Description

Mercedes-benz 380 SL, 380 SLC, 560 SL, 240 D, 300 D Service Manual

You ever cracked open an aftermarket manual for a W107 or W123 and found torque specs that were flat wrong? I have. That’s why I keep a stack of factory originals on the shelf. This Mercedes-benz 380 SL, 380 SLC, 560 SL, 240 D, 300 D Service Manual is the real deal – 327 pages of OEM procedures that Mercedes put together for their own dealers. If you’re trying to keep a 560 SL on the road or resurrect a 300 D Turbo, you need the numbers that came out of Stuttgart, not some third-party reprint.

Engine Section (0101) – What the Factory Actually Wrote

PDF bookmark 0101 points to the Engine section. That’s where you’ll find the full breakdown for the 116.960, 116.962, 117.967, 616.912, and 617.912 powerplants. Inspection intervals, component checks, and the exact sequence for valve adjustments. Page 73 in the PDF gives you the charge pressure specs for the OM617 turbo – don’t trust your gauge without confirming those numbers. The manual covers gasoline and diesel engines across five model years, and every torque value is listed in ft-lbs with the correct tightening angle. No guesswork.

Suspension (0090) and Water System (0091) Coverage

Two bookmarks that often get skipped: 0090 (Suspension) and 0091 (Water). The suspension section includes front and rear axle checks, shock absorber inspection, and ball joint play limits. The water section covers coolant system service, thermostat testing, and belt tension. If you’re swapping a water pump on a 380 SLC, check the tightening sequence on page 1351 – it’s not the same as the 560 SL. Differences like that cost hours when you assume.

Checking and Adjusting – 0560, 0760, 0761

These three bookmarks are gold for any tech who’s dialing in a car after a rebuild. 0560 covers checking procedures – fuel injection system on the 380 SL, idle speed on the 240 D. 0760 and 0761 get into adjusting the automatic transmission linkage and the clutch pedal free play. I’ve seen more ruined transmissions from a misadjusted kickdown cable than from mechanical failure. The manual gives you the exact gap measurement and the tool you need (hint: a 4mm drill bit works in a pinch, but a pin gauge is better). Don’t skip the retorque sequence in 4970 either – head bolts on the 617 diesel require a specific pattern after a certain mileage.

Transmission Repairs – 2702, 2710, and the Manual Transmission Section

PDF 2702 and 2710 both deal with automatic transmissions – the 722.3 and 722.4 units that lived behind the 300 D and 560 SL. Valve body service, shift point adjustment, and line pressure tests. If you’re working on a 240 D with a four-speed manual, the clutch and manual transmission sections (2910, 2950) are in the PDF too. The manual covers both Manual Transmission and automatic in the same document, which is rare. You won’t find that level of coverage in a Haynes or Chilton.

Brake System (4290) and Retightening (4970)

Brake caliper overhaul, master cylinder bleeding, and parking brake adjustment are under 4290. The retightening section (4970) is critical for the 380 SLC after a brake job – it lists the repeated torque checks required on the caliper mounting bolts. Neglect that and you get a pull on hard stops. The manual spells out the intervals: after 200 miles, re-torque to 85 ft-lbs. I’ve seen bolts back off on test drives. Factory spec keeps them put.

Who Needs This Manual

Home garage enthusiasts who own a 300 D Turbo and want to do their own valve adjustments without paying a dealer $800. DIY mechanics rebuilding a 560 SL engine in a storage unit – you need the factory gap specs for the timing chain tensioner. Beginners who have never touched a Mercedes but want to learn: skip the forums and start here. The bookmarks are organized by component so you can jump to “Checki” (inspection) or “Adjust” without reading 327 pages cover to cover. But honestly, read the preface first – page 5 explains the maintenance system intervals. That alone will save you a 50-mile tow.

Source Authenticity – OEM vs Aftermarket

This is the original Mercedes-Benz Service Manual printed for dealer use. The PDF came from the Classic Cars & Cycles archive – it’s a direct scan of the factory binder, not a compilations from 12 different sources. Aftermarket manuals often combine data from different years and engines, leaving you with a torque spec that’s close but wrong. The OEM document keeps each model separate: 380 SL vs 560 SL vs 240 D, with dedicated specs per engine code. When you see “116.960” in the engine table, that’s the exact serial number matching your vehicle. No ambiguity.

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Frequently Asked Questions

Does this manual include wiring diagrams?

No. Wiring diagrams are not part of this maintenance manual. It focuses on mechanical service, inspection, and adjustment procedures.

Will this cover my 1985 300 D Turbo?

Yes. The 300 D Turbo (model 123.133, engine 617.952) is listed in the preface for model years 1985. The manual covers all 300 D variants through 1993.

Are torque specs listed in ft-lbs or Nm?

The manual uses ft-lbs for all torque values. No conversion tables included – you’ll need a calculator if working in Nm.

What about the 560 SL soft top operation?

Section 7750 covers the soft top hydraulic system. Pump inspection, cylinder replacement, and fluid level check are included. No full removal procedure.

If you’re tired of chasing loose specs and want the same information the Mercedes dealer uses, Access the Factory Manual now. 327 pages, immediate access, no waiting for shipping. Get the bookmarks loaded on your tablet and keep it greasy.