Cart
(0)
Mercedes-Benz Service Manual Chassis & Body Series 116 | Volume 1
$16.00
Mercedes-Benz W116 S-Class workshop manual with chassis and body technical information
Includes factory service documentation for vehicle identification, technical data, chassis suspension, front axle, rear axle, propeller shaft, hydraulic and mechanical brakes, pneumatic brakes and steering, with direct application to 280 S, 280 SE, 450 SE, 450 SEL, 450 SEL 6.9 and 300 SD, and technical value for other W116 models with shared chassis, brake and steering systems.
English PDF | 600 pages | Instant digital delivery.
- Volume 1 | Factory chassis and body service manual
- Original Mercedes-Benz specifications for Series 116
- Inspection, removal, adjustment, repair and assembly procedures
- Useful reference for professional maintenance and classic W116 restoration
Security payment
Digital delivery
Returns
COOKIE PREFERENCES (EU GDPR)
Cookies: We use necessary cookies for the cart and login to work. You can accept, decline, or configure non-essential cookies.
Mercedes-Benz Service Manual Chassis & Body Series 116 | Volume 1 | PDF
First volume of the chassis and body workshop manual for Mercedes-Benz W116 Series models.
The Mercedes-Benz W116 Series represents a key generation of the S-Class, recognized for its engineering, comfort and technical complexity. This manual is intended for maintenance, repair and restoration work related to the chassis, suspension, axles, propeller shaft, brakes and steering systems of the vehicle.
This digital PDF edition provides factory service documentation for vehicle identification, technical data, inspection, removal, installation, adjustment and component checking. It is especially useful for workshops, specialized mechanics, restorers and owners who need original Mercedes-Benz technical procedures for the Series 116.
The scope of the manual can be reviewed in greater detail in the Complete Index tab, where the groups and operations are listed according to the original technical structure of the publication.
Main topics covered in this Mercedes-Benz W116 Series chassis and body manual | Volume 1
- Vehicle identification
- General technical data
- Chassis suspension system
- Front axle
- Rear axle
- Propeller shaft
- Hydraulic and mechanical brakes
- Pneumatic brake system
- Steering
- Inspection, removal, installation and adjustment procedures
W116 Series models listed in the manual application table
- 280 S and 280 SE
- 450 SE, 450 SEL and 450 SEL 6.9
- 300 SD
Other Mercedes-Benz W116 Series models for which this manual is also useful
- 280 SEL
- 350 SE and 350 SEL
Important: this manual corresponds to Volume 1 of the factory service documentation for Mercedes-Benz Series 116. Although the application table mentions specific models, the content is organized as a technical manual for the W116 Series, and many chassis, suspension, axle, brake and steering operations are common to the platform. When an operation applies only to a specific version, the manual identifies it by the corresponding chassis number. For this reason, it is also a very useful reference for owners of 280 SEL, 350 SE and 350 SEL models, especially since no separate factory edition was issued for every individual W116 variant.
Workshop manual suitable for maintenance, repair and restoration
The content is designed for technical work on chassis, suspension, axle, brake and steering assemblies. It includes tables, factory values, component references, technical illustrations and step-by-step procedures that make it easier to consult the correct information during repair or restoration work on a Mercedes-Benz W116.
As a digital PDF manual, it can be viewed from a computer, tablet or mobile phone, and the required pages can be printed for workshop use without handling original printed documentation.
Product details
- Format: PDF
- Language: English
- Pages: 600
- File size: 39.2 MB
- Delivery method: download link
Frequently asked questions about Mercedes-Benz Service Manual Chassis & Body Series 116 | Volume 1
What type of technical information does this W116 Series volume provide?
This volume provides factory documentation related to chassis and body service, with a strong focus on vehicle identification, technical data, suspension, front axle, rear axle, propeller shaft, hydraulic brakes, pneumatic brake system, steering, and inspection, removal, installation or adjustment procedures.
Can this manual be used for a Mercedes-Benz 450 SEL 6.9?
Yes. The 450 SEL 6.9 is included in the manual application table. The publication also clarifies that some operations may apply to the entire Series 116, while others may apply to a specific chassis, so the relevant technical section should always be checked before carrying out the work.
Does it include information for the Mercedes-Benz 300 SD W116?
Yes. The 300 SD appears among the models listed in the manual application table. This documentation is useful for chassis, suspension, brake and steering systems, although it does not replace the specific diesel engine manual when engine information is required.
What should be considered before buying this manual?
This product corresponds to Volume 1 for chassis and body service. It is not a parts catalog, it is not an owner’s manual, and it does not replace specific documentation for engine, transmission or systems not covered in this volume. Its main value is the original technical procedures for the groups covered by this publication.
Is it also useful for a Mercedes-Benz 280 SEL, 350 SE or 350 SEL?
Yes. Although those models are not highlighted in the main application table, this manual was developed for the W116 Series and much of the chassis, suspension, axle, brake and steering information is common to the platform. Where differences exist by version, the manual uses chassis numbers or specific references. For that reason, it is also very useful documentation for those models when working on shared Series 116 systems.
How is the information organized inside the PDF?
The publication keeps the original Mercedes-Benz technical structure, with numbered work groups, tables, illustrations, technical data and step-by-step procedures. This allows the content to be consulted more accurately than with a generic guide or scattered online information.
Why choose this PDF instead of searching for separate information online?
Because it brings structured technical documentation into a single file, prepared for service work on W116 models. This makes consultation easier during repair or restoration work and reduces the risk of relying on incomplete, disorganized or non-applicable information.
Mercedes-Benz W116 Chassis and Body Manual | Volume 1 | Index
This index lists the main sections and job numbers included in the Mercedes-Benz Service Manual Chassis & Body Series 116 | Volume 1.
Each entry is listed in accordance with the manual’s original technical layout and numbering.
00 General, technical data
- 00-005 Instructions for use of service manual
- 00-010 Engine and vehicle identification
- 00-015 Vehicle and identification number location
- 00-020 Technical data
32 Chassis suspension systems
Shock absorbers
- 32-100 Removal and installation of front shock absorber
- 32-110 Removal and installation of rear shock absorber
- 32-120 Checking of shock absorber
Springs
- 32-200 Removal and installation of front spring
- 32-205 Removal and installation of front spring (in combination with removal and installation of front axle half on vehicles following an accident)
- 32-230 Removal and installation of rear spring
Torsion bars
- 32-300 Removal and installation of torsion bar on front axle
- 32-300 Removal and installation of torsion bar on front axle, hydropneumatic suspension
- 32-310 Removal and installation of torsion bar on rear axle (diagonal swing axle)
- 32-320 Removal and installation of torsion bar on rear axle (diagonal swing axle with starting torque compensation)
- 32-320 Removal and installation of torsion bar on rear axle, hydropneumatic suspension
- 32-325 Removal and installation of wheel carrier support on torsion bar (diagonal swing axle with starting torque compensation)
- 32-325 Removal and installation of supports of wheel carrier on torsion bar, hydropneumatic suspension
Checkups
- 32-515 Checking tube shocks for leaks
- 32-520 Checking tube shocks for leaks
- 32-530 Checking pressure oil pump
- 32-540 Checking valve unit, electric pressure switch for warning lamp and central reservoir
- 32-555 Checking level controller for function
- 32-560 Checking level controller for leaks
Assembly jobs
- 32-600 General jobs on vehicles with hydropneumatic suspension
- 32-605 Removal and installation of tube shock for front axle
- 32-607 Checking and renewing suspension of tube shock for front axle
- 32-610 Removal and installation of tube shock for rear axle
- 32-612 Checking and renewing suspension of tube shock for rear axle
- 32-615 Removal and installation of pressure reservoir for front axle
- 32-620 Removal and installation of pressure reservoir for rear axle
- 32-625 Removal and installation of central reservoir
- 32-640 Removal and installation of pressure oil pump
- 32-650 Removal and installation, disassembly and assembly of valve unit
- 32-665 Removal and installation of level controller for front axle
- 32-670 Removal and installation of level controller for rear axle
- 32-675 Renew pressure lines to pressure reservoirs on front axle, model 116.036
33 Front axle
Cross yoke
- 33-150 Removal and installation of cross yoke
- 33-155 Checking of cross yoke
Front axle halves
- 33-200 Removal and installation of front axle half
Front wheel hub
- 33-300 Adjustment of wheel bearing end play
- 33-310 Removal and installation of front wheel hub
- 33-320 Disassembly, inspection, repair and assembly of front wheel hub
Steering knuckle
- 33-400 Removal and installation of steering knuckle
- 33-410 Checking of steering knuckle
- 33-420 Removal and installation of steering knuckle arm
Steering knuckle bearing
- 33-425 Inspection of supporting and guide joint of steering knuckle bearing
- 33-430 Replacement of sleeves for supporting and guide joint of steering knuckle bearing
- 33-440 Replacement of supporting joint for steering knuckle bearing
Control arm
- 33-500 Removal and installation of upper control arm
- 33-510 Removal and installation of lower control arm
- 33-530 Checking and repairing front bearing of lower control arm
- 33-535 Checking and repairing rear bearing of lower control arm
- 33-550 Checking and repairing bearing of upper control arm
- 33-560 Checking upper control arm
- 33-570 Checking lower control arm
35 Rear axle
Rear axle
- 35-010 Removal and installation of complete rear axle
- 35-040 Removal and installation of front rubber bearing of rear axle suspension
- 35-050 Removal and installation of rear rubber bearing of rear axle suspension
Semi-trailing arm
- 35-110 Removal and installation of semi-trailing arm, replacement of rubber bearings
- 35-130 Removal and installation of rear axle shaft flange, adjustment of bearings
Coupled semi-trailing arm
- 35-310 Removal and installation of coupled semi-trailing arm, replacement of rubber bearing
- 35-330 Removal and installation of link between coupled semi-trailing arm and caliper carrier
- 35-350 Disassembly, assembly and adjustment of wheel carrier
- 35-360 Removal and installation of caliper carrier and rear axle shaft flange, adjustment of wheel bearing
Inspection of wheel location
- 35-410 Complete inspection of rear axle directional stability
- 35-420 Checking semi-trailing arms
- 35-430 Checkup of rear axle carrier
Rear axle center piece
- 35-500 Differentiating characteristics, installation survey for rear axle center piece
- 35-520 Removal and installation of rear axle center piece with rear axle shafts
- 35-530 Replacement of radial sealing ring on drive pinion
- 35-540 Replacement of radial sealing ring of rear axle shaft
- 35-550 Disassembly and assembly of rear axle center piece, adjustment of gear assembly
- 35-560 Reconditioning differential
Rear axle shaft
- 35-620 Removal and installation of rear axle shaft
- 35-660 Exchanging rubber sleeves on rear axle shaft
- 35-680 Removal and installation of ring-shaped weight on inner joints of rear axle shafts
41 Propeller shaft
Removal and installation
- 41-050 Removal and installation of propeller shaft
Reconditioning
- 41-100 Removal and installation of propeller shaft intermediate bearing, replacement of radial ball bearing
- 41-200 Replacement of centering sleeve
42 Brakes, hydraulic and mechanical
Brake system
- 42-010 Bleeding the brake system or renewing the brake fluid
- 42-012 Checking brake lines and brake hoses
- 42-015 Checking the brake system for leaks
- 42-035 Checking warning device in expansion tank
- 42-040 Inspection or adjustment of mechanical brake light switch
Brake caliper
- 42-100 Removal and installation of caliper on front axle
- 42-120 Removal and installation of caliper on rear axle
- 42-160 Replacement of brake pads
Brake disc
- 42-220 Removal and installation of brake disc on front axle
- 42-228 Removal and installation of brake disc on rear axle
- 42-260 Cleaning of brake discs
Tandem main cylinder and brake unit
- 42-310 Removal and installation of tandem main cylinder
Parking brake
- 42-510 Removal and installation of pedal system of parking brake
- 42-515 Replacement of rubber stop in pedal system of parking brake
- 42-520 Removal and installation of front brake cable control
- 42-525 Removal and installation of rear brake cable control
- 42-530 Removal and installation of brake shoes of parking brake
- 42-540 Readjustment or adjustment of brake shoes of parking brake
43 Brakes, pneumatics
Brake booster
- 43-350 Removal and installation of brake unit
Vacuum pump
- 43-615 Removal and installation of double diaphragm vacuum pump
- 43-618 Removal and installation of piston vacuum pump
- 43-625 Renewing diaphragms and disc valves of double diaphragm vacuum pump
- 43-628 Renewing piston seal and disc valves of piston vacuum pump
- 43-635 Renewing rocker arm of piston vacuum pump
- 43-660 Checking double diaphragm and piston vacuum pump
46 Steering
Checking the steering system
- 46-110 Checking play of steering components
- 46-120 Checking start of manual restriction
- 46-130 Checking oil pressure power steering pump
Power steering
- 46-412 Removal and installation of power steering
- 46-480 Adjustment of power steering in vehicle
- 46-490 Adjustment of removed power steering
Steering linkage and steering arms
- 46-510 Removal and installation of pitman arm
- 46-520 Removal and installation of intermediate steering arm
- 46-540 Removal and installation of track rod
- 46-550 Removal and installation of drag link
Steering wheel, jacket tube, steering shaft, steering lock
- 46-610 Removal and installation of steering wheel
- 46-640 Removal and installation of steering lock
Power steering pump
- 46-700 Replacement of power steering pump radial sealing ring
- 46-710 Removal and installation of power steering pump
Mercedes Benz W116 | Manual cover | Volume 1