1991 MERCEDES-BENZ 300D REPAIR MANUAL -- HOW TO FIX YOUR CAR OR TRUCK

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1991 MERCEDES-BENZ 300D CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT MERCEDES-BENZ REPAIR SHOPS DON'T WANT YOU TO KNOW

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Get Full Access Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 1991 MERCEDES-BENZ 300D car and truck repair procedures including MERCEDES-BENZ engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up & drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix your MERCEDES-BENZ 300D automobile. Try the Automotix DIY solution today!
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Using the Automotix DIY repair procedures will save you hundreds and even thousands of dollars! In addition, it will save you hours of touring the city searching for MERCEDES-BENZ mechanics you can trust. The Automotix DIY solution is particularly affordable. A full access to the entire DIY repair procedures and diagrams for your 1991 MERCEDES-BENZ 300D vehicle will cost less than a single gallon of gas. Here are some of the DIY repair tips and procedures you will find here:

A/C & HEATER SERVICE PROCEDURES FOR 1991 MERCEDES-BENZ 300D AUTOMOBILES

Electrical Symbol & Wire Color Code Identification -> Wire Color Code Identification -> Imported Vehicles
Vehicle: 1991 MERCEDES-BENZ 300D 2.5 2.5 L5 DIESEL

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BRAKE SERVICE PROCEDURES FOR 1991 MERCEDES-BENZ 300D AUTOMOBILES

MERCEDES-BENZ, HYDRAULIC BRAKE SYSTEMS -> HYDRAULIC BRAKE SYSTEMS -> MASTER CYLINDER REPLACEMENT
Vehicle: 1991 MERCEDES-BENZ 300D 2.5 2.5 L5 DIESEL

On Vehicles Equipped With Anti-Lock Brakes Refer To "Anti-Lock Brake Systems."

  • Drain fluid from front and rear brakes.
  • Using a suitable screwdriver, lift tangs on warning switch, and disconnect electrical connector.
  • Disconnect and cap brake lin...

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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 MERCEDES-BENZ 300D AUTOMOBILES

Mercedes-Benz -> Fuel Filter Replacement -> Diesel Engines -> Fuel System Pressure Relief -> Removal & Installation
Vehicle: 1991 MERCEDES-BENZ 300D 2.5 2.5 L5 DIESEL

Fuel System Pressure Relief

Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.

Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental fuel spray.

After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven while it relearns its adaptive strategy.

  • Ensure the ignition switch is in the Off position.
  • Remove the fuel pump protect...

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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1991 MERCEDES-BENZ 300D AUTOMOBILES

DRIVESHAFT, Replace
Vehicle: 1991 MERCEDES-BENZ 300D 2.5 2.5 L5 DIESEL

  • Raise vehicle and support.
  • Unscrew exhaust shielding plate.
  • On models with 4MATIC, unscrew exhaust shielding plate.
  • Lift transmission and support.
  • Unscrew hex, head screws and hex nut and remove rear engine carrier with engine mount.
  • Unscrew cross bridge.
  • On all models, loosen propeller shaft clamping nut for approx. two turns without sliding back rubber sleeve (sliding along).
  • Remove front propeller shaft from transmission. Flexible coupling remains on propeller shaft.
  • Remove front propeller shaft from transfer case.
  • Prior to sliding back propeller shaft, loosen vulcanized fitted ...

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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1991 MERCEDES-BENZ 300D AUTOMOBILES

Alternator, Replace
Vehicle: 1991 MERCEDES-BENZ 300D 2.5 2.5 L5 DIESEL

  • Read fault memory with suitable scan tool.
  • Disconnect battery ground wire.
  • Remove complete suction filter with air-mass sensor.
  • Remove fan.
  • Disconnect plug connection on suction filter housing.
  • Release screws.
  • Loosen hose clamp on intake manifold.
  • Unclip upper section of suction-filter housing and place ...

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MAINTENANCE LAMP RESET PROCEDURES FOR 1991 MERCEDES-BENZ 300D AUTOMOBILES

Mercedes-Benz -> Check Engine Lamp ->
Vehicle: 1991 MERCEDES-BENZ 300D 2.5 2.5 L5 DIESEL

The Check Engine lamp should illuminate when the ignition switch is placed in the On position to indicate the lamp is operational. After the engine has been started, the warning lamp should go off. If warning lamp comes on while th...

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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 MERCEDES-BENZ 300D AUTOMOBILES

Heater Hose, Replace -> Bypass -> Inlet -> Outlet
Vehicle: 1991 MERCEDES-BENZ 300D 2.5 2.5 L5 DIESEL

Inlet

  • Drain coolant into a suitable container.
  • Reposition clamp on heat exchanger feed pipe and remove hose.
  • Reposition clamp on cylinder head and remove hose.
  • Remove hose from vehicle.
  • Reverse procedure to install.

Outlet

  • Drain coolant into a suitable container.
  • Reposition clamp on heat exchanger return pipe and remo...

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SERPENTINE BELT SERVICE PROCEDURES FOR 1991 MERCEDES-BENZ 300D AUTOMOBILES

Serpentine Drive Belt, Replace
Vehicle: 1991 MERCEDES-BENZ 300D 2.5 2.5 L5 DIESEL

  • Remove fan and fan shroud.
  • Loosen tension mounting bolt 1/4 to 1/2 turn.
  • Loosen tensioning device at nut by turning nut to the left until the serpentine drive belt can be removed.
  • Remove drive belt.
  • Clean and inspect belt surfaces of ...

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COMPONENT LOCATION DIAGRAMS FOR 1991 MERCEDES-BENZ 300D AUTOMOBILES

Component location diagrams for most 1991 MERCEDES-BENZ 300D cars and light trucks sold in the U.S. from 1990+.

LH Footwell Diagram for 1991 MERCEDES-BENZ 300D 2.5 2.5 L5 DIESELLH Footwell Diagram for 1991 MERCEDES-BENZ 300D 2.5 2.5 L5 DIESEL

Components on diagram:
  • Kickdown Switch
    • Lower RH Side Of Luggage Compartment Diagram for 1991 MERCEDES-BENZ 300D 2.5 2.5 L5 DIESELLower RH Side Of Luggage Compartment Diagram for 1991 MERCEDES-BENZ 300D 2.5 2.5 L5 DIESEL

    Components on diagram:
  • Rear Window Washer Pump

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    WIRING DIAGRAMS FOR 1991 MERCEDES-BENZ 300D AUTOMOBILES

    OEM drawn wiring diagrams for most 1991 MERCEDES-BENZ 300D cars and light trucks sold in the U.S.

    1991 MERCEDES-BENZ 300D 2.5 2.5 L5 DIESEL Wiring Diagram1991 MERCEDES-BENZ 300D 2.5 2.5 L5 DIESEL Wiring Diagram

    Components on diagram:
  • Symbol Identification
    • 1991 MERCEDES-BENZ 300D 2.5 2.5 L5 DIESEL Wiring Diagram1991 MERCEDES-BENZ 300D 2.5 2.5 L5 DIESEL Wiring Diagram

    Components on diagram:
  • Fuse Panel

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    TECHNICAL SERVICE BULLETINS FOR 1991 MERCEDES-BENZ 300D AUTOMOBILES

    OEM TSB listings for most 1991 MERCEDES-BENZ 300D cars and light trucks sold in the U.S. from 1985+.

    Document: Introduction of Improved Single-Component Windshield/Window Bonding System
    Vehicle: 1991 MERCEDES-BENZ 300D 2.5 2.5 L5 DIESEL

    Auto Systems:
  • Labor Times, Manuals, Warranty, Aids
  • Glass, Doors, Hood, Decklid, Tailgate, Liftgate, Locks
    • Document: Instrument Cluster Oil Level Messages
    Vehicle: 1991 MERCEDES-BENZ 300D 2.5 2.5 L5 DIESEL

    Auto Systems:
  • Labor Times, Manuals, Warranty, Aids

    • CLICK HERE TO GET FULL ACCESS TO 1991 MERCEDES-BENZ 300D TECHNICAL SERVICE BULLETINS!

    COMPONENT/PARTS SPECIFICATIONS FOR 1991 MERCEDES-BENZ 300D AUTOMOBILES

    BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1991 MERCEDES-BENZ 300D cars and light trucks sold in the U.S. and Canada from 1970+.

    • Brake caliper mounting bolt torque
    • Brake drum runout, machining, & discard specs
    • Minimum brake lining thickness.
    • Brake rotor runout, parallelism, machining, discard, & finish specs

    A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 1991 MERCEDES-BENZ 300D cars and light trucks sold in the U.S. and Canada from 1980+.

    • Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap

    COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.

    PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules

    QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 1991 MERCEDES-BENZ 300D cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.

    • Automatic transmission/transaxles capacities, lubricant recommendations
    • Differential/final drive capacities, lube recommendations, grades, & viscosities
    • Final drive fill & drain plug torques
    • Number of lubrication fittings & plugs
    • Power steering, brake, & clutch fluid recommendations
    • Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
    • Number of lubrication fittings & plugs
    • Power steering, brake, & clutch fluid recommendations
    • Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
    • Severe service maintenance & interval recommendations
    • Tire sizes, wheel nut/bolt torque, pressures & rim sizes
    • Transfer case capacities, lube recommendations, grades, & viscosities

    TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 1991 MERCEDES-BENZ 300D cars and light trucks sold in the U.S. and Canada from 1980+

    • Airflow sensor electrical specifications
    • Tensioning specifications for systems with automatic tensioners
    • Barometric pressure sensor specs
    • Battery group number and cranking performance
    • Crankshaft & camshaft position sensor resistance
    • Engine compression pressures
    • Coolant temperature sensor specs
    • Computer advance.
    • Diesel fuel temperature sensor resistance.
    • Distributor advance specifications
    • Ignition pickup coil resistance
    • Exhaust gas recirculation temperature sensor resistance
    • Engine fastener torque values
    • Firing order diagrams
    • Fuel system pressures
    • Generator (alternator) specs
    • Intake air temperature sensor specs
    • Ignition coil specifications
    • Fuel injector resistance
    • Engine idle speeds
    • Knock sensor resistance
    • Manifold absolute pressure sensor specs
    • Mixture control solenoid resistance
    • Voltage regulator specs
    • Spark plug applications & gaps
    • Starter motor electrical specs.
    • Tensioning specifications for systems without automatic tensioners
    • Throttle body temperature sensor resistance
    • Ignition timing in degrees at rpm
    • Transmission oil temperature sensor resistance
    • Throttle position sensor specs
    • Vacuum sensor valve specs

    CLICK HERE TO GET FULL ACCESS TO 1991 MERCEDES-BENZ 300D SPECIFICATIONS DATA!

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