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Mercedes-Benz Service Manual V-8 Engines M116.96 (3.8) & M117.96 (5.0)
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Workshop manual for Mercedes-Benz V-8 M116.96 3.8-liter and M117.96 5.0-liter engines
Provides official service information for diagnosis, inspection, disassembly, measurement, adjustment, assembly, and repair of Mercedes-Benz M116.96 and M117.96 V-8 engines, with application in W107 and W126 vehicles built between 1981 and 1985. Because it focuses on the 3.8- and 5.0-liter versions, this edition is especially useful for the intermediate stage of the M116/M117 family.
PDF in English | 636 pages | Instant download.
- Factory manual for M116.96 and M117.96 engines
- Includes technical data, identification, compression, leak testing, and CIS system
- Contains tables, procedures, special tools, and original technical illustrations
- Especially useful for repair, maintenance, and restoration
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Mercedes-Benz Service Manual V-8 Engines M 116.96 (3.8) & M 117.96 (5.0) | PDF
Service and repair manual for Mercedes-Benz V-8 M116.96 3.8-liter and M117.96 5.0-liter engines, linked to W107 and W126 applications from this evolutionary stage of the M116/M117 family.
This edition covers the intermediate stage of the Mercedes-Benz M116/M117 family and is aimed at the lightweight alloy V-8 engines used in W107 and W126 models from the early and mid-1980s. Because it focuses on the 3.8- and 5.0-liter versions, it is especially useful for diagnosis, maintenance, repair, and restoration work on vehicles from this technical transition within the brand’s V-8 range.
Unlike the earlier 3.5 and 4.5-liter manual and the later 4.2 and 5.6-liter edition, this PDF focuses on M116.960, 116.961, 116.962, 116.963, and M117.963 versions, with inspection, disassembly, measurement, machining, assembly, and adjustment procedures, along with technical tables, tightening torques, special tools, and service illustrations.
If you want to review the scope of the content in more detail before buying, you can also check the Complete Index tab, where the groups and operations included in this edition are listed.
Main topics covered in the Mercedes-Benz V-8 M116.96 3.8 and M117.96 5.0 engine manual
- General data, engine identification, and technical specifications
- Crankcase, cylinder head, and removal and installation procedures
- Crankshaft assembly, connecting rods, pistons, seals, and flywheel
- Valve timing, valves, camshafts, and timing chain
- CIS mechanical fuel injection system
- Air cleaner and belt drive
- Intake and exhaust manifolds
- Engine electrical system
- Lubrication and cooling
- Engine mounts and throttle control
- Fuel system
- Exhaust system
Mercedes-Benz models identified in this edition with the M116.96 3.8-liter engine:
W107 series: 380 SLC and 380 SL
W126 series: 380 SE, 380 SEL, and 380 SEC
Mercedes-Benz models identified in this edition with the M117.96 5.0-liter engine:
W126 series: 500 SEL and 500 SEC
Other Mercedes-Benz models related to 5.0-liter M117.96 V-8 variants:
W107 series: 500 SL, 500 SLC, and 450 SLC 5.0
W126 series: 500 SE
W463 series: 500 GE V-8
Important clarification: the first two lists correspond to the applications directly identified in the initial table of this edition. The third list includes other Mercedes-Benz models that also used 5.0-liter variants of the M117 E 50 family, including the 117.965 of the 500 GE V-8, but are not explicitly developed in this manual. For that reason, their inclusion should be understood as a reference for mechanically related models, not as direct factory coverage for all of them.
This publication corresponds to the workshop manual for Mercedes-Benz V-8 M116.96 3.8-liter and M117.96 5.0-liter engines. If you are looking for documentation for the earlier 3.5 and 4.5-liter versions, or the later 4.2 and 5.6-liter variants, a different edition applies. Before buying, the best approach is to verify the exact engine code installed in the vehicle and review the Complete Index tab. The file is supplied in PDF format with bookmarks for chapter navigation, preserves the original technical content, and can be consulted from a PC, tablet, or smartphone, while also allowing you to print only the pages needed for each job.
Item details:
- Format: PDF
- Language: English
- Pages: 636
- File size: 80.2 MB
- Delivery method: Download link
Frequently asked questions about the Mercedes-Benz M116.96 3.8 and M117.96 5.0 engine manual
How can I tell whether this M116.96 / M117.96 manual is the right one before buying?
The safest way is to check the exact engine code installed in the vehicle. This edition focuses on M116.960, 116.961, 116.962, 116.963, and M117.963 variants, corresponding to the intermediate stage of the M116/M117 family.
Is this PDF intended only for the 380 and 500 models identified in the initial table?
Those are the applications identified directly in this edition. However, because of the technical similarities between different variants in the M116/M117 family, it can also provide useful information for work on other related 3.8- and 5.0-liter V-8 engines, always checking compatibility by engine code first.
Does it include internal engine procedures or only basic maintenance tasks?
It includes far more than basic maintenance. The content covers work on the crankcase and cylinder head, compression testing, leak testing, crankshaft assembly, pistons, valves, timing chain, lubrication system, and other deeper repair procedures.
Does it cover the CIS injection system?
Yes. The technical groups included cover the CIS mechanical fuel injection system, along with inspection and service procedures that are especially valuable for Mercedes-Benz engines from this period.
How does it differ from the other M116/M117 manuals on the site?
It differs because it focuses on the intermediate stage of the family. It does not cover the early 3.5 and 4.5-liter variants or the later 4.2 and 5.6-liter versions, but rather the 3.8- and 5.0-liter configurations used mainly in W107 and W126 models between 1981 and 1985.
Is it a good reference for serious restoration and maintenance?
Yes. Because of its level of detail, technical tables, workshop procedures, and original illustrations, it is a very useful reference for properly preserving, repairing, and restoring Mercedes-Benz V-8 models from the early 1980s.
Mercedes-Benz V-8 M116.96 3.8 and M117.96 5.0 Engines Manual | Index
This index lists the main sections and job numbers included in the Mercedes-Benz Service Manual V-8 Engine M 116.96 (3.8) & M 117.96 (5.0).
Entries are presented according to the original technical structure and numbering of the manual.
00 General, Technical Data
- 00-005 Instructions for use of service manual
- 00-010 Engine and vehicle identification
- 00-015 Vehicle identification number locations
- 00-020 Technical data
01 Crankcase and cylinder head
- 01-001 Engine and model survey
- 01-010 Checking compression pressure
- 01-015 Checking cylinders for leaks
- 01-020 Evaluating cylinder bores
- 01-030 Removal and installation of engine (oil capacity)
- 01-040 Engine breathing system - operation
- 01-112 Measuring, honing and silicon-lapping cylinder bores
- 01-120 Machining crankcase mating surface
- 01-122 Reconditioning of threaded bores for cylinder head bolts
- 01-124 Reconditioning threaded bores for intermediate flange and transmission mounting
- 01-126 Coolant preheater in crankcase (installation instruction)
- 01-210 Removal and installation of timing case cover
- 01-220 Installation and centering of intermediate flange
- 01-222 Removal and installation of end cover
- 01-310 Removal and installation of oil pan
- 01-415 Removal and installation of cylinder head
- 01-418 Facing cylinder head mating surface
- 01-420 Pressure-testing cylinder head
03 Crankshaft assembly
- 03-310 Checking, renewing and tightening connecting rod bolts
- 03-313 Reconditioning and squaring connecting rods
- 03-316 Removal and installation of pistons
- 03-317 Renewal of piston rings
- 03-318 Checking and reconditioning of crankshaft
- 03-320 Mounting of crankshaft
- 03-324 Replacing front crankshaft radial sealing ring
- 03-327 Replacing rear crankshaft radial sealing ring
- 03-342 Removal and installation of hub, vibration damper and V-belt pulley
- 03-345 Checking and correcting adjustment of TDC transmitter
- 03-410 Removal and installation of driven plates
- 03-430 Renewing ring gear
05 Engine timing, valves
- 05-211 Checking and replacing hydraulic valve clearance compensaqting elements
- 05-213 Checking and correcting basic position of hydraulic valve clearance compensating elements
- 05-215 Checking and adjusting camshaft timing
- 05-220 Removal and installation of camshafts
- 05-225 Grinding camshaft bearing journals
- 05-230 Removal and installation of rocker arms
- 05-250 Removal and installation of valve springs
- 05-260 Checking valve springs and valve spring preload
- 05-270 Replacing valve stem seals
- 05-280 Checking and machining valves
- 05-285 Checking, replacing valve guides
- 05-290 Replacing valve seat rings
- 05-291 Machining valve seats
- 05-293 Decoking valves
- 05-310 Removal and installation of chain tensioner
- 05-320 Replacing timing chain
- 05-330 Removal and installation of tension rail
- 05-340 Removal and installation of slide rails
- 05-434 Removal and installation of intermediate gear for distributor drive
- 05-440 Removal and installation of return sprocket
07.3 Mechanical gasoline injection system (CIS)
- 07.3-001 Functional description
- 07.3-105 Checking and adjusting on/off ratio
- 07.3-111 Performing comparison of cylinders with SUN 2110 engine tester
- 07.3-112 Testing electronic idle speed control
- 07.3-120 Checking fuel pressures and for internal leaks
- 07.3-125 Checking choke system
- 07.3-127 Performing cold start
- 07.3-130 Checking fuel pump
- 07.3-135 Testing injection valves
- 07.3-152 Testing, adjusting throttle valve switch
- 07.3-160 Checking constant delivery of fuel distributor
- 07.3-165 Checking fuel pump relay with electronic rpm control (breakaway speed)
- 07.3-199 Survey mixture preparation
- 07.3-200 Removal and installation of mixture control unit
- 07.3-205 Renewing fuel distributor
- 07.3-210 Reconditioning system pressure regulator and pressure compensating valve
- 07.3-215 Removal and installation of injection valves
- 07.3-220 Renewing air flow sensor
- 07.3-225 Removal and installation of mixture control unit with air guide housing
- 07.3-230 Removal and installation of throttle valve housing
- 07.3-242 Retrofitting safety switch to air flow sensor
- 07.3-245 Renewing, centering air flow sensor plate, checking and adjusting zero position of air flow sensor plate
- 07.3-269 Survey fuel pump assembly
- 07.3-270 Removal and installation of fuel reservoir
- 07.3-275 Removal and installation of fuel filter
- 07.3-280 Removal and installation of fuel pump
- 07.3-281 Renewing holder for fuel pump, fuel filter and fuel reservoir
- 07.3-283 Subsequent installation of separate check valve on fuel pump
- 07.3-310 Checking inlet valves for deposits (coking), cleaning as necessary
09 Air cleaner
- 09-400 Removal and installation of air cleaner
13 Belt drive
- 13-335 Instructions concerning V-belt replacement and tensioning
- 13-340 Replacing and tensioning V-belt
14 Intake manifold, exhaust manifold
- 14-001 Identification of vehicles
- 14-050 Operation emission control system
- 14-100 Checking emission control system
- 14-200 Removal and installation of catalytic converter (controlled)
- 14-250 Removal and installation of air pump
- 14-260 Removal and installation of electromagnetic clutch
- 14-450 Removal and installation of intake manifold upper and lower part, renewing gaskets
- 14-455 Renewing intake manifold (intake manifold removed)
- 14-470 Renewing intake manifold (intake manifold removed)
- 14-475 Checking EGR
- 14-500 Operation EGR
15 Electrical system, engine
- 15-501 Testing and adjusting ignition timing (firing point)
- 15-502 Vacuum adjustment of ignition timing (firing point)
- 15-508 Evaluating oscilloscope pattern
- 15-510 Removal and installation of ignition distributor
- 15-528 Notes concerning jobs on breakerless transistorized ignition system
- 15-530 Description of breakerless transistorized ignition system
- 15-562 Testing breakerless transistorized ignition system
18 Engine lubrication
- 18-005 Oil circuit
- 18-010 Oil pressure, valves in oil circuit, oil filter and thermostat (model 126)
- 18-110 Removal and installation of oil filter
- 18-210 Removal and installation of oil pump
- 18-215 Removal and installation of oil pressure relief valve
- 18-220 Checking oil level indication
- 18-230 Removal and installation of oil level transmitter
20 Engine cooling
- 20-005 Coolant circuit and engine cooling
- 20-010 Draining and filling-in of coolant - antifreeze table
- 20-015 Cleaning cooling and heating system
- 20-110 Removal and installation of coolant thermostat
- 20-210 Removal and installation of coolant pump
- 20-220 Reconditioning of coolant pump
- 20-225 Sealing coolant pump
- 20-320 Viscofan clutch
- 20-420 Removal and installation of radiator
- 20-425 Repairing radiator
- 20-430 Checking expansion tank cap
22 Engine mounts
- 22-211 Removal and installation of front engine mount
- 22-212 Removal and installation of rear engine mount
- 22-240 Removal and installation of engine shock absorber
30 Throttle control
- 30-300 Adjusting regulating linkage
- 30-310 Removal and installation of longitudinal regulating shaft
- 30-320 Removal, installation and adjustment of chassis regulating shaft
- 30-330 Removal and installation of accelerator pedal
- 30-335 Lubricating regulating linkage and regulating shafts
47 Fuel system
- 47-010 Operation of fuel tank with steadying bowl
- 47-020 Operation of transmitter for fuel readout
- 47-030 Operation of fuel tank positive and negative venting system
- 47-100 Removal and installation of fuel tank
- 47-110 Removal and installation of fuel expansion tank
- 47-120 Removal and installation of transmitter for fuel readout
- 47-200 Operation of fuel evaporation control system
- 47-300 Checking fuel evaporation control system
- 47-400 Operation of fuel cooler
49 Exhaust system
- 49-100 Removal and installation of exhaust system
Mercedes-Benz V-8 M116.96 3.8-ltr. M117.96 5.0-ltr. engines | Workshop manual cover