2002 Mercedes SL-Class (R230) Service and Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: SL-Class Model Code: R230 Year: 2002 Codes Chassis Code: R230 👋 Introduction Market Position Positioning: Luxury Grand Tourer Roadster, positioned at the pinnacle of Mercedes-Benz's convertible offerings. Competitive Analysis Competitors: BMW 6 Series Convertible, Porsche 911 Cabriolet, Jaguar XK Convertible, Ferrari California (higher end). Key Features Design: Retractable hardtop (Vario-Roof), advanced aerodynamics, luxurious interior appointments. Technology: Active Body Control (ABC) suspension, COMAND infotainment, optional bi-xenon headlights. Powertrain: Powerful V8 engine (SL500) and V12 engine (SL600) options, emphasizing smooth power delivery and refinement. 📋 Manual Details Coverage Areas Coverage Scope: All Models & All Repairs A-Z Repair Type: Vehicle Specific Service and Repair Technician Level: Dealership Technician Equivalent Page Count Estimated Page Count: Extensive (typically 1500+ pages for a full service manual) Manual Type Type: Service and Repair Manual Language Language: English Format Format: Likely Digital (PDF) given common sales practices, but could be Printed. Explicitly stated as 'exact same manual used by technicians at the dealerships'. 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, component diagnosis, timing, seals, gaskets, cooling system, lubrication system, emission controls. Engine Electronic: ECU diagnosis, fuel injection, ignition system, sensors, actuators, emissions monitoring. Transmission: Automatic transmission (e.g., 5G-TRONIC or 7G-TRONIC depending on engine variant), diagnosis, repair, fluid service, valve body, torque converter. Drivetrain: Driveshaft, differential, axles, wheel bearings. Suspension: Active Body Control (ABC) system, standard suspension components (struts, shocks, springs, control arms), alignment specifications. Steering: Power steering system, steering column, steering rack/gearbox, hydraulic lines. Brakes: Hydraulic system, ABS, ESP, SBC (Sensotronic Brake Control) if applicable, brake pads, rotors, calipers, bleeding procedures, parking brake. Electrical System: Battery, charging system, starter, lighting, wiring diagrams, fuses, relays, CAN bus communication. Body And Interior: Interior trim, seats, dashboard, doors, windows, convertible top mechanism (vario-roof), body panel repair, rust prevention. Comfort Systems: Climate control (HVAC), heated seats, ventilated seats, multi-contour seats, power accessories. Infotainment Navigation: Audio system, COMAND system, navigation, telematics. Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection/replacement. Diagnostic Procedures: Troubleshooting guides, symptom-based diagnostics, fault code interpretation, use of diagnostic tools (e.g., STAR diagnostic system). Repair Procedures: Step-by-step instructions for component removal, replacement, and reassembly of all major vehicle systems. Component Rebuild: Detailed instructions for internal engine, transmission, and differential rebuilds. Adjustment Procedures: Wheel alignment, headlight aiming, door fitment, convertible top calibration. Electrical Troubleshooting: Component testing, circuit diagnosis using wiring diagrams, fuse and relay testing. Troubleshooting Guides: Includes detailed troubleshooting trees and diagnostic flowcharts for common and uncommon faults. Technical Depth Depth: Comprehensive: Covers routine maintenance to complete overhaul and advanced diagnostics. Detail Level: Highly detailed, including torque specifications, measurement specifications, and component tolerances. Wiring Diagrams: Includes detailed, system-specific wiring diagrams. Schematics: Provides hydraulic, pneumatic, and electrical schematics for complex systems like ABC and COMAND. Special Tools: Lists required special tools and equipment for specific repairs and diagnostics, essential for dealership-level accuracy. 📊 Manual Specifications File Format Format: Likely PDF. Searchable text, high-resolution diagrams and illustrations. Printable. Print Quality Quality: High Resolution (if digital). Original print quality equivalent for printed versions. Binding Type Type: If printed: Spiral-bound for lay-flat use in a workshop environment, or perfect bound. If digital: PDF. Paper Type Type: If printed: Durable, possibly glossy paper for illustrations and diagrams. Completeness Coverage: Comprehensive A-Z coverage, not generic. This is the definitive factory-level manual. ⚙️ Engine Specifications Primary Engine Engine Code Sl500: M113 (113.962) Engine Type Sl500: 4.966 cc (5.0L) SOHC 24-valve V8 (Naturally Aspirated) Performance Horsepower Sl500: 302 hp @ 5600 rpm Torque Sl500: 339 lb-ft (460 Nm) @ 3250-4000 rpm Horsepower Sl600: 500 hp @ 5000 rpm Torque Sl600: 590 lb-ft (795 Nm) @ 1800-3500 rpm Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (SFI) Fuel Type: Premium Unleaded (91+ octane) Engine Code Sl600 Engine Code: M137 (137.970) Engine Type Sl600 Engine Type: 5.760 cc (5.8L) SOHC 24-valve V12 (Bi-Turbocharged) Engine Design Bore X Stroke Sl500: 97.0 mm x 84.0 mm Compression Ratio Sl500: 10.0:1 🔧 Transmission Standard Transmission Sl500: 5-speed automatic (722.6) with Touchshift Transmission Sl600: 5-speed automatic (722.6) with Touchshift Features Electronic Control: Electronically controlled transmission with adaptive shift programs. 📐 Dimensions Exterior Length: 4535 mm (178.5 in) Width: 1800 mm (70.9 in) Height: 1300 mm (51.2 in) Wheelbase: 2560 mm (100.8 in) Weights Curb Weight Sl500: Approx. 1845 kg (4068 lbs) Curb Weight Sl600: Approx. 1970 kg (4343 lbs) 🛡️ Safety Features Ratings Federal Crash Testing: While specific NCAP/IIHS ratings for this exact year/model might vary by region, Mercedes-Benz vehicles of this era were engineered to high safety standards, often achieving good results in relevant tests. Active Features ABS: Anti-lock Braking System (ABS) Esp: Electronic Stability Program (ESP) Traction Control: Acceleration Skid Control (ASR) Sensotronic Brake Control: Optional Sensotronic Brake Control (SBC) for enhanced braking performance and integration with ESP. Passive Features Airbags: Frontal airbags, side...

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Type: Car

Sku: 459441

Collections: ALL Mercedes

Availability: In stock

Tags: 2002 Car Cars Mercedes Misc R230 SL-Class

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

SL-Class

Model Code:

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Positioning:

Luxury Grand Tourer Roadster, positioned at the pinnacle of Mercedes-Benz's convertible offerings.

Competitive Analysis

Competitors:

BMW 6 Series Convertible, Porsche 911 Cabriolet, Jaguar XK Convertible, Ferrari California (higher end).

Key Features

Design:

Retractable hardtop (Vario-Roof), advanced aerodynamics, luxurious interior appointments.

Technology:

Active Body Control (ABC) suspension, COMAND infotainment, optional bi-xenon headlights.

Powertrain:

Powerful V8 engine (SL500) and V12 engine (SL600) options, emphasizing smooth power delivery and refinement.

📋 Manual Details

Coverage Areas

Coverage Scope:

All Models & All Repairs A-Z

Repair Type:

Vehicle Specific Service and Repair

Technician Level:

Dealership Technician Equivalent

Page Count

Estimated Page Count:

Extensive (typically 1500+ pages for a full service manual)

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Likely Digital (PDF) given common sales practices, but could be Printed. Explicitly stated as 'exact same manual used by technicians at the dealerships'.

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine overhaul, component diagnosis, timing, seals, gaskets, cooling system, lubrication system, emission controls.

Engine Electronic:

ECU diagnosis, fuel injection, ignition system, sensors, actuators, emissions monitoring.

Transmission:

Automatic transmission (e.g., 5G-TRONIC or 7G-TRONIC depending on engine variant), diagnosis, repair, fluid service, valve body, torque converter.

Drivetrain:

Driveshaft, differential, axles, wheel bearings.

Suspension:

Active Body Control (ABC) system, standard suspension components (struts, shocks, springs, control arms), alignment specifications.

Steering:

Power steering system, steering column, steering rack/gearbox, hydraulic lines.

Brakes:

Hydraulic system, ABS, ESP, SBC (Sensotronic Brake Control) if applicable, brake pads, rotors, calipers, bleeding procedures, parking brake.

Electrical System:

Battery, charging system, starter, lighting, wiring diagrams, fuses, relays, CAN bus communication.

Body And Interior:

Interior trim, seats, dashboard, doors, windows, convertible top mechanism (vario-roof), body panel repair, rust prevention.

Comfort Systems:

Climate control (HVAC), heated seats, ventilated seats, multi-contour seats, power accessories.

Infotainment Navigation:

Audio system, COMAND system, navigation, telematics.

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection/replacement.

Diagnostic Procedures:

Troubleshooting guides, symptom-based diagnostics, fault code interpretation, use of diagnostic tools (e.g., STAR diagnostic system).

Repair Procedures:

Step-by-step instructions for component removal, replacement, and reassembly of all major vehicle systems.

Component Rebuild:

Detailed instructions for internal engine, transmission, and differential rebuilds.

Adjustment Procedures:

Wheel alignment, headlight aiming, door fitment, convertible top calibration.

Electrical Troubleshooting:

Component testing, circuit diagnosis using wiring diagrams, fuse and relay testing.

Troubleshooting Guides:

Includes detailed troubleshooting trees and diagnostic flowcharts for common and uncommon faults.

Technical Depth

Depth:

Comprehensive: Covers routine maintenance to complete overhaul and advanced diagnostics.

Detail Level:

Highly detailed, including torque specifications, measurement specifications, and component tolerances.

Wiring Diagrams:

Includes detailed, system-specific wiring diagrams.

Schematics:

Provides hydraulic, pneumatic, and electrical schematics for complex systems like ABC and COMAND.

Special Tools:

Lists required special tools and equipment for specific repairs and diagnostics, essential for dealership-level accuracy.

📊 Manual Specifications

File Format

Format:

Likely PDF. Searchable text, high-resolution diagrams and illustrations. Printable.

Print Quality

Quality:

High Resolution (if digital). Original print quality equivalent for printed versions.

Binding Type

Type:

If printed: Spiral-bound for lay-flat use in a workshop environment, or perfect bound. If digital: PDF.

Paper Type

Type:

If printed: Durable, possibly glossy paper for illustrations and diagrams.

Completeness

Coverage:

Comprehensive A-Z coverage, not generic. This is the definitive factory-level manual.

⚙️ Engine Specifications

Primary Engine

Engine Code Sl500:

M113 (113.962)

Engine Type Sl500:

4.966 cc (5.0L) SOHC 24-valve V8 (Naturally Aspirated)

Performance

Horsepower Sl500:

302 hp @ 5600 rpm

Torque Sl500:

339 lb-ft (460 Nm) @ 3250-4000 rpm

Horsepower Sl600:

500 hp @ 5000 rpm

Torque Sl600:

590 lb-ft (795 Nm) @ 1800-3500 rpm

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (SFI)

Fuel Type:

Premium Unleaded (91+ octane)

Engine Code Sl600

Engine Code:

M137 (137.970)

Engine Type Sl600

Engine Type:

5.760 cc (5.8L) SOHC 24-valve V12 (Bi-Turbocharged)

Engine Design

Bore X Stroke Sl500:

97.0 mm x 84.0 mm

Compression Ratio Sl500:

10.0:1

🔧 Transmission

Standard

Transmission Sl500:

5-speed automatic (722.6) with Touchshift

Transmission Sl600:

5-speed automatic (722.6) with Touchshift

Features

Electronic Control:

Electronically controlled transmission with adaptive shift programs.

📐 Dimensions

Exterior

Length:

4535 mm (178.5 in)

Width:

1800 mm (70.9 in)

Height:

1300 mm (51.2 in)

Wheelbase:

2560 mm (100.8 in)

Weights

Curb Weight Sl500:

Approx. 1845 kg (4068 lbs)

Curb Weight Sl600:

Approx. 1970 kg (4343 lbs)

🛡️ Safety Features

Ratings

Federal Crash Testing:

While specific NCAP/IIHS ratings for this exact year/model might vary by region, Mercedes-Benz vehicles of this era were engineered to high safety standards, often achieving good results in relevant tests.

Active Features

Anti-lock Braking System (ABS)

Electronic Stability Program (ESP)

Traction Control:

Acceleration Skid Control (ASR)

Sensotronic Brake Control:

Optional Sensotronic Brake Control (SBC) for enhanced braking performance and integration with ESP.

Passive Features

Airbags:

Frontal airbags, side airbags, knee airbags (driver side), and roll-over protection system (pop-up bars).

Body Structure:

High-strength steel construction for passenger safety cell.

Seatbelts:

Pretensioning seatbelts with force limiters.

💡 Technology Features

Infotainment

Comand System:

COMAND (Cockpit Management and Navigation) system with CD player, radio, and optional navigation. Early versions may have less sophisticated interfaces compared to later models.

Driver Assistance

Adaptive Cruise Control:

Optional DISTRONIC adaptive cruise control system.

Parking Assistance:

Optional parking sensors (PARKTRONIC).

Connectivity

Telematics:

Optional telematics systems for emergency calls or vehicle assistance.

Convenience

Keyless Go:

Optional KEYLESS-GO entry and start system.

🔧 Maintenance

Service Intervals

Major Service Points:

Typically around 15,000 miles or 12 months for routine service. Major services (e.g., spark plugs, transmission fluid) at 60,000-100,000 mile intervals, as dictated by the Flexible Service System (ASSYST).

Tire Rotation:

Recommended every 7,500-10,000 miles.

Fluid Specifications

Engine Oil:

Mobil 1 0W-40 Synthetic (MB Approval 229.5). Capacity: Approx. 8.5 liters (SL500), 9.5 liters (SL600).

Transmission Fluid:

MB Approval 236.14 (e.g., Pentosin ATF 134, Shell ATF 134). Capacity: Approx. 8.0 - 9.5 liters depending on method.

Coolant:

Mercedes-Benz Approved Antifreeze/Coolant (e.g., ZEREX G-05, Pentofrost G05). Mix 50/50 with distilled water. Capacity: Approx. 10 liters.

Brake Fluid:

DOT 4 PLUS (MB Approval 331.0). Fluid should be replaced every 2 years.

Power Steering Fluid:

Pentosin CHF 11S (or equivalent MB approval). Capacity: Approx. 1.5 liters.

Known Issues

Abc System Leaks:

Common issues include leaks from ABC hydraulic lines, struts, and pumps, leading to vehicle sag or system failure. Requires specialized knowledge and fluid.

Varioroot Actuators:

Hydraulic cylinders and seals for the retractable hardtop can degrade, leading to leaks and operational faults.

Ignition Coils:

Coil-on-plug ignition coils can fail, causing misfires and rough running, particularly on the M113 engine.

Sbc Brake System:

Early SBC systems can experience faults, leading to warning lights and reduced braking function. Requires specific diagnostic tools and procedures for repair/replacement.

Semiconductor Failure:

Due to the complex electronics, various semiconductor components and modules can fail over time.

Mass Air Flow Sensor:

Can become contaminated or fail, leading to poor engine performance and check engine light.

📚 Vehicle History

Brand Heritage

Heritage:

Mercedes-Benz has a long history of producing high-end, technologically advanced roadsters and grand tourers, with the SL designation tracing back to the iconic 300 SL 'Gullwing' of the 1950s.

Model Evolution

Generation Introduction:

The R230 generation of the SL-Class was introduced for the 2003 model year, with the 2002 model year representing the transition or potentially a very early release of the new generation in some markets. However, standard industry practice places the R230 starting with the 2003 model year. This manual likely covers the initial R230 models.

Production

Manufacturing Location:

Bremen, Germany

🏆 Awards & Recognition

Recognitions

Model Recognition:

While specific awards for the 2002 model year may vary, the R230 SL-Class generation generally received acclaim for its technological advancements, luxurious comfort, and performance, solidifying its reputation as a top-tier grand tourer.