Note. Below are the procedures for checking fluid levels every 1000 km, monthly and before each long trip. A description of other fluid level checks can be found later in the Sections on specific maintenance procedures. Regardless of the scheduled inspection intervals, do not allow fluid to leak under the vehicle, such leaks indicate a malfunction that should be repaired immediately.
Fluids are an integral part of the lubrication, cooling, brake and windshield washer systems. Due to the gradual consumption and / or contamination of fluids during normal vehicle operation, they should be replaced periodically. Check out Section «Types and volumes of lubricants and fluids used» V Specifications, before adding fluid to any of the listed components.
Note. Whenever checking the fluid level, the vehicle must be on a level surface.
Visually inspect the following piping, hoses and connections for leaks, chafing, cracks or damage:
- Fuel lines;
- Cooling system hoses;
- Brake pipelines and hoses;
- Power steering hydraulic lines;
- Air conditioning lines.
Engine oil
Visual control of leaks
1. With an oily engine and high oil consumption, check for leaks. For this, the following places are checked:
- Filler cap gasket for cracks or damage.
- Crankcase ventilation: ventilation hose from cylinder head cover to air intake hose.
- Cylinder head cover gasket.
- Cylinder head gasket.
- Oil removal plug (round ring).
- Oil filter gasket: Fitting the filter to the flange.
- Oil pan gasket.
- Front and rear crankshaft seals.
2. Since oil spreads over a large surface of the engine in the presence of leaks, it is difficult to immediately determine the location of leaks.
3. Flush the engine. Close the generator with a plastic bag. Spray the engine with a normal cold cleaner and after a short time wash it with water at a car wash.
4. Sprinkle the mating points and oil seals on the engine with lime or talc from the outside.
5. Check the oil level, top up if necessary.
6. Take a test drive. Since the oil in a hot engine reduces its viscosity and leaks out more quickly at leaks, a test drive of about 30 km on the highway should be carried out.
Finally, examine the engine with a lamp and locate leaks by troubleshooting.
Checking the oil level with a dipstick
The oil level is displayed by an indicator located on the dashboard (see above). For 4-cylinder petrol engines «271» from model year 6/02 and for 6-cylinder petrol engines and diesel engines hole for oil dipstick (1) stoppered (2). For these engines, a special dipstick ET No. 120 589 07 21 00 is used to check the oil level during maintenance.
4-cylinder petrol engine
1. Drive the vehicle to warm up the engine and stop on level ground.
2. After stopping the engine, wait about 5 minutes for the oil to drain into the oil pan.
If you start measuring the engine oil level immediately after turning off the engine, some of the oil will remain in the upper part of the engine, which will significantly affect the accuracy of the measurement.
3. Remove the oil level indicator (1) and wipe it with a clean cloth. (2) - cover of the oil filling hole.
4. Insert the level indicator into the hole as far as it will go and pull it out again.
5. Check the oil level on the pointer. It must be between the MAX marks (3) and MIN (4).
Attention! If the oil level is above the MAX mark, there is a risk of damage to the catalytic converter.
6. If the oil level is at the mark (4) or lower, add oil to the MAX mark. The difference in oil levels between the MAX and MIN·marks corresponds to a volume of 2 liters.
Attention! If oil has been spilled by accident, it must be sucked out using a special device.
7. Oil is added through the plug (2) cylinder head covers. (1) – oil level gauge (refer to illustration 5.10). For topping up, use only the oil specified in the Specifications.
Attention! An arbitrary combination of oils of different types is not recommended. If possible, oils of the same type, but of different brands, should also not be mixed. Engine oils of the same type, of the same brand, but of different viscosities, if necessary, can be mixed.
6-cylinder 112 petrol engine, diesel engines
1. Drive the vehicle to warm up the engine and stop the vehicle on level ground.
2. After stopping the engine, wait about 5 minutes for the oil to drain into the oil pan.
3. Remove the cover (1) with hole for oil gauge (2). (3) – fuel filter, the illustration shows a 611 diesel engine.
4. Insert a special dipstick to determine the oil level into the hole until it stops.
5. After 3 sec. Remove the dipstick and check the oil level on it.
Engine 112:
Oil level according to the dipstick | Oil volume |
120 mm | 4.00 l |
126 mm | 4.50 l |
132 mm | 5.00 l |
140 mm | 5.50 l |
148 mm | 6.00 l |
154 mm | 6.46 l |
161 mm | 7.00 l |
168 mm | 7.50 l |
175 mm | 8.00 l |
183 mm | 8.50 l |
187 mm | 8.75 l |
6. Gasoline engine 112: Recalculate the oil level given in the table to the appropriate volume. Determine the difference and, if necessary, add it to the engine.
7. Diesel engines 611:
Engines up to No. 448 572 (Ind. No. 30, plant in Untertürkheim) and No. 069 844 (Ind. No. 40, plant in Berlin)
- MAX=138mm,
- MIN = 110 mm.
Engines from No. 448 573 (Ind. No. 30, plant in Untertürkheim) and engine no. 069 845 (Ind. No. 40, plant in Berlin)
- MAX=127.5mm,
- MIN = 99.5 mm.
Note. Ind. No. is located behind the 6-digit engine model designation, for example, «611.962».
8. Diesel engine 612:
- Engines up to No. 134 163
- MAX=135mm,
- MIN = 110 mm.
- Engines from No. 134 164
- MAX=124.5mm,
- MIN = 99.5 mm.
9. Diesel engine 612: The oil level must be between the MAX and MIN·marks.
Engine oil consumption
Max. 1l/1000km, depending on driving style.
The oil consumption of the engine can only be determined after a long distance has been covered. During the break-in period, it may exceed the given value. Frequent driving at high engine speeds leads to increased oil consumption.
Checking the oil level is an important preventive procedure. A persistent drop in oil level indicates either oil leaks from damaged seals or loose connections, or oil burning (internal leaks through worn piston rings or through valve guides). In addition, you should pay attention to the condition of the oil itself. If the oil has a milky color or you can see drops of water in its composition, this indicates a possible leak in the cylinder head gasket or a crack in the cylinder head or block. In this case, the engine should be repaired immediately. Each time you check the oil level, run your thumb and forefinger over the dipstick blade before wiping. If dirt particles or metal particles are found adhering to the dipstick, the oil should be changed (refer to section Changing the engine oil and oil filter).
Engine cooler
Attention! Do not allow antifreeze to come into contact with your skin or painted vehicle surfaces. If this does happen, rinse off the antifreeze immediately with plenty of water. Antifreeze is extremely toxic if ingested. Never leave it unattended in an open container or spilled on the floor; children or animals may be attracted to its sweet smell and drink it.
1. All vehicles covered in this manual are equipped with an overpressure compensation type cooling system. The white plastic expansion tank is located in the engine compartment and is connected by a hose to the radiator. As the engine warms up during operation, the expanding coolant fills the reservoir. When the engine cools down, the coolant automatically flows back into the cooling system, which ensures that a constant level is maintained.
2. Checking the coolant level in the tank should be done regularly, with the car in a strictly horizontal position and the engine off. In the cold state of the coolant, its level in the expansion tank should reach the level indicated by the arrow in the illustration.
When the coolant is hot, the level should be about 1.0 cm higher.
Add 40%/60% ethylene glycol based antifreeze and water. The composition specified in the Specifications should be used.
Attention! Do not remove the filler cap of the expansion tank or the radiator cap to check the coolant level before the engine has completely cooled down! The level in the reservoir fluctuates depending on the temperature of the engine. When the engines are cold, the coolant level should be above the mark «MIN» on the tank. As the engine warms up, the level should approach the mark «MAX». If not, let the engine cool down and then remove the tank cap.
3. Run the car and measure the coolant level again. If only a small amount of coolant needs to be added to the correct level, clean water can be used for this. However, frequent additions of water will dilute the antifreeze. In order to ensure the correct ratio of antifreeze and water, always top up to the correct level with the required mixture.
4. If the coolant level drops regularly, there may be a leak in the system. Inspect the radiator, hoses, filler cap, drain plugs and water pump (refer to section Checking the functioning of the cooling system and frost resistance of the coolant. Fluid replacement). If no leaks are found, have the expansion tank cap and radiator leak tested in a workshop.
5. If you need to remove the cover, wait until the engine has completely cooled down, then wrap a piece of thick rag around the cover and unscrew it to the first stop. If steam or coolant starts to escape from under the cap, allow the engine to cool a little more before removing the cap.
6. You should also check the condition of the cooler. It should be relatively clean. If the fluid is brown or rusty in color, it must be drained, the system flushed and filled with a new mixture. Even if the coolant looks normal, the corrosion inhibitors it contains lose their effectiveness over time, so it should be replaced at regular intervals.
7. To check the frost resistance of the coolant, you must use a hydrometer.
Brake fluid
Attention! Brake fluid can harm your eyes and damage the painted surfaces of your vehicle, so be very careful when handling it. Do not use brake fluid that has been exposed for a long time or is more than one year old. Brake fluid tends to absorb moisture from the air, which can lead to a dangerous loss of brake system performance. Use only the recommended type of brake fluid. Mixing different types of fluid can cause brake system failure.
1. Brake fluid reservoir (1) located at the rear left in the engine compartment. It has two chambers, each for its own braking circuit.
2. The brake fluid level is checked visually, according to the marks on the plastic reservoir installed on the master cylinder. With the cap closed, the brake fluid level must be between the MAX marks (2) and MIN (3).If the level is low, first wipe the top of the reservoir and the cover with a clean cloth to prevent dirt from entering the system after removing the cover. Top up to the correct level with the recommended fluid, but do not overfill.
3. While the reservoir cap is off, check the fluid and master cylinder reservoir for contamination.
If it contains particles of rust, dirt or drops of water, the fluid from the system should be drained and filled with new.
4. After filling the reservoir to the correct level, make sure that the lid is installed evenly to avoid fluid leakage and / or dirt ingress.
5. The fluid level in the master cylinder will drop slightly as a result of worn brake linings. There is no need to add it as long as the level remains near the mark «MIN»; it will rise after changing the pads. A very low level may indicate worn brake pads. Check them for wear (refer to section Brake system checks. Parking brake adjustment).
6. If the brake fluid level keeps dropping, check the entire system for leaks immediately. Inspect brake lines, hoses and fittings, along with calipers, wheel cylinders and master cylinder (refer to Sections Brake system checks. Parking brake adjustment, Checking the condition and replacing the engine compartment hoses, localizing leaks).
7. If the reservoir is empty or nearly empty when checking the fluid level, the brake system must be checked for leaks and bled (contact the head Clutch and drive shafts).
Checking the oil level in the reservoir of the hydraulic system of the power steering
The power steering hydraulic system reservoir is located at the rear of the engine compartment. Refer to Section Checking the fluid level of the power steering system.
Windshield washer fluid
Detergent concentrate is highly flammable.
Do not use fire, open flames or smoking when handling glass cleaner concentrate.
1. Open the lid (1) and visually check the fluid level.
2. If necessary, add a mixture of glass cleaner and potable water. The capacity of the tank is given in the Specifications.
3. In temperate regions, the system can be charged with normal water, but it is recommended to add glass cleaner to the water. The tank should be no more than two-thirds full, so that there is free space in case the water expands when it freezes. In cold climates, use a windshield washer antifreeze that lowers the fluid's freezing point, available from any auto supply store. It is usually sold in concentrated or prepared form. If you purchased concentrated antifreeze, mix it with water according to the manufacturer's instructions on the package.
Note. For models with heated jets, as a rule, the frost resistance of the mixture to -10°C is sufficient.
Attention! Do not use antifreeze in the cooling system - it will damage the painted surfaces of the car.
4. Check up adjustment of jets, address to the Head Body.