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1991 Mercedes SL-Class (R129) Service and Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: SL-Class Model Code: R129 Year: 1991 Generation Generation: Third Generation (R129) Codes Chassis Code: R129 👋 Introduction Market Position Vehicle Class: Luxury Grand Tourer (GT) Target Audience: Affluent consumers seeking a sophisticated, high-performance convertible Competitive Analysis Primary Competitors: BMW 8 Series Convertible, Jaguar XJS, Porsche 911 Cabriolet, Lexus SC400 Key Features Convertible Top: Fully automatic, power-operated soft top with integrated hard cover and rear defroster, a marvel of engineering for its time Safety Features: Integrated roll-over bar (Automatic Roll Bar - ARB), advanced ABS system Comfort And Luxury: Supple leather upholstery, sophisticated wood trim, advanced climate control, premium sound systems, power-adjustable seats with memory Handling And Performance: Sophisticated multi-link suspension, powerful V8 or V12 engines, refined ride quality 📋 Manual Details Coverage Areas Coverage Statement: Covers all models and all repairs A-Z Page Count Estimated Page Count: Approximately 1000+ Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: Digital (Likely PDF, searchable text implied) 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, fuel injection, ignition, lubrication, cooling, exhaust Transmission Systems: Automatic transmission (4-speed 4G-TRONIC, 5-speed 5G-TRONIC where applicable for the year), clutch, driveshaft, differential Brake Systems: Front and rear brakes, ABS (Anti-lock Braking System), parking brake Suspension Steering: Front and rear suspension components, steering gear, power steering Electrical Systems: Battery, charging system, starting system, lighting, instruments, dashboard, body electrical, climate control electronics, convertible top hydraulics and electronics Body Chassis: Body construction, doors, hood, trunk, bumpers, convertible top mechanism, interior trim Comfort Convenience: Climate control system (A/C), power windows, power seats, central locking, cruise control, convertible top operation Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection/replacement, brake pad/rotor replacement, tire rotation Troubleshooting Diagnostics: Fault code diagnosis, symptom-based troubleshooting, electrical system diagnostics, engine performance issues Repair Procedures: Engine overhaul, transmission repair, brake system repair, suspension component replacement, steering system repair, electrical component repair/replacement, convertible top repair Alignment Specifications: Wheel alignment angles (camber, caster, toe) Diagnostic Procedures: Detailed diagnostic flowcharts and explanations for various systems Technical Depth Depth Of Coverage: Factory-level technical information, suitable for dealership technicians Detail Level: Comprehensive repair instructions with diagrams, torque specifications, and component testing procedures Special Tools: Identification and usage of specialized Mercedes-Benz tools 📊 Manual Specifications File Format Digital Format Quality: High-resolution scans or digitally native content, ensuring readability of diagrams and text Searchability: Searchable text capabilities for quick information retrieval Print Quality Diagram Clarity: Clear, precise line drawings and exploded views for component identification and assembly Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Variant 1991: M119.960 (4.2L V8) Engine Displacement 42L: 4196 cc (256 cu in) Engine Configuration 42L: V8, 32-valve (4 valves per cylinder) Engine Block Material 42L: Aluminum-silicon alloy Bore Stroke 42L: 92.0 mm x 78.9 mm Compression Ratio 42L: 10.0:1 Horsepower 42L: 275 hp @ 5700 rpm (SAE Net) Torque 42L: 387 Nm (285 lb-ft) @ 3700 rpm (SAE Net) Engine Variant 1991 Alt: M119.970 (5.0L V8) Engine Displacement 50L: 4973 cc (303 cu in) Engine Configuration 50L: V8, 32-valve (4 valves per cylinder) Horsepower 50L: 322 hp @ 5500 rpm (SAE Net) Torque 50L: 480 Nm (354 lb-ft) @ 3900 rpm (SAE Net) Fuel System Fuel Delivery System: Bosch KE-Jetronic (CIS-E) fuel injection (mechanical/electronic hybrid) for 4.2L, Bosch LH-Jetronic for 5.0L and later models Fuel Type: Premium Unleaded Gasoline (91 octane or higher) Engine Management: Electronic Engine Control (EEC) 🔧 Transmission Standard Standard Transmission: 4-speed Automatic (4G-TRONIC, 722.4) Optional Optional Transmission: 5-speed Automatic (5G-TRONIC, 722.6) - Introduced later in the R129 generation, may not be present on all early 1991 models. Features Shift Modes: Economy (E) and Sport (S) modes Transmission Fluid Type: MB 236.1, MB 236.3, or equivalent DEXRON II (Consult manual for specific application) 📐 Dimensions Exterior Length: Approximately 4450 mm (175.2 in) Width: Approximately 1810 mm (71.3 in) Height: Approximately 1300 mm (51.2 in) Wheelbase: 2500 mm (98.4 in) Front Track: Approximately 1530 mm (60.2 in) Rear Track: Approximately 1525 mm (60.0 in) Weights Curb Weight: Approximately 1800-1950 kg (3970-4300 lbs), depending on engine and options Gross Vehicle Weight Rating: Approximately 2200-2350 kg (4850-5180 lbs) Towing Capacity: Not specified/intended for towing Cargo Trunk Volume: Approximately 0.26 m³ (9.2 cu ft) with soft top up 🛡️ Safety Features Ratings Safety Rating Era: While official NCAP ratings were not prevalent in 1991, the R129 was designed with significant safety advancements for its era. Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional ASR (Acceleration Slip Regulation) was introduced in later models, check specific vehicle Passive Features Roll Over Protection: Automatic Roll Bar (ARB) system deploying instantly in a rollover scenario, a groundbreaking feature Airbags: Driver's side airbag standard Seatbelts: Three-point inertia-reel seatbelts with pretensioners Body...
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1991 Mercedes SL-Class (R129) Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
SL-Class
Model Code:
R129
Year:
1991
Generation
Generation:
Third Generation (R129)
Codes
Chassis Code:
R129
👋 Introduction
Market Position
Vehicle Class:
Luxury Grand Tourer (GT)
Target Audience:
Affluent consumers seeking a sophisticated, high-performance convertible
Competitive Analysis
Primary Competitors:
BMW 8 Series Convertible, Jaguar XJS, Porsche 911 Cabriolet, Lexus SC400
Key Features
Convertible Top:
Fully automatic, power-operated soft top with integrated hard cover and rear defroster, a marvel of engineering for its time
Safety Features:
Integrated roll-over bar (Automatic Roll Bar - ARB), advanced ABS system
Comfort And Luxury:
Supple leather upholstery, sophisticated wood trim, advanced climate control, premium sound systems, power-adjustable seats with memory
Handling And Performance:
Sophisticated multi-link suspension, powerful V8 or V12 engines, refined ride quality
📋 Manual Details
Coverage Areas
Coverage Statement:
Covers all models and all repairs A-Z
Page Count
Estimated Page Count:
Approximately 1000+
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (Likely PDF, searchable text implied)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, fuel injection, ignition, lubrication, cooling, exhaust
Transmission Systems:
Automatic transmission (4-speed 4G-TRONIC, 5-speed 5G-TRONIC where applicable for the year), clutch, driveshaft, differential
Brake Systems:
Front and rear brakes, ABS (Anti-lock Braking System), parking brake
Suspension Steering:
Front and rear suspension components, steering gear, power steering
Electrical Systems:
Battery, charging system, starting system, lighting, instruments, dashboard, body electrical, climate control electronics, convertible top hydraulics and electronics
Body Chassis:
Body construction, doors, hood, trunk, bumpers, convertible top mechanism, interior trim
Comfort Convenience:
Climate control system (A/C), power windows, power seats, central locking, cruise control, convertible top operation
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection/replacement, brake pad/rotor replacement, tire rotation
Troubleshooting Diagnostics:
Fault code diagnosis, symptom-based troubleshooting, electrical system diagnostics, engine performance issues
Repair Procedures:
Engine overhaul, transmission repair, brake system repair, suspension component replacement, steering system repair, electrical component repair/replacement, convertible top repair
Alignment Specifications:
Wheel alignment angles (camber, caster, toe)
Diagnostic Procedures:
Detailed diagnostic flowcharts and explanations for various systems
Technical Depth
Depth Of Coverage:
Factory-level technical information, suitable for dealership technicians
Detail Level:
Comprehensive repair instructions with diagrams, torque specifications, and component testing procedures
Special Tools:
Identification and usage of specialized Mercedes-Benz tools
📊 Manual Specifications
File Format
Digital Format Quality:
High-resolution scans or digitally native content, ensuring readability of diagrams and text
Searchability:
Searchable text capabilities for quick information retrieval
Print Quality
Diagram Clarity:
Clear, precise line drawings and exploded views for component identification and assembly
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Variant 1991:
M119.960 (4.2L V8)
Engine Displacement 42L:
4196 cc (256 cu in)
Engine Configuration 42L:
V8, 32-valve (4 valves per cylinder)
Engine Block Material 42L:
Aluminum-silicon alloy
Bore Stroke 42L:
92.0 mm x 78.9 mm
Compression Ratio 42L:
10.0:1
Horsepower 42L:
275 hp @ 5700 rpm (SAE Net)
Torque 42L:
387 Nm (285 lb-ft) @ 3700 rpm (SAE Net)
Engine Variant 1991 Alt:
M119.970 (5.0L V8)
Engine Displacement 50L:
4973 cc (303 cu in)
Engine Configuration 50L:
V8, 32-valve (4 valves per cylinder)
Horsepower 50L:
322 hp @ 5500 rpm (SAE Net)
Torque 50L:
480 Nm (354 lb-ft) @ 3900 rpm (SAE Net)
Fuel System
Fuel Delivery System:
Bosch KE-Jetronic (CIS-E) fuel injection (mechanical/electronic hybrid) for 4.2L, Bosch LH-Jetronic for 5.0L and later models
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher)
Engine Management:
Electronic Engine Control (EEC)
🔧 Transmission
Standard
Standard Transmission:
4-speed Automatic (4G-TRONIC, 722.4)
Optional
Optional Transmission:
5-speed Automatic (5G-TRONIC, 722.6) - Introduced later in the R129 generation, may not be present on all early 1991 models.
Features
Shift Modes:
Economy (E) and Sport (S) modes
Transmission Fluid Type:
MB 236.1, MB 236.3, or equivalent DEXRON II (Consult manual for specific application)
📐 Dimensions
Exterior
Length:
Approximately 4450 mm (175.2 in)
Width:
Approximately 1810 mm (71.3 in)
Height:
Approximately 1300 mm (51.2 in)
Wheelbase:
2500 mm (98.4 in)
Front Track:
Approximately 1530 mm (60.2 in)
Rear Track:
Approximately 1525 mm (60.0 in)
Weights
Curb Weight:
Approximately 1800-1950 kg (3970-4300 lbs), depending on engine and options
Gross Vehicle Weight Rating:
Approximately 2200-2350 kg (4850-5180 lbs)
Towing Capacity:
Not specified/intended for towing
Cargo
Trunk Volume:
Approximately 0.26 m³ (9.2 cu ft) with soft top up
🛡️ Safety Features
Ratings
Safety Rating Era:
While official NCAP ratings were not prevalent in 1991, the R129 was designed with significant safety advancements for its era.
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional ASR (Acceleration Slip Regulation) was introduced in later models, check specific vehicle
Passive Features
Roll Over Protection:
Automatic Roll Bar (ARB) system deploying instantly in a rollover scenario, a groundbreaking feature
Airbags:
Driver's side airbag standard
Seatbelts:
Three-point inertia-reel seatbelts with pretensioners
Body Structure:
Reinforced A-pillars and body structure for enhanced crash protection
💡 Technology Features
Infotainment
Audio System:
Premium sound system with AM/FM stereo, cassette player. Some models may have optional CD changer integration.
Climate Control:
Automatic climate control with advanced features for temperature and air distribution management.
Driver Assistance
Cruise Control:
Standard cruise control system.
Power Seats:
Electrically adjustable front seats with memory function for driver's seat.
Connectivity
Diagnostics Port:
OBD-I diagnostic port (typically under the hood) for early engine and system diagnostics. Manual details access and interpretation.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 15,000 km (9,000 miles) or 12 months, whichever comes first (with synthetic oil).
Major Service Interval:
Refer to manual for specific mileage/time intervals for transmission fluid, coolant, brake fluid, and other major component checks.
Fluid Specifications
Engine Oil Specification:
API SJ or higher, ACEA A3/B3 or equivalent, viscosity grade 0W-40 or 5W-40 (e.g., Mobil 1 Formula M, Castrol Syntec) or 10W-30/10W-40 for older specs. Always consult manual.
Engine Oil Capacity 42L:
Approximately 8.0 liters (8.5 US quarts) with filter change
Engine Oil Capacity 50L:
Approximately 8.0 liters (8.5 US quarts) with filter change
Coolant Specification:
Mercedes-Benz approved coolant (e.g., MB 325.0) mixed with distilled water (50/50 ratio)
Brake Fluid Specification:
DOT 4 or DOT 4 Plus
Known Issues
Wiring Harness:
Degradation of insulation on wiring harnesses (especially older ones) due to age and heat, leading to electrical gremlins. The manual will detail how to inspect and potentially repair/replace these.
Convertible Top Hydraulics:
Leaking hydraulic lines or pump failure for the convertible top. Manual covers troubleshooting and replacement procedures.
Mas Sensor:
Mass Airflow Sensor (MAS) issues on later models can affect engine performance. The manual will provide diagnostic steps.
Interior Plastics:
Cracking or fading of interior plastic components due to UV exposure and age. Manual may offer some cosmetic repair guidance.
Seat Heater Elements:
Failure of seat heating elements or their wiring. Manual covers seat removal and electrical checks.
📚 Vehicle History
Brand Heritage
Mercedes Benz Legacy:
Mercedes-Benz has a long-standing reputation for engineering excellence, luxury, and safety, particularly with its SL line.
Model Evolution
R129 Introduction:
The R129 generation debuted in 1989 as a successor to the acclaimed R107 SL-Class.
Design Philosophy:
Represented a significant leap forward in technology, safety, and aerodynamics compared to its predecessor.
Production
Production Years:
1989-2001
Manufacturing Plant:
Sindelfingen, Germany
Engine Options Overview:
Initially offered with 3.0L inline-six and 5.0L V8 engines. The 4.2L V8 and later 6.0L V12 (SL 600) were introduced in subsequent years.
🏆 Awards & Recognition
Recognitions
Historical Recognition:
The R129 SL-Class was widely praised upon its release for its advanced engineering, safety, and luxury, solidifying Mercedes-Benz's reputation in the high-end convertible market.
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