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Mercedes-Benz Service Manual Chassis & Body Series 116 | Volume 2
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Mercedes-Benz W116 S-Class Volume 2 chassis and body workshop manual
Includes factory service documentation for electrical equipment and instruments, glass and windows, interior equipment, doors, trunk lid, outside flaps, sliding roof, central locking system, body electrical system, detachable body components, seats and seat belts, with technical value for maintenance, repair and restoration of Mercedes-Benz Series 116 models.
English PDF | 278 pages | Instant digital delivery.
- Volume 2 | Factory chassis and body service manual
- Electrical systems, interior equipment, doors, glass and body components
- Inspection, removal, adjustment, repair and assembly procedures
- Useful reference for preservation and restoration of classic W116 models
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Mercedes-Benz Service Manual Chassis & Body Series 116 | Volume 2 | PDF
Second volume of the chassis and body workshop manual for Mercedes-Benz W116 Series models.
This volume complements Volume 1 with technical information focused on body systems, interior equipment, instruments, glass, doors, sliding roof, central locking system, body electrical system, detachable body components, seats and seat belts.
The content is based on Mercedes-Benz factory documentation and is especially useful when working on interior parts, door mechanisms, windows, outside flaps, auxiliary electrical systems or passenger compartment safety components. It includes inspection, removal, installation, adjustment and checking procedures applied to the Series 116.
The Complete Index tab allows the technical groups and included operations to be reviewed in greater detail, following the original organization of the manual.
Main topics covered in this Mercedes-Benz W116 Series chassis and body manual | Volume 2
- Electrical equipment and instruments
- Glass and windows
- Interior equipment
- Doors
- Trunk lid and outside flaps
- Sliding roof
- Central locking system
- Body electrical system
- Detachable body components
- Seats and seat belts
- 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 2 of the factory documentation for Mercedes-Benz Series 116. It is not structured as a separate edition for each individual version, but as a technical manual for the W116 Series. For this reason, many interior, body, glass, door, seat, seat belt, central locking and electrical system operations are useful for different models built on the same platform. When differences exist by equipment, market or configuration, the manual allows the corresponding operation to be verified.
Workshop manual for interior, body and electrical system work
This volume is a practical reference for working on areas of the vehicle where problems often appear due to wear, use, moisture or aging components: window mechanisms, locks, door panels, dashboard, instruments, sliding roof, seats, seat belts, outside flaps and electrical circuits associated with the body.
The PDF format makes it easier to consult the manual during workshop work, search for specific sections and print only the pages needed before removing delicate or hard-to-find parts on a classic Mercedes-Benz W116.
Product details
- Format: PDF
- Language: English
- Pages: 259
- File size: 23.4 MB
- Delivery method: download link
Frequently asked questions about Mercedes-Benz Service Manual Chassis & Body Series 116 | Volume 2
What does this second volume of the W116 manual cover?
Volume 2 focuses on body and interior systems: instruments, glass, windows, doors, trunk lid, outside flaps, sliding roof, central locking system, body electrical system, detachable body components, seats and seat belts.
How is it different from Volume 1?
Volume 1 is focused on mechanical chassis systems, such as suspension, axles, brakes, propeller shaft and steering. Volume 2 concentrates on body, interior, instruments, glass, doors, sliding roof, central locking, seats, seat belts and electrical systems linked to the vehicle body.
Is it useful for restoring the interior of a Mercedes-Benz W116?
Yes. It is especially useful for restoration or repair work on the passenger compartment, dashboard, instruments, seats, seat belts, panels, door mechanisms, windows and sliding roof. It also helps avoid incorrect disassembly of old or hard-to-replace parts.
Is it useful for all W116 Series models?
Yes, it is a very useful technical reference for the W116 Series in general. Many body, interior, door, glass, seat, seat belt and central locking systems are shared across versions. If there is any difference by equipment or market, the manual allows the specific operation to be checked before carrying out the work.
Does it include engine, transmission or suspension information?
No. This product corresponds to Volume 2 of the chassis and body documentation. For suspension, axles, brakes, steering and other mechanical chassis systems, Volume 1 should be consulted. Engine or transmission work requires the specific technical documentation for those assemblies.
Why is this PDF useful when working on a W116?
Because it brings together original Mercedes-Benz procedures for areas of the vehicle that often require care during removal, adjustment or repair. It is an organized source specific to the Series 116, more reliable than searching for isolated data without confirming its application to the correct model.
Mercedes-Benz W116 Chassis and Body Manual | Volume 2 | 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.
54 Electrical equipment and instruments
Battery
- 54-005 Battery test, service and maintenance
- 54-010 Operation battery venting system model 116.120 (USA) 1980
Instruments
- 54-250 Removal and installation of instrument cluster
- 54-251 Removal and installation of indicating instruments
- 54-253 Removal and installation of tachometer
- 54-256 Operation immersion tube transmitter for fuel gauge
- 54-257 Testing fuel gauge
- 54-258 Removal and installation of time clock
- 54-259 Revolution counter model 116.120
- 54-270 Pressure difference warning system wiring diagrams model 116
Switches
- 54-305 Removal and installation of rotary light switch
- 54-310 Removal and installation of combination switch
Light for ashtray
- 54-391 Renewing bulb for ashtray light
Seat belt warning device
- 54-400 Seat belt warning system (USA) 1972, 1973
- 54-405 Seat belt warning system with starter interlock (USA) 1974
- 54-407 Seat belt warning system with starter interlock and override switch (USA) 1975-1977
- 54-410 Seat belt warning device, ignition key, lamps (USA) starting 1978
Cruise control
- 54-500 Operation
- 54-505 Checking the actuator
- 54-510 Checking switch, control unit and line harness
- 54-515 Checking switch
- 54-520 Checking sensor
- 54-525 Checking cable control
- 54-530 Checking control unit
- 54-535 Checking with tester
- 54-540 Removal and installation of actuator
- 54-545 Removal and installation of switch
- 54-550 Removal and installation of sensor
- 54-555 Removal and installation of cable control
- 54-560 Adjustment of cable control
- 54-565 Removal and installation of control unit
- 54-570 Vacuum connection for throttle servo unit
- 54-580 Wiring diagram
67 Glass and windows
Windshield
- 67-100 Removal and installation of windshield
- 67-120 Removal and installation of ornamental frame on windshield
- 67-200 Removal and installation of rear window
68 Interior equipment
Instrument panel
- 68-100 Removal and installation of instrumental panel
- 68-105 Removal and installation of loudspeaker cover
- 68-120 Glovebox cover
- 68-140 Removal and installation of glovebox
- 68-150 Removal and installation of covering under instrument panel
Center console
- 68-200 Removal and installation of center console
- 68-220 Removal and installation of type plate on center console
- 68-230 Removal and installation of covering on shift lever
Covering
- 68-400 Removal and installation of reveal molding on top of windshield
- 68-405 Removal and installation of reveal molding on windshield
- 68-430 Removal and installation of head lining
- 68-440 Removal and installation of carpet on entrance
- 68-445 Removal and installation of lining on sides of roof frame
- 68-447 Removal and installation of panelling on roof frame rear
- 68-449 Removal and installation of panelling on rear pillar
- 68-458 Removal and installation of hat rack
- 68-470 Removal and installation of cover on box-type pillar
Ornamental moldings, ornamental grilles, moldings
- 68-500 Removal and installation of trim strips
- 68-510 Removal and installation of trim strips on upper edge of driver's or rear door
- 68-515 Removal and installation of trim strip left or right on snap lock trunk lid
- 68-516 Removal and installation of trim strip at center of trunk lid snap lock
- 68-520 Removal and installation of ornamental trim on front wall pillar
- 68-530 Removal and installation of weather strip and ornamental molding on rear pillar
- 68-560 Removal and installation of ornamental frame on rear window
Partitions
- 68-700 Removal and installation of partition between tank and trunk
72 Doors
Driver's door, front passenger door
- 72-100 Removal and installation of door lining
- 72-110 Removal and installation of window crank
- 72-140 Removal and installation of arm rest with grip
- 72-160 Removal and installation of inside sealing strip
- 72-170 Removal and installation of outer sealing strip
- 72-180 Removal and installation of windows opener
- 72-183 Removal and installation of drive motor for electric window opener at driver's door
- 72-185 Removal and installation of electric window opener on driver's door
- 72-187 Removal and installation of electric window opener on rear door
- 72-190 Removal and installation of crank window
- 72-195 Adjustment of crank window
- 72-197 Removal and installation of fixed window
- 72-198 Removal and installation of flexible window running rail
- 72-200 Removal and installation of windows guide rail on driver's door
- 72-210 Removal and installation of door holder
- 72-214 Installation of reveal molding on driver's door
- 72-220 Removal and installation of sealing frame on driver's or rear door
- 72-226 Removal and installation of reveal molding or rear dog
- 72-230 Removal and installation of inside door actuation
- 72-240 Removal and installation of outside door handle
- 72-250 Removal and installation of door lock
- 72-260 Removal and installation of striker eye
- 72-270 Removal and installation of outside rear view mirror
- 72-300 Removal and installation of trim strips on window frame
75 Trunk lid and outside flaps
Trunk lid
- 75-100 Removal and installation of trunk lid
- 75-102 Removal and installation of trunk lid lock
- 75-112 Removal and installation of hinge lever for trunk lid spring
Outside flaps
- 75-300 Removal and installation of tank flap
- 75-310 Instructions covering water drain on tank recess
77 Sliding roof
Sliding roof
- 77-100 Removal and installation of sliding roof cover
- 77-110 Adjustment of sliding roof cover
- 77-140 Removal and installation of drive cable control
- 77-150 Removal and installation of drive cable control
- 77-180 Removal and installation of holder with motor and gear unit
- 77-190 Trouble diagnosis, electrical sliding roof
80 Central locking system
Functional description
- 80-010 General
- 80-020 Design and operation of central interlock
Central interlock
- 80-200 Removal and installation, as well as adjustment of vacuum switch of driver's door
- 80-210 Removal and installation of vacuum element of front passenger's door
- 80-220 Removal and installation of vacuum element of rear doors
- 80-230 Removal and installation of vacuum element of tank filler neck flap
- 80-240 Removal and installation of vacuum element for trunk lid
- 80-250 Removal and installation of vacuum supply tank
- 80-260 Checking central interlock
Functional diagrams
- 80-900 Functional diagram central interlock
- 80-901 Functional diagram central interlock and air-conditioning system
82 Electrical system of body
Lamps
- 82-040 Adjusting lamps, front
- 82-052 Removal and installation of lamp unit
- 82-062 Removal and installation of lamp unit bulbs
- 82-067 Removal and installation of lamp unit glass
- 82-252 Removal and installation of tail lamp unit
- 82-348 Removal and installation of licence plate lamp
Radio, antenna, interference suppression
- 82-500 Connection for radio Model 116
- 82-530 Function of automatic antenna (USA)
- 82-535 Interference suppression of short-time interference
Wiping-washing system
- 82-610 Removal and installation of wiper arm
- 82-620 Removal and installation of wiper blade
- 82-625 Removal and installation of wiper blade rubber profile strip
- 82-680 Removal and installation of wiper motor
Seat heating system
- 82-800 Operation of seat heating system
- 82-810 Checking seat heating system
- 82-820 Removal and installation of pushbutton switch for seat heating system and renewing bulb
- 82-830 Renewing heating pad of seat heating system
88 Detachable body components
Fenders
- 88-100 Removal and installation of front fender
Bumpers
- 88-200 Removal and installation, disassembly and assembly of front bumper
- 88-220 Removal and installation, disassembly and assembly of rear bumper
- 88-225 Removal and installation of bumper top rear
Engine hood
- 88-300 Removal and installation of engine hood
- 88-310 Removal and installation of cable control for engine hood
Radiator shell
- 88-400 Removal and installation, disassembly and assembly of radiator shell
- 88-405 Removal and installation of Mercedes-Star
91 Seats and seat belts
Driver's seat
- 91-050 Adjustment of friction torque on headrest
- 91-105 Removal and installation of driver's seat
- 91-110 Removal and installation of front passenger seat
- 91-120 Removal and installation of reclining seat fittings
- 91-160 Removal and installation of armrest on driver's backrest
Rear seat
- 91-170 Removal and installation of rear seat and rear backrest
Safety belt
- 91-500 Removal and installation of safety belt
- 91-550 Safety belt - Replacement instructions
Mercedes Benz Service Manual Chassis & Body Series 116 Volume 2