42-7 Replacement of Piston Seals in Brake Caliper 
42-10 Tandem Master Cylinder 
Removal 
Installation 
42-11 Disassembly, Inspection and Assembly of Tandem Master Cylinder 
Disassembly 
Checking 
Assembly 
42-12 Removal and Installation of Brake Booster 
Removal 
Installation 
42-14 Removal and Installation of Brake Disk 
A. Front Axle 
Removal 
Installation 
B. Rear Axle 
Removal 
Installation 
42-16 Foot-operated Parking Brake 
A. Removal and Installation 
Removal 
Installation 
42-18 Removal and Installation of Brake Cable 
A. Front Brake Cable 
Removal 
Installation 
B. Rear Brake Cable 
Installation 
42-20 Bleeding the Brakes 
42-22 Checking of Brake System 
A. Performance Test 
B. Leak Check 
42-23 Adiustment Operations 
A. Foot-Operated Parking Brake 
B. Mechanical Stop Light Switch 
46 Steering Assembly 

46-0 Steering 
General Data, Dimensions and Tolerances 
46-0 Removal and Installation of Power Steering 
Removal 
Installation 
46-5 Removal and Installation of Steering Relay Arm 
Removal 
Checking and Repairing 
Installation 
46-6 Removal and Installation of Steering Linkage 
A. Center Tie Rod
B. Tie Rod 
46-20 Checking of Power Steering and High-Pressure Oil Pump 
A. Checking of Oil Pressure in the High-Pressure Oil Pump 
B. Checking of Beginning of Manual Power Limitation 
46-21 Bleeding of Power Steering and High-Pressure Oil Pump

 
47 Fuel System 
47-0 Fuel System 
47-4 Fuel Tank Ventilation 
49 Exhaust System 
49-1 Removal and Installation of Exhaust System 
Removal 
Installation 

50 Radiator 
50-1 Removal and Installation of Radiator 
Removal 
Installation 
50-2 Removal, Installation and Adjustment of Fan Shroud or Cover 
Removal 
Installation 
Adjustment 
50-4 Cleaning of Cooling System 
A. Radiator 
B. Transmission Oil Cooler 
50-3 Checking Cooling System for Leaks 

54 Electrical Equipment and Instruments 
54-0 Function and Color Coding of Sleeve Unions at Main Wiring Harness 
54-5 Electrical Operation of the Release Mechanism for Foot-Operated Parking Brake 
54-6 Horn Assembly 

67 Windows 
67-1 Removal and Installation of Rear Window 
Removal 
Installation 
67-2 Removal and lnsta!lation of Rear Window Reveal Molding 
Removal 
Installation 
67-4 Removal and Installation of Rear Side Window 
Removal 
Installation 
67-5 Removal and Installation of Rear Side Window Reveal Moldings 
Removal 
Installation 

68 Coverings 
68-1 Removal and Installation of Hat Tray Lining 
Removal 
Installation 

72 Front and Rear Doors 
72-3 Removal and Installation of Window Reveal Moldings 
Removal 
Installation 
72-5 Removal and Installation of Control Knob for Outside Mirror 
Removal 
Installation 
72-6 Removal and Installation of Door Trim Panel 
Removal
Installation 
72-7 Removal and Installation of Windows 
A. Removal and Installation of Front Door Windows 
B. Removal and Installation of the Rear Door Windows 
72-8 Removal and Installation of Window Regulator 
Removal 
Installation 
Check 
72-12 Removal and Installation of Flexible Window Run Channel 
Removal 
Installation 
72-13 Ventilator and Ventilator Lock 
A. Removal and Installation of Ventilator and Ventilator Lock 
B. Removal and Installation of Ventilator Lock 
72-14 Removal and Installation of Outside Mirror with Operating Mechanism 
Removal 
Installation 
72-15 Door Lock and Actuating Mechanism 
A. Removal and Installation of Door Lock 
B. Removal and Installation of Door Handle 
C. Removal and Installation of Cylinder Lock 

75 Rear Compartment Lid 
75-2 Removal and Installation of Rear Compartment Lid Hinge 
Removal 
Installation 

76 Master-Lock Control System 
76-1 Main Features of Master-Lock Control System 
76-2 Design and Operation of Master-Lock Control System 
76-3 Adiusting and Testing Procedures for Master-Lock Control System 
A. Adjustment of Vacuum Switch 
B. Leakage Check of Master-Lock Control System 
C. Function Check 
76-4 Trouble Shooting Hints - Master-Lock Control System 

80 Finger-Tip Hydraulic System 
80-0 Finger-Tip Hydraulics 
General data and measurements 
80-1 General Description of Finger-Tip Hydraulic System 
A. General 
B. Principle of Operation of Hydraulic System 
C. Design and Operation of Individual Component Assemblies 
80-2 Maintenance Jobs 
80-3 Testing and Adjustment Jobs 
A. General Hints 
B. De-Pressurization of Hydraulic=System 
C. Bleeding of Finger-Tip Control Hydraulic Pump 
D. Testing Oil-Pressure Container and Finger-Tip Control Hydraulic Pump 
E. Adjustment of Power-Assisted Door or Trunk Lid Lock 
F. Adjustment of Opening or Closing Speed of Trunk Compartment Lid 
G. Adjustment of Speed at which Driver's Seat Shifts Position 
80-5 Trouble Shooting Hints 
A. Malfunctions with Engine Running 
B. Malfunction after Engine is Switched Off 
C. Malfunction of Hydraulically-Operated Units 
D. Malfunction with Defective Hydraulic Switch or Hydraulic Element
80-6 Consequences of Hydraulic Switch Malfunction 
A. Hydraulic Switch for Double-Acting Hydraulic Element 
B. Hydraulic Switch for Single-Acting Hydraulic Element 
C. Compound Hydraulic Switch for Single-Acting Hydraulic Element 
80-7 Consequences of Hydraulic Element Malfunction 
A. Double-Acting Hydraulic Element 
B. Single-Acting Hydraulic Element 
80-10 Disassembly and Assembly Work 
A. General Hints 
B. Disconnecting and Stopping of Plug-In Unions for Hydraulic Lines 
C. Removal and Installation of Finger-Tip Control Hydraulic Pump, see Job No. 23-1 
D. Removal and Installation of Oil-Pressure Container 
E. Removal and Installation of Door Lock 
F. Removal and Installation of Trunk Compartment Lid Lock 
G. Removal and Installation of Hydraulic Elements 
H. Removal and Installation of Hydraulic Switch 
80-11 Operation of Vehicle with Finger-Tip Hydraulic System out of Action

 
83 Heating, Ventilation and Cooling System 
83-1 Heating and Installation 
83-3 Removal and Installation of Control Assembly for Heating, Ventilation and Cooling 
Removal 
Installation 
83-4 Replacement of Veneer Molding on Control Assembly 
Removal 
Installation 
83-5 Replacement of Fuse in Control Assembly 
83-8 Removal and Installation of Front Heater Case 
Removal 
Installation 
83-10 Removal and Installation of Front Heat Exchanger 
Removal 
Installation 
83-11 Heat Sensing Element 
A. Performance Test of Heat Sensing Element 
B. Removal and Installation of Heat Sensing Element 
83-12 Replacement of Air Filter Element in Front Blower Wheel 
Removal 
Installation 
83-13 Electromagnetic Hot-Water Valve (Solenoid Valve) 
A. Removal and Installation of Solenoid Valve 
B. Replacement of Solenoid Valve 
83-14 Removal and Installation of Rear Heat Exchanger 
Removal 
Installation 
83-20 Air Conditioning System 
A. General 
B. Operation and Air Flow Control 
C. Temperature Control 
D. Safety Precautions 
E. Servicing 
F. Repair Instructions 
83-21 Refrigerant Operationa I Checks 
A. Leak Check 
B. Charging or Partially Charging the Air Conditioning System
C. Discharging of Cooling System 
D. Oil Level Check in Refrigerant Compressor 
83-22 Replacement of Filter Dryer 
83-23 Trouble Shooting Hints 

91 Front and Rear Seats 
91-1 Removal and Installation of Front Seat 
Removal 
Installation 
91-2 Removal and Installation of Front Seat Cushion 
Removal 
Installation 
91-3 Removal and Installation of Rear Seat 
Removal 

97 Seat Accessories 
97-1 Removal and Installation of Head Rests in Rear Compartment 
Removal 
Installation 
Alphabetical Index