Mercedes-Benz Transporter 207D, 307D, 210D, 410D, 208D, 308D, 310D, 408D DETAILED DESCRIPTION OF — REMOVAL, INSTALLATION, ADJUSTMENTS, REPAIRS, OVERHAUL AND SERVICING OF ALL THE MAJOR VEHICLE PARTS (except body), INCL. ENGINE, VALVES, DIESEL FUEL INJECTION” SYSTEM, CLUTCH, BRAKES, STEERING, TRANSMISSION (except overhaul), FRONT AND REAR AXLES AND SUSPENSION, ENGINE ELECTRICS — WITH EXPLODED VIEWS AND COMPLETE TECHNICAL DATA AND WIRING DIAGRAMS. eephone VEnICLe ‘wwvcrussek-manuals.co.uk : PETER RUSSEK PUBLICATIONS LTD. Mercedes-Benz 207D, 307D, 210D, 410D 208D, 308D, 310D, 408D 2.3, 2.4 AND 2.9 LITRE MANGAL, DIESEL ENGINES ADJUSTMENTS @ TUNE-UP REPAIRS © OVERHAULS SERVICING FAULT FINDING MANUALSPOCKET MECHANIC Mercedes-Benz 207D, 307D, 210D, 310D, 410D, 208D, 308D, 408D 2.3, 2.4 and 2.9 Litre Diesel COVERIN GENERAL INFORMATION, DIMENSIONS, WEIGHTS, ‘CAPACITIES, GENERAL, SERVICING NOTES. 4 ENGINES. 8 LUBRICATION SYSTEM. 65 COOLING SYSTEM, 8 DIESEL FUEL INJECTION SYSTEM 7 ‘CLUTCH, 89 MANUAL TRANSMISSION 94 FRONT AXLE, ‘100 REAR AXLE AND PROPELLER SHAFT 110 FRONT AND REAR SUSPENSION 118 STEERING, 120 BRAKE SYSTEM 17 ELECTRICAL SYSTEM 145 2A LITRE DIESEL ENGINE - TYPE 616. 153 ‘SERVICING AND MAINTENANCE 176 FAULT FINDING SECTION. 179 WIRING DIAGRAMS 188 IBY PETER RUSSEKORDER NO. 448 vet fabled SiaFlow, Bock Cemmeral Square High weombe, Bucks, Hes) 2 ‘ra FighWycomoe (oy <40809 "ov4oa)s2seun an (0434) 473080 mal ni oats ISON No, 1298700455, \WiTt FAULT Fnuoine SECTION IATEND OF MANUAL Te, publser woul he to tank Damir Cher UK Ue fe No pa ofthis pubeaton may be reproduced sored ina rebel systm of ‘avenger ahr means wt premise ee No iat can be accepted tor ary inaccuracies or Omissions in is vary ponte ear hs been ten fo ake [oshble Every cae her io beer taken to nu or damege to ecipmet when warng en he ehice Uehove Weta cover at moons prosicas th cay of pubicaton bet oe “nabe fo refer tal rdentone and changer crn mets oot Re-publsed an eit nary 2008 © pater RORussek-2000 Pad in England 2 PREFACE ‘Smal though his Wosshop Manual tn sz, lots no dan covering Ios of te seni a tepa a the Mercedes van and Carper Sars Ios ited on ho ouside cover wth 23 ana. ee engine (onaine pee {551 an802 andthe enter 24 Wve engine onanetvoa S10) Bet, easytofotow ietuctons are ghen, tee tom all necessary omplcatons ond repelions, Yt cortainng mi the egured chic deal tnd ltomaton, nd many dagrarsondiluators. Compile an Rusted by expr, this manual provides» cones source of rip tat, st af wich hat ean woes checked fe acrracy the Imanuacra’s ofcal series and ropa preseute, but many inetusions ‘avo dervod fom acual prstesto fate your work Wher ge aos "rerequed, these are eed to ext f abso necessary ae we 30 fot Heat fo sdvoe youl we feta he perstoneannat be papa nanan nate se of Shoe The rears oom judgement rue ese ust what work he let able To undetahe, btthre ono dou tal wt ts man fo ast hm ee be may esc wae he Sly cmrece me s “he manu eaed "Pocket Mecha” and spruces In handy glove cht ze with hea that shoul be pt fe wri htt You are {ravting ay garage mechanics themseves Use ese publeaare {nar war apd you have he marl wn you mte vhs yeu vl hare 2 Invluale sure ofrference which wl ued repey odes oe ‘A genara ating (reublesootng) secon eluded atthe and of he Imanua an at fame tated are toton Yom sel espererce, oer wh ‘he necessary remedies to coe fauts and malurctonng of cera ae, Important Note: The main text ofthe engine Section and some lather sections associated withthe engine, covers the 0" and 1602 engine, altmough technical data are alzo given for the 616 engine Ditferences forthe 816 engine are described at the end ‘ofthe manual na toparate section.the Ci doer ptr, se oem.02 tng capacen nae eniemimer ro cabateres ose Bi ceuereecere aa ee ike Si iotencae a Sees aS een a et raians ah Se repeat reas inmate ae aren aay ‘ 0.3. General Servicing Notes marae cpt ce rte tr Daas siestmeenreer ies ts 2S eae eer ty posma cata aorta orn mise amin to rae he beat oe the apace setae, we Sort fepea ten Opera SSeS alk caeceormcaeae Serer oh eee Reepasreconsramrars porn Ate ren san eth et ip tcc cron 6 etree teat ran ganda sey tb aan 8 ot ‘Sewn neat evens boar ese Serve att ‘eae mia ss he ole base supped, nn pnd ble ‘Remtecng swt one wun be Sar" ans econo oie oe ‘beta aang and proper sone a nl agit or ‘Ft ene ae wa ol py ty hese of he hte tr and ee ates mn een an sag ten rg eo oracle cso Use San tobe ae he pepe mt ned om Felgen none rae ran ca oe a het Fenove an teste bea every ‘otto ona We svengy cant you te cee cry ne osee ‘reese yee mance bot san my se epacenet ‘4: Te ines sime_and ttn of coporarta_ en aupted_by he Se gRtite Gi lt an tnd te Us Ge pana spt ate bon See US may dee 2 ae of 2 Stning rena prea an Me beauevn ee ee phan secomnin fle bore petite roenesein e ‘TR: Inde he Tne Resrg a shown 3 & 100: Tapas cane tpn ng sake Neo Merapone penne 0.4. sacking up of he Vehicle er uae, up ie 8 nr nthe Owns a th oe Eyota apie ne nce a ets joe ue rc ae vei tce Aasion wih tu eye bene! es eps ‘Tolnk upite whice compat tak up theft en Chock er wha e Leen ot ae hee web cane Voom ns feerapng a thonn mig 04 easy fr th feteSSeS “ere end of the ei i fc iced sant baba, rary ftts Gen ab. Aan ate ne a etcotond woh et nee cane = ager Cyne: ae x2 ae 157 gm (18 ot 2000 - 200 {a 08 2) 240 ~ 2509 Bi aem e0 Am) t 20Cemmata beni Sex eten bea Ecaingayton Soe "hn pe rode ‘emes Grrr amet Sareea eee teams + Beit ave ope mesoe “ammonia ate rming— New Timing Chain 18 cola: Eshes, peaabe == ed ig nea ‘Yay Cranes 616 Engine Eng we ihe eer ‘0mm a00tin) Exot aes 830mm(oorsin ay Canoes E86 Engine Eng cot “ielwer 0150 0008 in) ct aes 535mm (oot) = =e i a ‘eri vey pater and eu tl ay be enya vok fice te tort te vt poston wl tek wpe Ramone be 10 "Decree tetany eatin The itr can ae be ener hove ere me wngre i ty at. in Open he ee ek can Hi eure al etapa eaeeect Seen anny uo ara ear + ESR RL Eee fone ena roo Prt pon ram mdene Sea betoncenc shgiera pom emt gon po ay fmt nece of nn eprstane wih can be ctind cu te engine ad ave Cnn won, al ge Yue come dsr oe oopve, 43. Engine -Overhaut 130. Cylinder Head and Vahes ~ Technical Data tnt eae tine nes poate 129-1421 nm ‘rece O80 ee mmm, 2400 mp ie erent adr ESS ‘overeating ee acest) 10mm npg tet ann bendy a8 ego ad aes nd head esig ace 816 Weshegomconre ta ve am ter OF Fe 2 Me tengm cg 2 inet 25mmisie= 12:6 1¢mm) ca es SSmmm{sieed2 28mm) om an e16- cere) re Aste) 25mm (s16=13101 6 mm) Bini SSm{siecds “sam vests 515 162209 tips eed nae Siew (eer caesien colere sn mareanomermnrorme an Setetecane totais Sener bene Geto cade as ier green or paves ries trae ote sore ite en Se. Tes, Freleng ss0rm 820m Setememwon Seman 2 sa ioe BBE ‘et ave Gusen SERRE Bm | atcHtsee = nner drmeter ‘8000-8015 mm Seperate eat sine 14106-14253 mmMegeret rags oe, Except 616 Eraioe oo mana 6 Engine Seeman 1.301, cylinder Head ~ Removal and instalation ‘The tog oman sb bed her waked oon ent ae +7 Toe pina a mae ofa. Eng ent rae th at {etude gr helen ea ge ne eed Wop Oe ee ‘te ge acorspreanuaion rumen ape ed ‘Sth ime Anos Nena oun ne esas 16 TEtinown erste ype : itn cinema of st pone on rr. {Resameressonreveremene ayia bese at pe Zam + Seta uments Se _ssserbiy veal postion e ; Sheets vo Slice are Seiaseivehocew ner aeriraeacnc en SERRE iacarsraentes oe sctitirarasariatanetst pemietats 7 anie sean ——<« a rom the ecu arte anduncrnhe exaust ppe spp act om the anon hee eh) manoterapng te ting cain oe cab see Pul he al ot inde tbe owe ee cin on sp oe 5 Rett rato a ti + Ute ern ts ots er rr ton shown ng 1.14 PERS SIaCGE eae ar Pak Nee 8 pep hes ee eS Sees en aT i Tgten te banrevese coe ae om any a tyne ican ie ee ap st SLR em eng SoS SS Sah payne es lp et Se, cater p hecamat eg hte cfc ed Set re ire hr em se ang Ee +a pra a et euzr wte k » + erat ater rena, Trecesoy, arate eer i : i In nena ang mre: pace anew ner ad gua nPorn, Re Siar dct pew ng ce + Gene tenis of cinerea tot te dr bot eas ‘er uments he har Seen mene oerseee + Teor einer hed ote ogra ied and hope ares) end {shtn em nih eqn hor nfige ae vee Sages Te ‘Gnng cael aps bee + Toptna bts mtnecove ot} Sham 815) ‘Ttan oor mcr oe’ te3Shgm GORE) 1 Angotgtn a eos nse core png ret T0. ha rt ‘in win mh! ach al 4a they rt Pe ‘fee ermudt ‘are oes te a ein ya SCE ea ie heehee te hy ke + elite eat mtn en ur me man ead Wren artes Sig gma) Sage mt sng en set, in nt Set are tenses ante Stan t3say Pera tes Sa 22 a sii a ea eae + RRS een eras en Seaieeerarica teeter Soemaceeioenas | Rahiyhcetee edirttarmeanignonseny "merging Sea emcee Sot antnae Peo Recomm n or sp caies ut nt mas Ana to a recon on Hos. eit ston nthe nen son, a —‘Shs tn tee se'veammd cy cy acnens theta poms ote cout Pm elt TS Sea 1302, Cynder Head - Dismanting TRe'slonng session csaaes thal heen haa io be race ¥ ny ‘opened ated fre the acon Teton The ope rsprstetamcan npn wh nad iat man yp r= hyn he ng heat man 7 Siamen can™ estas ema et eee et he bee re tear aie en go +7" Remove he ale tpg ear and hw vas The wave sige (ne ES Tce ma te tnd“ Aha eg aed Soeeeah wer Spt snr onoed Fin 1173 chow ec oe aes 2 ‘Ao or shuld nt ant cana (oa Thera oa aa-naar mage hu Str eh tear sor oe are tee e310 tow vr pa ofa Pag ashen mas ce plotting ope ohne ‘hers a 21.303. Oyinder Head - Overhaut tte dns tre ie tel wa sh vaes re ma fat Yon at Resto fend mutt egy aed ander fA oman! ret ten Ct eats er a rer freed (Te deinen tneebe meh eorieted leo sino lg» ptm ch rch be oe ses fn rae sce, eye ete Sores ares en ee Fececomastatee Eepcaiee Stara or arora Attar unin hak be tring ang he ec in Toaagrng Ain ced wi ttc on tee ut lett aie mechan ZO ssw inh. ot at engl #8 cn nw‘Shared by ung eae aia ange (rem Tra ca see oye Pn. Repareret of oes tet ten rd eT ‘e's eee pean” we abo you te rg to onde ead You Free teu the we he tapece ae a rg op Snttewa nin'm'9q 12" tne manson mon be Sebeen tan OS om he leur sag etm amt = grooving Ihe wea manly sigh. vaves ean be groan he niga angie rg mache onsen etre Sah tra ot ot ‘Sun ves ne used "as fe yore by rane mbar ne os ee a suman ie ny age epee Sees Ss oe Et | eet aes of gc eral S03 Mave ace rato“ pce © 52 sh are pp eee pam! | Safe tee ane cnn ten ae OX ‘Ih it shrge ane mprnany, ba bm wah SSSIIRZ IIe canto ot on te pre contution cnaars to et feta ‘ee met perce ‘one ‘Steno nag sesame of ane capes ore rave ‘Socrates eck ‘The toning pls an be Seether ea ‘strenght shh aentosr came et ‘naman andar sn beloefes bythe shape a 129). Feteenterteer nr Soi Tatoos womens eat erg 2Wiaenats aves Some tertnett eaves 1+ Remove necanaat ee ern ln * Shapiphevtve + attenen sas th angie od crtty ous am 1 He ae son ‘fmt sane mtb eer tet nee "Pusnne see ‘te puso ort ey neato + Fartne samen na tsoomaa pane seo congo yry soy, a yale cate ates eae. Soene the sping Seng corranion i sn, ft re Pveo a aoe e 13.04, cylinder Head - Assembly isaac tnd vel of he rag pce, et 2 ateate te wae aera wt engbe land nae he aes ioe cae 2 oeistetenanng esi 1308 Hydraulic Vale Clearance Compensation‘he nate ae croaaing seme redo rca rsa pce ‘Govaerts (eh eres lowe a | seo 2 4 3] = Theta pins) ot ey tater = <= Ei ~* re oe sees 6 ewok Y aE a ee te ‘hun th cree hw ova pt he ae | {arpet te tr) nba nol "ea Si THER Tar sl eve appt eo aa rer ivr arate a cn ow tone say crane ee Nima Sean pone wm oer ‘he ennnes 8 ep chen te wo cae (0) betwee ne wane 9) oh ‘Mteateting ser tase mamat aye ota pas ha same 20 tute ene dr gos. Smuts! 300 p. 1 Resmetne cng feces Fe cra ru cam fr he tpt be cece I ping itera t Felppetott sige br freed. Refine cane ay drtbeg aaa er sate eee aaa ete ters proce. a1 peTowanpeoMectne RODS 310. Tea Segara Prk Rig ear: sme tence oa ere ‘ae = Poon i ac ~ ”In pate, ‘a nen 008 = 0.015 ae 12-1 = : mage cmt See et een a ort Seen Soran eo Pitonbaete St Pion No.0, Plone 64, Pho Ne 36,4 in nt eee nea ed 25005-26000" Someta go12-20%3 a acre as0-a4smn mesg edt tae 12..4.__ eonand Comedia Ro Remon Se as et er EA eg See eae soe Eo 2Steen ease 120) BEET Sc ene sate wht nce ruber The oper sae ae LSI ing ncn cant tre rat amas A ome no Teese cen Sop ge pte sown Fig 3, Yu ae Remunisctst ee mace tete cates Farell eee aoa Behemeamrnaeaee ceo pan rns ae 0 035 {na pum re nestles ut othe ercer Sey cara sents he tne! [Spe Rt Seca be cy Tenors ne pan 35 he igs to beret, mak te cea i af aw (ro, ndeatng be fing econ mo wanped ioe 13-42 ‘Measuring the Cynder Bores Anil calor mceanry tomar he tof the cnc bre, The srvaie_ rma pore Song vo we pote ene aa ct ere ic * SISRSe Stra ee te -aoEke henge tamer, ane oy Aven ori ‘on ‘Site ge mong too wee (bette "A toernc 0% mm persia Fr L Shaldyoctoech Ayu newton reamed + Crmecng de sh cc te a at, prey en te ene Tas con gh mage speci meer ee pn ae 131, cheng ton and Coonesing Ross ‘clave vatcvenans Caste peoe oacswcingoieicioe =” Exige toy mare mT mi ee pene % aiy. 8 Seton! wo floc) ust ete tine pon an har cea earte nes end tah, fa row Bak Itecocir ode et oun mnt be reamete der 0 Te to rane caret puton pn rung’ force ange we ‘doomenstoneetne ot cvieou by at eng soon 1.3.44, Checking the Big End Bearing Clearance “Thee oprtan ae dibdin cenectn wth thea Satin $322), 1.3.1.5. Piston and Connecting Rods - Assembly oe tens ate te, chek te pen own marge Be cane ns {rete nw cowl rs weed srarge em Peccrane wth he rae Nnownuneer Pama fae ar ban rice ccc oto of eye earn aon Ei’ ooo poten man ve emoes re he cee Seinty Totter neree cae wate, ale 4 Itot ne eng roi te pon a ai tee brs, Mate sre a {Retro tegen cto a om babi se ean Itcmstet sancti cage satonnin i 138. eat egnenten elon are SE SWAT ane oe F Canes ene pen 2h geo ard ely ap nero Boor he pln Pn recess sno un mln ao ‘efeonmne rete ne, Mouton oe Gag pat pon a tre pon os froth te to stg ah mo. Tia'Shoas tore seus mace" Une Shatin toonesae'aten ga coanee te Seichicomcctaee ome comets Tie sg pena wh an EGR ese, patone rece yo ah ‘Sie isd rey a OE ge) 1.4.8, Pistons and Connecting Rods = Installation ervey Mente te one eres wi lang 9 cmecig rods and ‘Scag eapamstte noe ehh ob The arom neon rons a ee nr ino gr‘ange ne on tr et ones 12 ein he crater pant ane ue ttn tg ergrstr pa ergo a Nee Efe nt a inp ae ay pe inet acd Beating tt ra hcg ro ening ap, tg (tn'be TW ade sea fe acon ave! sooncsng oa Chest tt ‘Sruingeaeapmar rtasg ech ht ‘eather wrens rcpt wth org an an en bac Sotgugeninjtremestsiges Pam bcpesiin totter cot toy ver 50-00. am itt ag toe tre wench Nest a ‘NeatehGutshne bet meatier raat) Seed eae he rans fhe tw rearing carp eat eto ea crt “rontne wo oer pten-omecny od ssonies rb sue mer hake petone anderen ad rce orc maafon an th Spl oh engavtn ho pe eet ‘Wen sf gape meas the se eure of ah oe hg ca Be ‘rnin The marie 80 4.32, CYLINDER BLOCK 4320, Technical Data ine te Dante 012 eas a fcaeemee eens Siemon) vucsuing piers pe coe woe eae, rede Ste lant (61 eno —Varse ona erner’ Susp yaar 31009-51019 ie ee Darter 01 ng = Varn 2: Tone ane Soup Cyinaerhe 010mm 000th) “0 Eee ‘aia eater fees "tetereseane ce ane 10IM Serre aiemioeosm) 1324, Serving pect inson caddies th dato wach me ne ranean hs ‘Sx tave eapctin veer ho bres neo be fecmachned et reget and enive aca of rete to ort te Symes ern tte ‘See pce hone! Fors he pal auc Ye 0m tana a Se ae Bein tmnt ohn Pt vs Sen gies ile secede oe pte ck and he ened ‘Secs Ss treo pac cee bore ni ovded flit: Also an ros 18m plato 08900, neat [3s fn pum fat oom 6 8 fo Ned arena eee ak feta whe pb ah net ree ounces pea {Tench cane tare epic te tel a sews ase Sepia amore ramen tye Ui rao fant rd S0 nny anc ut te ‘a hams rts he ere aap ni Tray sae ‘manelei cernecun toma rf Ta cet Sintr manner o Secrbed fr Be ener De [sonra seater “ect in grease nance ontpncing te tn ae tet ponton (Steir. at enor epee, a4h arson pen ep ECR yt 4.33. CRANKSHAFT AND BEARINGS 133.0, Technical Data ee rnd ten 005m nc fap ramps Soom ioc bert eosam “cimetor hes 207mm “cr ct a at Vr) aoa ee on neg cn: pois em-asem igi sm.im tase aoe cose, 3400-344rm thts washes) 400-2421 tng beng) ‘a ates ren anes wae) ins wrod eas cen lat C0180 rg: aan oma $ 7989-79050 03.967 nm (bes 0 mm) ‘es-oor mot O=0 eccpeeees io 2S ES #E ny bn at ee Sedan fe Sivitign oasis oo rete 46S 5-96 wim) +80~ 100" 4s