Fuel / exhaust systems - Diesel models ContentsI Accelerator cable - removal, refitting and adjustment...................11[Accelerator pedal - removal and refitting........................................12lAirdeanerand associated components - removal and refitting .. .21[ Air filter renewal..........................................................See Chapter 1l Exhaust system - general information and component renewal .. .22I Fuel filter renewal ......................................................See Chapter 1| Fuel filter water draining ............................................See Chapter 1I Fast idle thermostatic sensor - removal, refitting and adjustment.. .4I Fuel injection pump - removal and refitting.....................................6| Fuel injectors - testing, removal and refitting................................10Fuel lavel sender - removal and refitting ........................................13Fuel pick-up unit - removal and refitting .........................................14I Fuel system - priming and bleeding................................................2I Fuel tank - removal and refitting .................................................... 15I General information and precautiona..............................................1

Degrees of difficultyIdle speed and anti-stall speed checking

and adjustment ..........................................................See Chapter 1Injection timing - checking methods and adjustment .......................... 7Injection timing (Bosch fuel injection pump) - checking and

adjustment ....................................................................................... 9Injection timing (Lucas fuel injection pump) - checking and

adjustment ....................................................................................... 8Intercooler - removal and refitting ..................................................... 20Manifolds - removal and refitting ........................................................ 16Maximum speed - checking and adjustment ........................................ 3Stop solenoid - description, removal and refitting................................5Turbocharger - description and precautions......................................17Turbocharger - examination and renovation .....................................19Turbocharger - removal and refitting 18

.2 The oil level should be checked with the vehicle standing on level ground, before it is driven, or atleast 5 minutes after the engine has been switched off. If the oil is checked immediately after driving the vehicle, some ofthe oil will remain in the upper engine components and oil galleries, resulting in an inaccurate reading on the dipstick.3 Withdraw the dipstick from the tube, and wipe all the oil from the end with a clean rag or paper towel.Insert the clean dipstick back into the tube as far as it will go, then withdraw it once more. Note the oil level on the end ofthe dipstick. Add oil as necessary until the level is between the upper ("MAX") mark and lower ("MIN") mark on thedipstick (see illustrations). Note that approximately 1.5 litres of oil will be required to raise the level from the lower mark tothe upper mark.4 Always maintain the level between the two dipstick marks. If the level is allowed to fall below thelower mark, oil starvation may result, which could lead to severe engine damage. If the engine is overfilled to any greatextent by adding too much oil, this could result in oil leaks or oil seal failures.

MIN MAX1.3a Withdrawing the engine oil level dipstick - Diesel engine

1,3b Engine oil level dipstick markings5 Oil is added to the engine via the filler cap on the cylinder head cover on petrol models, and via thefiller/breather cap on Diesel models. Unscrew the cap and top-up the level; an oil can spout or funnel may help to reducespillage (see illustration). Add the oil slowly, checking the level on the dipstick frequently. Always use the correct gradeand type of oil.2 Coolant level check

A Warning: DO NOT attempt to remove the expansion tank pressure cap when the engine is hot, as there is a verygreat risk of scalding.1 All vehicles covered by this manual have a pressurised cooling system. An expansion tank isincorporated in the cooling system; it is built into the side of the radiator. As engine temperature increases, the coolantexpands, and the level in the expansion tank rises. As the engine cools, the coolant is automatically drawn back into thesystem, to maintain the correct level.2 The coolant level in the expansion tank should be checked regularly. The level in the tank varies withthe temperature of the engine. When the engine is cold, the coolant level should be between the "MIN" and "MAX"marks on the side of the tank. When the engine is hot, the level may rise slightly above the "MAX" mark.

The manual is divided

As engine temperature increases, the coolant expands, and the level in the expansion tank rises. As the engine cools,the coolant is automatically drawn back into the system, to maintain the correct level.2 The coolant level in the expansion tank should be checked regularly. The level in the tank varies

with the temperature of the engine. When the engine is cold, the coolant level should be between the "MIN" and

mark on the dipstick (see illustrations). Note that approximately 1.5 litres of oil will be required to raise the level from thelower mark to the upper mark.4 Always maintain the level between the two dipstick marks. If the level is allowed to fall below thelower mark, oil starvation may result, which could lead to severe engine damage. If the engine is overfilled to any greatextent by adding too much oil, this could result in oil leaks or oil seal failures.

MIN MAX1.3a Withdrawing the engine oil level dipstick - Diesel engine

1,3b Engine oil level dipstick markings5 Oil is added to the engine via the filler cap on the cylinder head cover on petrol models, and via thefiller/breather cap on Diesel models. Unscrew the cap and top-up the level; an oil can spout or funnel may help to reducespillage (see illustration). Add the oil slowly, checking the level on the dipstick frequently. Always use the correct gradeand type of oil.2 Coolant level check

A Warning: DO NOT attempt to remove the expansion tank pressure cap when the engine is hot, as there is a verygreat risk of scalding.1 All vehicles covered by this manual have a pressurised cooling system. An expansion tank isincorporated in the cooling system; it is built into the side of the radiator. As engine temperature increases, the coolantexpands, and the level in the expansion tank rises. As the engine cools, the coolant is automatically drawn back into thesystem, to maintain the correct level.2 The coolant level in the expansion tank should be checked regularly. The level in the tank varies withthe temperature of the engine. When the engine is cold, the coolant level should be between the "MIN" and "MAX"marks on the side of the tank. When the engine is hot, the level may rise slightly above the "MAX" mark.

(Use distilled water - not applicable to 'Maintenance Free' battenes)

Turbo Diesel modelsA Engine oil level dipstick and filler cap, (Use Multigrade engine oil, SAE 10W/40 or 15W/50 to API SG/CD 1.5 litres

approximate difference between MIN and MAX marks) B Coolant expansion tank(Use 50/50 mixture of water and ethylene glycol-based antifreeze) C Brake fluid reservoir(Use universal brake fluid) D Power steering fluid reservoir(Use automatic transmission fluid) E Screen washer fluid reservoir F Battery

(Use distilled water - not ap

(Use distilled water - not applicable to 'Maintenance Free' battenes)

Turbo Diesel modelsA Engine oil level dipstick and filler cap, (Use Multigrade engine oil, SAE 10W/40 or 15W/50 to API SG/CD 1.5 litres

approximate difference between MIN and MAX marks) B Coolant expansion tank(Use 50/50 mixture of water and ethylene glycol-based antifreeze) C Brake fluid reservoir(Use universal brake fluid) D Power steering fluid reservoir(Use automatic transmission fluid) E Screen washer fluid reservoir F Battery

(Use distilled water - not applicable to 'Maintenance Free' batteries)1 Engine oil level check

1 The engine oil level is checked with a dipstick that extends through the dipstick tube and into thesump at the bottom of the engine. The dipstick is located at the rear of the engine on 1.8 litre petrol engine models, andat the front of the engine on all other models. The dipstick top is brightly-coloured for easy identification.2 The oil level should be checked with the vehicle standing on level ground, before it is driven, or atleast 5 minutes after the engine has been switched off. If the oil is checked immediately after driving the vehicle, some ofthe oil will remain in the upper engine components and oil galleries, resulting in an inaccurate reading on the dipstick.3 Withdraw the dipstick from the tube, and wipe all the oil from the end with a clean rag or paper towel.Insert the clean dipstick back into the tube as far as it will go, then withdraw it once more. Note the oil level on the end ofthe dipstick. Add oil as necessary until the level is between the upper ("MAX") mark and lower ("MIN") mark on thedipstick (see illustrations). Note that approximately 1.5 litres of oil will be required to raise the level from the lower mark tothe upper mark.4 Always maintain the level between the two dipstick marks. If the level is allowed to fall below thelower mark, oil starvation may result, which could lead to severe engine damage. If the engine is overfilled to any greatextent by adding too much oil, this could result in oil leaks or oil seal failures.

MIN MAX1.3a Withdrawing the engine oil level dipstick - Diesel engine

1,3b Engine oil level dipstick markings5 Oil is added to the engine via the filler cap on the cylinder head cover on petrol models, and via thefiller/breather cap on Diesel models. Unscrew the cap and top-up the level; an oil can spout or funnel may help to reducespillage (see illustration). Add the oil slowly, checking the level on the dipstick frequently. Always use the correct gradeand type of oil.2 Coolant level check

A Warning: DO NOT attempt to remove the expansion tank pressure cap when the engine is hot, as there is a verygreat risk of scalding.1 All vehicles covered by this manual have a pressurised cooling system. An expansion tank isincorporated in the cooling system; it is built into the side of the radiator. As engine temperature increases, the coolantexpands, and the level in the expansion tank rises. As the engine cools, the coolant is automatically drawn back into the

system, to maintain the correct level.2 The coolant level in the expansion tank should be checked regularly. The level in the tank varies withthe temperature of the engine. When the engine is cold, the coolant level should be between the "MIN" and "MAX"marks on the side of the tank. When the engine is hot, the level may rise slightly above the "MAX" mark.

(Use distilled water - not applicable to 'Maintenance Free' battenes)

Turbo Diesel modelsA Engine oil level dipstick and filler cap, (Use Multigrade engine oil, SAE 10W/40 or 15W/50 to API SG/CD 1.5 litres

approximate difference between MIN and MAX marks) B Coolant expansion tank(Use 50/50 mixture of water and ethylene glycol-based antifreeze) C Brake fluid reservoir(Use universal brake fluid) D Power steering fluid reservoir(Use automatic transmission fluid) E Screen washer fluid reservoir F Battery

(Use distilled water - not applicable to 'Maintenance Free' batteries)1 Engine oil level check

1 The engine oil level is checked with a dipstick that extends through the dipstick tube and into thesump at the bottom of the engine. The dipstick is located at the rear of the engine on 1.8 litre petrol engine models, andat the front of the engine on all other models. The dipstick top is brightly-coloured for easy identification.2 The oil level should be checked with the vehicle standing on level ground, before it is driven, or atleast 5 minutes after the engine has been switched off. If the oil is checked immediately after driving the vehicle, some ofthe oil will remain in the upper engine components and oil galleries, resulting in an inaccurate reading on the dipstick.3 Withdraw the dipstick from the tube, and wipe all the oil from the end with a clean rag or paper towel.Insert the clean dipstick back into the tube as far as it will go, then withdraw it once more. Note the oil level on the end ofthe dipstick. Add oil as necessary until the level is between the upper ("MAX") mark and lower ("MIN") mark on thedipstick (see illustrations). Note that approximately 1.5 litres of oil will be required to raise the level from the lower mark tothe upper mark.4 Always maintain the level between the two dipstick marks. If the level is allowed to fall below thelower mark, oil starvation may result, which could lead to severe engine damage. If the engine is overfilled to any greatextent by adding too much oil, this could result in oil leaks or oil seal failures.

MIN MAX1.3a Withdrawing the engine oil level dipstick - Diesel engine

1,3b Engine oil level dipstick markings5 Oil is added to the engine via the filler cap on the cylinder head cover on petrol models, and via thefiller/breather cap on Diesel models. Unscrew the cap and top-up the level; an oil can spout or funnel may help to reducespillage (see illustration). Add the oil slowly, checking the level on the dipstick frequently. Always use the correct gradeand type of oil.2 Coolant level check

A Warning: DO NOT attempt to remove the expansion tank pressure cap when the engine is hot, as there is a verygreat risk of scalding.1 All vehicles covered by this manual have a pressurised cooling system. An expansion tank isincorporated in the cooling system; it is built into the side of the radiator. As engine temperature increases, the coolantexpands, and the level in the expansion tank rises. As the engine cools, the coolant is automatically drawn back into thesystem, to maintain the correct level.2 The coolant level in the expansion tank should be checked regularly. The level in the tank varies withthe temperature of the engine. When the engine is cold, the coolant level should be between the "MIN" and "MAX"marks on the side of the tank. When the engine is hot, the level may rise slightly above the "MAX" mark.

plicable to 'Maintenance Free' batteries)1 Engine oil level check

1 The engine oil level is checked with a dipstick that extends through the dipstick tube and into the

sump at the bottom of the engine. The dipstick is located at the rear of the engine on 1.8 litre petrol engine models, andat the front of the engine on all other models. The dipstick top is brightly-coloured for easy identification.2 The oil level should be checked with the vehicle standing on level ground, before it is driven, or atleast 5 minutes after the engine has been switched off. If the oil is checked immediately after driving the vehicle, some ofthe oil will remain in the upper engine components and oil galleries, resulting in an inaccurate reading on the dipstick.3 Withdraw the dipstick from the tube, and wipe all the oil from the end with a clean rag or paper towel.Insert the clean dipstick back into the tube as far as it will go, then withdraw it once more. Note the oil level on the end ofthe dipstick. Add oil as necessary until the level is between the upper ("MAX") mark and lower ("MIN") mark on thedipstick (see illustrations). Note that approximately 1.5 litres of oil will be required to raise the level from the lower mark tothe upper mark.4 Always maintain the level between the two dipstick marks. If the level is allowed to fall below thelower mark, oil starvation may result, which could lead to severe engine damage. If the engine is overfilled to any greatextent by adding too much oil, this could result in oil leaks or oil seal failures.

MIN MAX1.3a Withdrawing the engine oil level dipstick - Diesel engine

1,3b Engine oil level dipstick markings5 Oil is added to the engine via the filler cap on the cylinder head cover on petrol models, and via thefiller/breather cap on Diesel models. Unscrew the cap and top-up the level; an oil can spout or funnel may help to reducespillage (see illustration). Add the oil slowly, checking the level on the dipstick frequently. Always use the correct gradeand type of oil.2 Coolant level check

A Warning: DO NOT attempt to remove the expansion tank pressure cap when the engine is hot, as there is a verygreat risk of scalding.1 All vehicles covered by this manual have a pressurised cooling system. An expansion tank isincorporated in the cooling system; it is built into the side of the radiator. As engine temperature increases, the coolantexpands, and the level in the expansion tank rises. As the engine cools, the coolant is automatically drawn back into thesystem, to maintain the correct level.2 The coolant level in the expansion tank should be checked regularly. The level in the tank varies withthe temperature of the engine. When the engine is cold, the coolant level should be between the "MIN" and "MAX"marks on the side of the tank. When the engine is hot, the level may rise slightly above the "MAX" mark.

The manual is divided into thirteen Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided intoSections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers following on fromthe Section they are in, eg 5.1, 5.2, 5.3 etc.

It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms ofillustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in theChapter - eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in relatedgroups) as the Section or sub-section to which they relate.

There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its ownindividual contents list.

References to the 'left' or 'right' of the vehicle are in the sense of a person in the driver's seat facing forwards.Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise.

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3 Unscrew the two end plugs from the valve. Recover the O-rings.4 Remove the piston, spring, plungers and O-rings. Note their fitted order.5 Clean all parts with methylated spirit and inspect them. If the valve bore is badly worn, rusty or scored, renew thevalve complete. Otherwise, obtain a repair kit containing new O-rings (photo).6 Fit one end plug, using a new O-ring, and tighten it.7 Assemble the piston, plunges and spring. Lubricate the piston and the new O-rings with clean hydraulic fluid. Fitone of the O-rings to a plunger and insert the assembly into the valve bore, O-ring first.8 Fit the other O-ring into the bore and press it home with a small tube or other suitable tool.9 Fit the other end plug and O-ring.10 If the valve was removed for overhaul, refit it.11 Bleed the complete hydraulic system (Section 9), then check the success of the overhaul as follows.8,5 mm c f

Fig. 9.13 Fitting the second plunger O-ring to the pressure differential warning valve. Tool dimensions as shown (Sec 20)

12 Have an assistant depress the brake pedal hard for one minute. Watch the valve: if fluid emerges from the switch hole, renew the valve. If no fluid energes, refit the contact pin, spring and switch. Reconnect the switch.

21 Brake pedal - removal and refitting

if preferred, the pedal box can be removed complete (Chapter 5, Section 4) and the brake pedal removed on the bench. Otherwise,proceed as follows.1 Remove the steering column/pedal trim.2 Disconnect the brake pedal from the servo by removing the clevis pin.3 Remove the pedal pivot bolt and nut. The return spring will force the pedal downwards. Remove the pedal, spring

and pivot bolt.

4 The pedal sleeve and bushes may be renewed if required (photo). Grease the new bushes and sleeve before fittingthem.

5 Refit by reversing the removal operations.

also preceded by its own individual contents list.References to the 'left' or 'right' of the vehicle are in the sense of a person in the driver's seat facing forwards.Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise.Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated

into our manuals at the earliest opportunity.

The manual is divided into thirteen Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided intoSections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers following on fromthe Section they are in, eg 5.1, 5.2, 5.3 etc.

It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms ofillustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in theChapter - eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in relatedgroups) as the Section or sub-section to which they relate.

There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its ownindividual contents list.

References to the 'left' or 'right' of the vehicle are in the sense of a person in the driver's seat facing forwards.Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise.Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated

into our manuals at the earliest opportunity.We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and designchanges during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by theauthors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.Project vehiclesThe vehicles used in the preparation of this manual, and which appear in many of the photographic sequences, were: a 760 Turbo Saloon, a 760 GLE Saloon, and a 740 GL Estate.

2 The coolant level in the expansion tank should be checked regularly. The level in the tank varies withthe temperature of the eWe take great pride in the accuracy of information given in this manual, but vehicle manufacturersmake alterations and design changes during the production run of a particular vehicle of which they do not inform us. No liabilitycan be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, theinformation given.We take great pride in the accuracy of information given in this manual, but vehicle manufacturers makealterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability canbe accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the informationgiven.Project vehiclesThe vehicles used in the preparation of this manual, and which appear in many of the photographic sequences, were: a 760 Turbo Saloon,a 760 GLE Saloon, and a 740 GL Estate.We take great pride in the accuracy of information given in this manual, but vehiclemanufacturers make alterations and design changes during the production run of a particular vehicle of which they do notinform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, oromissions from, the information given.

Project vehiclesWe take great pride in the accuracy of information given in this manual, but vehicle manufacturers makealterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability canbe accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the informationgiven.Project vehiclesThe vehicles used in the preparation of this manual, and which appear in many of the photographic sequences, were: a 760 Turbo Saloon,a 760 GLE Saloon, and a 740 GL Estate.We take great pride in the accuracy of information given in this manual, but vehiclemanufacturers make alterations and design changes during the production run of a particular vehicle of which they do notinform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, oromissions from, the information given.

The vehicles used in the preparation of this manual, and which appear in many of the photographic sequences, were: a 760 Turbo Saloon, a 760 GLE Saloon, and a 740 GL Estate.

The manual is divided into thirteen Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided intoSections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers following on fromthe Section they are in, eg 5.1, 5.2, 5.3 etc.

It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms ofillustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in theChapter - eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in relatedgroups) as the Section or sub-section to which they relate.

There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its ownindividual contents list.

References to the 'left' or 'right' of the vehicle are in the sense of a person in the driver's seat facing forwards.Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise.

Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated intoour manuals at the earliest opportunity.We take great pride in the accuracy of information given in this manual, but vehiclemanufacturers make alterations and design changes during the production run of a particular vehicle of which they do notinform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, oromissions from, the information given.Project vehiclesThe vehicles used in the preparation of this manual, and which appear in many of the photographic sequences, were: a 760 Turbo Saloon,a 760 GLE Saloon, and a 740 GL Estate.We take great pride in the accuracy of information given in this manual, but vehiclemanufacturers make alterations and design changes during the production run of a particular vehicle of which they do notinform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, oromissions from, the information given.We take great pride in the accuracy of information given in this manual, but vehiclemanufacturers make alterations and design changes during the production run of a particular vehicle of which they do notinform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, oromissions from, the information given.Project vehiclesWe take great pride in the accuracy of information given in this manual, but vehicle manufacturers makealterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability canbe accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the informationgiven.Project vehiclesThe vehicles used in the preparation of this manual, and which appear in many of the photographic sequences, were: a 760 Turbo Saloon,a 760 GLE Saloon, and a 740 GL Estate.We take great pride in the accuracy of information given in this manual, but vehiclemanufacturers make alterations and design changes during the production run of a particular vehicle of which they do notinform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, oromissions from, the information given.We take great pride in the accuracy of information given in this manual, but vehiclemanufacturers make alterations and design changes during the production run of a particular vehicle of which they do notinform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, oromissions from, the information given.Project vehiclesWe take great pride in the accuracy of information given in this manual, but vehicle manufacturers makealterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability canbe accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the informationgiven.Project vehiclesThe vehicles used in the preparation of this manual, and which appear in many of the photographic sequences, were: a 760 Turbo Saloon,a 760 GLE Saloon, and a 740 GL Estate.We take great pride in the accuracy of information given in this manual, but vehiclemanufacturers make alterations and design changes during the production run of a particular vehicle of which they do notinform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, oromissions from, the information given.

The vehicles used in the preparation of this manual, and which appear in many of the photographic sequences, were: a 760 Turbo Saloon,a 760 GLE Saloon, and a 740 GL Estate.We take great pride in the accuracy of information given in this manual, but vehiclemanufacturers make alterations and design changes during the production run of a particular vehicle of which they do notinform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, oromissions from, the information given.

The vehicles used in the preparation of this manual, and which appear in many of the photographic sequences, were: a 760 Turbo Saloon,a 760 GLE Saloon, and a 740 GL Estate.We take great pride in the accuracy of information given in this manual, but vehiclemanufacturers make alterations and design changes during the production run of a particular vehicle of which they do notinform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, oromissions from, the information given.

We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and designchanges during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by theauthors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.Project vehiclesThe vehicles used in the preparation of this manual, and which appear in many of the photographic sequences, were: a 760 Turbo Saloon, a 760 GLE Saloon, and a 740 GL Estate.

The manual is divided into thirteen Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided intoSections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers following on fromthe Section they are in, eg 5.1, 5.2, 5.3 etc.

It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms ofillustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in theChapter - eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in relatedgroups) as the Section or sub-section to which they relate.

TThe manual is divided into thirteen Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided into

Sections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers following on fromthe Section they are in, eg 5.1, 5.2, 5.3 etc.

It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms ofillustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in theChapter - eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in relatedgroups) as the Section or sub-section to which they relate.

There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its ownindividual contents list.

References to the 'left' or 'right' of the vehicle are in the sense of a person in the driver's seat facing forwards.Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise.Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated

into our manuals at the earliest opportunity.

The manual is divided into thirteen Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided intoSections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers following on fromthe Section they are in, eg 5.1, 5.2, 5.3 etc.

It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms ofillustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in theChapter - eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in relatedgroups) as the Section or sub-section to which they relate.

There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its ownindividual contents list.

References to the 'left' or 'right' of the vehicle are in the sense of a person in the driver's seat facing forwards.Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise.Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated

into our manuals at the earliest opportunity.We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and designchanges during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by theauthors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.Project vehiclesThe vehicles used in the preparation of this manual, and which appear in many of the photographic sequences, were: a 760 Turbo Saloon, a 760 GLE Saloon, and a 740 GL Estate.We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and designchanges during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by theauthors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.Project vehiclesThe vehicles used in the preparation of this manual, and which appear in many of the photographic sequences, were: a 760 Turbo Saloon, a 760 GLE Saloon, and a 740 GL Estate.

The manual is divided into thirteen Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided intoSections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers following on fromthe Section they are in, eg 5.1, 5.2, 5.3 etc.

It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms ofillustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in theChapter - eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in relatedgroups) as the Section or sub-section to which they relate.

There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its ownindividual contents list.

References to the 'left' or 'right' of the vehicle are in the sense of a person in the driver's seat facing forwards.Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise.Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated

into our manuals at the earliest opportunity.We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and designchanges during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by theauthors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.Project vehiclesThe vehicles used in the preparation of this manual, and which appear in many of the photographic sequences, were: a 760 Turbo Saloon, a 760 GLE Saloon, and a 740 GL Estate.

The manual is divided into thirteen Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided intoSections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers following on fromthe Section they are in, eg 5.1, 5.2, 5.3 etc.

It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms ofillustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in theChapter - eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in relatedgroups) as the Section or sub-section to which they relate.

TThe manual is divided into thirteen Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided into

Sections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers following on fromthe Section they are in, eg 5.1, 5.2, 5.3 etc.

It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms ofillustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in theChapter - eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in relatedgroups) as the Section or sub-section to which they relate.

There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its ownindividual contents list.

References to the 'left' or 'right' of the vehicle are in the sense of a person in the driver's seat facing forwards.Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise.Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated

into our manuals at the earliest opportunity.

The manual is divided into thirteen Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided intoSections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers following on fromthe Section they are in, eg 5.1, 5.2, 5.3 etc.

It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms ofillustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in theChapter - eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in relatedgroups) as the Section or sub-section to which they relate.

There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its ownindividual contents list.

References to the 'left' or 'right' of the vehicle are in the sense of a person in the driver's seat facing forwards.Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise.Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated

into our manuals at the earliest opportunity.We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and designchanges during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by theauthors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.Project vehiclesThe vehicles used in the preparation of this manual, and which appear in many of the photographic sequences, were: a 760 Turbo Saloon, a 760 GLE Saloon, and a 740 GL Estate.

ngine. When the engine is cold, the coolant level should be between the "MIN" and

mark on the dipstick (see illustrations). Note that approximately 1.5 litres of oil will be required to raise the level from thelower mark to the upper mark.4 Always maintain the level between the two dipstick marks. If the level is allowed to fall below thelower mark, oil starvation may result, which could lead to severe engine damage. If the engine is overfilled to any greatextent by adding too much oil, this could result in oil leaks or oil seal failures.

MIN MAX1.3a Withdrawing the engine oil level dipstick - Diesel engine

1,3b Engine oil level dipstick markings5 Oil is added to the engine via the filler cap on the cylinder head cover on petrol models, and via thefiller/breather cap on Diesel models. Unscrew the cap and top-up the level; an oil can spout or funnel may help to reducespillage (see illustration). Add the oil slowly, checking the level on the dipstick frequently. Always use the correct gradeand type of oil.2 Coolant level check

A Warning: DO NOT attempt to remove the expansion tank pressure cap when the engine is hot, as there is a verygreat risk of scalding.1 All vehicles covered by this manual have a pressurised cooling system. An expansion tank isincorporated in the cooling system; it is built into the side of the radiator. As engine temperature increases, the coolantexpands, and the level in the expansion tank rises. As the engine cools, the coolant is automatically drawn back into thesystem, to maintain the correct level.2 The coolant level in the expansion tank should be checked regularly. The level in the tank varies withthe temperature of the engine. When the engine is cold, the coolant level should be between the "MIN" and "MAX"marks on the side of the tank. When the engine is hot, the level may rise slightly above the "MAX" mark.

(Use distilled water - not applicable to 'Maintenance Free' battenes)

Turbo Diesel modelsA Engine oil level dipstick and filler cap, (Use Multigrade engine oil, SAE 10W/40 or 15W/50 to API SG/CD 1.5 litres

approximate difference between MIN and MAX marks) B Coolant expansion tank(Use 50/50 mixture of water and ethylene glycol-based antifreeze) C Brake fluid reservoir(Use universal brake fluid) D Power steering fluid reservoir(Use automatic transmission fluid) E Screen washer fluid reservoir F Battery

(Use distilled water - not ap

(Use distilled water - not applicable to 'Maintenance Free' battenes)

Turbo Diesel modelsA Engine oil level dipstick and filler cap, (Use Multigrade engine oil, SAE 10W/40 or 15W/50 to API SG/CD 1.5 litres

approximate difference between MIN and MAX marks) B Coolant expansion tank(Use 50/50 mixture of water and ethylene glycol-based antifreeze) C Brake fluid reservoir(Use universal brake fluid) D Power steering fluid reservoir(Use automatic transmission fluid) E Screen washer fluid reservoir F Battery

(Use distilled water - not applicable to 'Maintenance Free' batteries)1 Engine oil level check

1 The engine oil level is checked with a dipstick that extends through the dipstick tube and into thesump at the bottom of the engine. The dipstick is located at the rear of the engine on 1.8 litre petrol engine models, andat the front of the engine on all other models. The dipstick top is brightly-coloured for easy identification.2 The oil level should be checked with the vehicle standing on level ground, before it is driven, or atleast 5 minutes after the engine has been switched off. If the oil is checked immediately after driving the vehicle, some ofthe oil will remain in the upper engine components and oil galleries, resulting in an inaccurate reading on the dipstick.3 Withdraw the dipstick from the tube, and wipe all the oil from the end with a clean rag or paper towel.Insert the clean dipstick back into the tube as far as it will go, then withdraw it once more. Note the oil level on the end ofthe dipstick. Add oil as necessary until the level is between the upper ("MAX") mark and lower ("MIN") mark on thedipstick (see illustrations). Note that approximately 1.5 litres of oil will be required to raise the level from the lower mark tothe upper mark.4 Always maintain the level between the two dipstick marks. If the level is allowed to fall below thelower mark, oil starvation may result, which could lead to severe engine damage. If the engine is overfilled to any greatextent by adding too much oil, this could result in oil leaks or oil seal failures.

MIN MAX1.3a Withdrawing the engine oil level dipstick - Diesel engine

1,3b Engine oil level dipstick markings5 Oil is added to the engine via the filler cap on the cylinder head cover on petrol models, and via thefiller/breather cap on Diesel models. Unscrew the cap and top-up the level; an oil can spout or funnel may help to reducespillage (see illustration). Add the oil slowly, checking the level on the dipstick frequently. Always use the correct gradeand type of oil.2 Coolant level check

A Warning: DO NOT attempt to remove the expansion tank pressure cap when the engine is hot, as there is a verygreat risk of scalding.1 All vehicles covered by this manual have a pressurised cooling system. An expansion tank isincorporated in the cooling system; it is built into the side of the radiator. As engine temperature increases, the coolantexpands, and the level in the expansion tank rises. As the engine cools, the coolant is automatically drawn back into the

system, to maintain the correct level.2 The coolant level in the expansion tank should be checked regularly. The level in the tank varies withthe temperature of the engine. When the engine is cold, the coolant level should be between the "MIN" and "MAX"marks on the side of the tank. When the engine is hot, the level may rise slightly above the "MAX" mark.

(Use distilled water - not applicable to 'Maintenance Free' battenes)

Turbo Diesel modelsA Engine oil level dipstick and filler cap, (Use Multigrade engine oil, SAE 10W/40 or 15W/50 to API SG/CD 1.5 litres

approximate difference between MIN and MAX marks) B Coolant expansion tank(Use 50/50 mixture of water and ethylene glycol-based antifreeze) C Brake fluid reservoir(Use universal brake fluid) D Power steering fluid reservoir(Use automatic transmission fluid) E Screen washer fluid reservoir F Battery

(Use distilled water - not applicable to 'Maintenance Free' batteries)1 Engine oil level check

1 The engine oil level is checked with a dipstick that extends through the dipstick tube and into thesump at the bottom of the engine. The dipstick is located at the rear of the engine on 1.8 litre petrol engine models, andat the front of the engine on all other models. The dipstick top is brightly-coloured for easy identification.2 The oil level should be checked with the vehicle standing on level ground, before it is driven, or atleast 5 minutes after the engine has been switched off. If the oil is checked immediately after driving the vehicle, some ofthe oil will remain in the upper engine components and oil galleries, resulting in an inaccurate reading on the dipstick.3 Withdraw the dipstick from the tube, and wipe all the oil from the end with a clean rag or paper towel.Insert the clean dipstick back into the tube as far as it will go, then withdraw it once more. Note the oil level on the end ofthe dipstick. Add oil as necessary until the level is between the upper ("MAX") mark and lower ("MIN") mark on thedipstick (see illustrations). Note that approximately 1.5 litres of oil will be required to raise the level from the lower mark tothe upper mark.4 Always maintain the level between the two dipstick marks. If the level is allowed to fall below thelower mark, oil starvation may result, which could lead to severe engine damage. If the engine is overfilled to any greatextent by adding too much oil, this could result in oil leaks or oil seal failures.

MIN MAX1.3a Withdrawing the engine oil level dipstick - Diesel engine

1,3b Engine oil level dipstick markings5 Oil is added to the engine via the filler cap on the cylinder head cover on petrol models, and via thefiller/breather cap on Diesel models. Unscrew the cap and top-up the level; an oil can spout or funnel may help to reducespillage (see illustration). Add the oil slowly, checking the level on the dipstick frequently. Always use the correct gradeand type of oil.2 Coolant level check

A Warning: DO NOT attempt to remove the expansion tank pressure cap when the engine is hot, as there is a verygreat risk of scalding.1 All vehicles covered by this manual have a pressurised cooling system. An expansion tank isincorporated in the cooling system; it is built into the side of the radiator. As engine temperature increases, the coolantexpands, and the level in the expansion tank rises. As the engine cools, the coolant is automatically drawn back into thesystem, to maintain the correct level.2 The coolant level in the expansion tank should be checked regularly. The level in the tank varies withthe temperature of the engine. When the engine is cold, the coolant level should be between the "MIN" and "MAX"marks on the side of the tank. When the engine is hot, the level may rise slightly above the "MAX" mark.

plicable to 'Maintenance Free' batteries)1 Engine oil level check

1 The engine oil level is checked with a dipstick that extends through the dipstick tube and into the

sump at the bottom of the engine. The dipstick is located at the rear of the engine on 1.8 litre petrol engine models, andat the front of the engine on all other models. The dipstick top is brightly-coloured for easy identification.2 The oil level should be checked with the vehicle standing on level ground, before it is driven, or atleast 5 minutes after the engine has been switched off. If the oil is checked immediately after driving the vehicle, some ofthe oil will remain in the upper engine components and oil galleries, resulting in an inaccurate reading on the dipstick.3 Withdraw the dipstick from the tube, and wipe all the oil from the end with a clean rag or paper towel.Insert the clean dipstick back into the tube as far as it will go, then withdraw it once more. Note the oil level on the end ofthe dipstick. Add oil as necessary until the level is between the upper ("MAX") mark and lower ("MIN") mark on thedipstick (see illustrations). Note that approximately 1.5 litres of oil will be required to raise the level from the lower mark tothe upper mark.4 Always maintain the level between the two dipstick marks. If the level is allowed to fall below thelower mark, oil starvation may result, which could lead to severe engine damage. If the engine is overfilled to any greatextent by adding too much oil, this could result in oil leaks or oil seal failures.

MIN MAX1.3a Withdrawing the engine oil level dipstick - Diesel engine

1,3b Engine oil level dipstick markings5 Oil is added to the engine via the filler cap on the cylinder head cover on petrol models, and via thefiller/breather cap on Diesel models. Unscrew the cap and top-up the level; an oil can spout or funnel may help to reducespillage (see illustration). Add the oil slowly, checking the level on the dipstick frequently. Always use the correct gradeand type of oil.

2 Coolant level check

As engine temperature increases, the coolant expands, and the level in the expansion tank rises. As the engine cools,the coolant is automatically drawn back into the system, to maintain the correct level.2 The coolant level in the expansion tank should be checked regularly. The level in the tank varies

with the temperature of the engine. When the engine is cold, the coolant level should be between the "MIN" and

mark on the dipstick (see illustrations). Note that approximately 1.5 litres of oil will be required to raise the level from thelower mark to the upper mark.4 Always maintain the level between the two dipstick marks. If the level is allowed to fall below thelower mark, oil starvation may result, which could lead to severe engine damage. If the engine is overfilled to any greatextent by adding too much oil, this could result in oil leaks or oil seal failures.

MIN MAX1.3a Withdrawing the engine oil level dipstick - Diesel engine

1,3b Engine oil level dipstick markings5 Oil is added to the engine via the filler cap on the cylinder head cover on petrol models, and via thefiller/breather cap on Diesel models. Unscrew the cap and top-up the level; an oil can spout or funnel may help to reducespillage (see illustration). Add the oil slowly, checking the level on the dipstick frequently. Always use the correct gradeand type of oil.2 Coolant level check

A Warning: DO NOT attempt to remove the expansion tank pressure cap when the engine is hot, as there is a verygreat risk of scalding.1 All vehicles covered by this manual have a pressurised cooling system. An expansion tank isincorporated in the cooling system; it is built into the side of the radiator. As engine temperature increases, the coolantexpands, and the level in the expansion tank rises. As the engine cools, the coolant is automatically drawn back into thesystem, to maintain the correct level.2 The coolant level in the expansion tank should be checked regularly. The level in the tank varies withthe temperature of the engine. When the engine is cold, the coolant level should be between the "MIN" and "MAX"marks on the side of the tank. When the engine is hot, the level may rise slightly above the "MAX" mark.

(Use distilled water - not applicable to 'Maintenance Free' battenes)

Turbo Diesel modelsA Engine oil level dipstick and filler cap, (Use Multigrade engine oil, SAE 10W/40 or 15W/50 to API SG/CD 1.5 litres

approximate difference between MIN and MAX marks) B Coolant expansion tank(Use 50/50 mixture of water and ethylene glycol-based antifreeze) C Brake fluid reservoir(Use universal brake fluid) D Power steering fluid reservoir(Use automatic transmission fluid) E Screen washer fluid reservoir F Battery

(Use distilled water - not ap

(Use distilled water - not applicable to 'Maintenance Free' battenes)

Turbo Diesel modelsA Engine oil level dipstick and filler cap, (Use Multigrade engine oil, SAE 10W/40 or 15W/50 to API SG/CD 1.5 litres

approximate difference between MIN and MAX marks) B Coolant expansion tank(Use 50/50 mixture of water and ethylene glycol-based antifreeze) C Brake fluid reservoir(Use universal brake fluid) D Power steering fluid reservoir(Use automatic transmission fluid) E Screen washer fluid reservoir F Battery

(Use distilled water - not applicable to 'Maintenance Free' batteries)1 Engine oil level check

1 The engine oil level is checked with a dipstick that extends through the dipstick tube and into thesump at the bottom of the engine. The dipstick is located at the rear of the engine on 1.8 litre petrol engine models, andat the front of the engine on all other models. The dipstick top is brightly-coloured for easy identification.2 The oil level should be checked with the vehicle standing on level ground, before it is driven, or atleast 5 minutes after the engine has been switched off. If the oil is checked immediately after driving the vehicle, some ofthe oil will remain in the upper engine components and oil galleries, resulting in an inaccurate reading on the dipstick.3 Withdraw the dipstick from the tube, and wipe all the oil from the end with a clean rag or paper towel.Insert the clean dipstick back into the tube as far as it will go, then withdraw it once more. Note the oil level on the end ofthe dipstick. Add oil as necessary until the level is between the upper ("MAX") mark and lower ("MIN") mark on thedipstick (see illustrations). Note that approximately 1.5 litres of oil will be required to raise the level from the lower mark tothe upper mark.4 Always maintain the level between the two dipstick marks. If the level is allowed to fall below thelower mark, oil starvation may result, which could lead to severe engine damage. If the engine is overfilled to any greatextent by adding too much oil, this could result in oil leaks or oil seal failures.

MIN MAX1.3a Withdrawing the engine oil level dipstick - Diesel engine

1,3b Engine oil level dipstick markings5 Oil is added to the engine via the filler cap on the cylinder head cover on petrol models, and via thefiller/breather cap on Diesel models. Unscrew the cap and top-up the level; an oil can spout or funnel may help to reducespillage (see illustration). Add the oil slowly, checking the level on the dipstick frequently. Always use the correct gradeand type of oil.2 Coolant level check

A Warning: DO NOT attempt to remove the expansion tank pressure cap when the engine is hot, as there is a verygreat risk of scalding.1 All vehicles covered by this manual have a pressurised cooling system. An expansion tank isincorporated in the cooling system; it is built into the side of the radiator. As engine temperature increases, the coolantexpands, and the level in the expansion tank rises. As the engine cools, the coolant is automatically drawn back into thesystem, to maintain the correct level.2 The coolant level in the expansion tank should be checked regularly. The level in the tank varies withthe temperature of the en