2002 Mercedes-Benz SL500 Service & Repair Manual Software
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🏷️ Basic Information Identification Make: Mercedes-Benz Model: SL500 Year: 2002 Codes Chassis Code: R230 👋 Introduction Market Position Segment: Luxury Grand Tourer / Sports Car Target Audience: Owners seeking in-depth knowledge for maintenance and repair, independent repair shops specializing in luxury vehicles. Competitive Analysis Competitors 2002: BMW 8 Series (discontinued but relevant comparison), Porsche 911 (996 generation), Jaguar XK8/XKR, Ferrari 360 Modena. Key Features Of Vehicle Unique Selling Propositions: Advanced Active Body Control (ABC) suspension, powerful V8 engine, retractable hardtop (Vario-Roof), luxurious interior, advanced safety features for its era. Key Features Of Manual Manual Value Proposition: Provides official, factory-accurate information, enabling accurate diagnosis and repair, saving costs compared to dealership service, empowering owners. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service and repair for all systems Page Count Estimated Pages: Extensive (typically 1000+ pages for a full service manual) Manual Type Type: Official Service and Repair Manual Software Language Language: English Format Format: Software/Digital (likely PDF or proprietary application) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, diagnosis, overhaul, timing system, lubrication, cooling. Engine Electrical: Ignition system, fuel injection (ME 2.8), starting and charging system, ECU diagnostics. Transmission: 5-speed automatic transmission (722.6), removal, installation, overhaul, fluid service, electronic control. Drivetrain: Rear-wheel drive, driveshafts, differentials, axle components. Suspension: Active Body Control (ABC), hydraulic system, struts, control arms, wheel bearings, alignment. Brakes: Hydraulic system, ABS, ESP, SBC (Sensotronic Brake Control) system, disc and pad replacement, fluid flushing. Steering: Hydraulic power steering system, steering column, steering gear, diagnosis. Electrical Chassis: Lighting, power windows, mirrors, seats, convertible top operation, central locking. Climate Control: Automatic climate control system, A/C refrigerant, components, diagnosis. Body And Interior: Exterior panels, interior trim, convertible top mechanism, sound insulation. Diagnostic Troubleshooting: OBD-II diagnostic codes, fault finding procedures, wiring diagrams. Procedures Included Maintenance Procedures: Oil and filter changes, fluid checks, spark plug replacement, air filter replacement, brake pad/rotor replacement. Repair Procedures: Component removal and installation, internal engine repair, transmission overhaul, suspension component replacement, brake system repair, electrical component troubleshooting and replacement. Troubleshooting Guides: Step-by-step diagnostic procedures for common and complex faults, wiring diagrams for fault tracing. Special Tools: Identification and usage of specific Mercedes-Benz special tools required for various procedures. Torque Specifications: Detailed torque values for all critical fasteners and components. Technical Depth Depth Of Coverage: Factory-level repair and diagnostic information, suitable for professional technicians and advanced DIY enthusiasts. Diagnostic Capability: Includes detailed diagnostic strategies and procedures for electronic control modules (ECUs) and sensor systems. Rebuild Procedures: Comprehensive instructions for engine and transmission rebuilds, including component specifications and clearances. 📊 Manual Specifications File Format File Type: Software (potentially executable or PDF) Print Quality Printability: High-resolution, printable pages (if PDF format). Binding Type Binding: N/A (Software format) Paper Type Paper Quality: N/A (Software format) ⚙️ Engine Specifications Primary Engine Engine Code: M113 E50 Engine Type: SOHC V8 Displacement: 4966 cc (5.0 Liters) Bore X Stroke: 97.0 mm x 84.0 mm Compression Ratio: 10.0:1 Performance Horsepower: 302 hp @ 5600 rpm Torque: 339 lb-ft @ 3250 rpm Fuel System Fuel Delivery: Sequential multi-point fuel injection (Bosch ME 2.8) Fuel Type: Premium Unleaded (91+ octane) Engine Internals Valvetrain: Single Overhead Camshaft (SOHC), 3 valves per cylinder (2 intake, 1 exhaust) 🔧 Transmission Standard Type: 5-speed Automatic (722.6) Gear Ratios: 1st: 3.59, 2nd: 2.19, 3rd: 1.41, 4th: 1.00, 5th: 0.83, Reverse: 3.17 Fluid Type: MB 236.10 or MB 236.12 Automatic Transmission Fluid (e.g., Mobil ATF 134) Features Electronic Control: Electronic Control Unit (ECU) with multiple modes (Comfort, Sport) 📐 Dimensions Exterior Length: 176.6 inches (4485 mm) Width: 71.4 inches (1814 mm) Height: 51.2 inches (1300 mm) Wheelbase: 101.8 inches (2585 mm) Weights Curb Weight: Approximately 4079 lbs (1850 kg) Gross Vehicle Weight Rating: Approximately 5159 lbs (2340 kg) Cargo Trunk Volume Hardtop: Approximately 11.3 cu ft (320 Liters) Trunk Volume Convertible: Approximately 7.7 cu ft (218 Liters) 🛡️ Safety Features Ratings NHTSA Front Impact: Not explicitly rated under modern NHTSA standards, but designed to high Mercedes-Benz safety standards. IIHS Side Impact: Not explicitly rated under modern IIHS standards. Active Features ABS: Standard Anti-lock Braking System Esp: Standard Electronic Stability Program Sbc: Sensotronic Brake Control (electro-hydraulic brake system) - a significant safety and performance feature. Passive Features Airbags: Front airbags, side airbags, head airbags. Rollover Protection: Pop-up roll bars integrated behind the headrests, deployed automatically in a rollover event. Seatbelts: Pretensioning seatbelts with force limiters. 💡 Technology Features Infotainment Head Unit: COMAND (Cockpit Management and Navigation) system with CD player, radio, optional navigation. Display: Central color LCD screen Driver Assistance Adaptive Cruise Control: Optional Distronic adaptive cruise control system. Parking Assist: Optional front and rear parking sensors. Connectivity Telematics: Optional Mercedes-Benz Tele Aid system for emergency assistance. Convertible Top Tech Varioroof: Electro-hydraulic retractable hardtop with glass rear window. 🔧 Maintenance Service Intervals Oil Change Interval: Variable (based on 'Service A' or 'Service B'...
Owners seeking in-depth knowledge for maintenance and repair, independent repair shops specializing in luxury vehicles.
Competitive Analysis
Competitors 2002:
BMW 8 Series (discontinued but relevant comparison), Porsche 911 (996 generation), Jaguar XK8/XKR, Ferrari 360 Modena.
Key Features Of Vehicle
Unique Selling Propositions:
Advanced Active Body Control (ABC) suspension, powerful V8 engine, retractable hardtop (Vario-Roof), luxurious interior, advanced safety features for its era.
Key Features Of Manual
Manual Value Proposition:
Provides official, factory-accurate information, enabling accurate diagnosis and repair, saving costs compared to dealership service, empowering owners.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive service and repair for all systems
Page Count
Estimated Pages:
Extensive (typically 1000+ pages for a full service manual)
Manual Type
Type:
Official Service and Repair Manual Software
Language
Language:
English
Format
Format:
Software/Digital (likely PDF or proprietary application)
MB 236.10 or MB 236.12 Automatic Transmission Fluid (e.g., Mobil ATF 134)
Features
Electronic Control:
Electronic Control Unit (ECU) with multiple modes (Comfort, Sport)
📐 Dimensions
Exterior
Length:
176.6 inches (4485 mm)
Width:
71.4 inches (1814 mm)
Height:
51.2 inches (1300 mm)
Wheelbase:
101.8 inches (2585 mm)
Weights
Curb Weight:
Approximately 4079 lbs (1850 kg)
Gross Vehicle Weight Rating:
Approximately 5159 lbs (2340 kg)
Cargo
Trunk Volume Hardtop:
Approximately 11.3 cu ft (320 Liters)
Trunk Volume Convertible:
Approximately 7.7 cu ft (218 Liters)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Not explicitly rated under modern NHTSA standards, but designed to high Mercedes-Benz safety standards.
IIHS Side Impact:
Not explicitly rated under modern IIHS standards.
Active Features
ABS:
Standard Anti-lock Braking System
Esp:
Standard Electronic Stability Program
Sbc:
Sensotronic Brake Control (electro-hydraulic brake system) - a significant safety and performance feature.
Passive Features
Airbags:
Front airbags, side airbags, head airbags.
Rollover Protection:
Pop-up roll bars integrated behind the headrests, deployed automatically in a rollover event.
Seatbelts:
Pretensioning seatbelts with force limiters.
💡 Technology Features
Infotainment
Head Unit:
COMAND (Cockpit Management and Navigation) system with CD player, radio, optional navigation.
Display:
Central color LCD screen
Driver Assistance
Adaptive Cruise Control:
Optional Distronic adaptive cruise control system.
Parking Assist:
Optional front and rear parking sensors.
Connectivity
Telematics:
Optional Mercedes-Benz Tele Aid system for emergency assistance.
Convertible Top Tech
Varioroof:
Electro-hydraulic retractable hardtop with glass rear window.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Variable (based on 'Service A' or 'Service B' indicators), typically every 10,000 miles or 1 year.
Transmission Fluid Interval:
Recommended every 40,000-60,000 miles for 722.6 transmission, especially under hard use. Check manual for specific recommendation.
Brake Fluid Interval:
Every 2 years (hygroscopic nature of brake fluid).
Spark Plug Replacement:
Typically around 100,000 miles for iridium spark plugs.
Fluid Specifications
Engine Oil Spec:
MB 229.5 engine oil (e.g., Mobil 1 0W-40).
Engine Oil Capacity:
8.5 Liters (approx. 9 US quarts) with filter change.
Coolant Spec:
MB 325.0 or 326.0 (Antifreeze/Coolant Concentrate).
Power Steering Fluid:
MB 343.0 (Hydraulic Fluid).
Abc Suspension Fluid:
MB 343.0 (Hydraulic Fluid, specifically for ABC).
Known Issues
Abc System Leaks:
Common issues include leaks in hoses, struts, and the ABC pump, leading to suspension sag and warning lights.
Sbc System Failures:
Sensotronic Brake Control (SBC) pump and accumulator failures can occur, requiring specialized diagnosis and replacement.
Varioroof Mechanism Issues:
Hydraulic leaks or sensor failures in the retractable hardtop mechanism can prevent proper operation.
Ignition Coil Failures:
Individual ignition coils can fail, leading to misfires and rough running.
📚 Vehicle History
Brand Heritage
Mercedes Benz Legacy:
Over a century of automotive innovation, known for engineering excellence, luxury, and safety.
Model Evolution
Sl Class Lineage:
The SL-Class has a long history dating back to the iconic 300SL 'Gullwing' and 'Roadster' of the 1950s, evolving into a sophisticated, high-performance grand tourer.
R230 Generation Introduction:
The R230 generation debuted for the 2003 model year (though the 2002 model year is often considered the transition or a very early R230 introduction, depending on market). This generation introduced the retractable hardtop, Active Body Control (ABC), and later the revolutionary Sensotronic Brake Control (SBC).
Production
Production Plant:
Bremen, Germany
Production Years:
2002-2008 (for R230 generation)
🏆 Awards & Recognition
Recognitions
Road Test Awards:
The SL500 consistently received accolades from automotive publications for its performance, luxury, and innovative technology during its production run.
Safety Awards:
While specific 'awards' are less common for safety features, the integration of ABC, SBC, and advanced airbags reflected Mercedes-Benz's commitment to safety.