2002 Mercedes-Benz CLK430 Service & Repair Manual Software

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: CLK430 Year: 2002 Codes Chassis Code: W208 Engine Code: M113.983 👋 Introduction Market Position Segment: Luxury Grand Tourer / Sport Coupe and Convertible Target Audience: Owners and independent repair facilities servicing the 2002 Mercedes-Benz CLK430. Competitive Analysis Competitors: BMW 3 Series (E46) Coupe/Convertible, Audi A4 Cabriolet, Lexus SC 430, Porsche Boxster Key Features Of Vehicle Design Philosophy: Elegant styling, powerful V8 performance, comfortable grand touring capabilities, and premium Mercedes-Benz build quality. Key Features Of Manual Licensing: Officially Licensed, ensuring accuracy and completeness aligned with manufacturer specifications. Delivery Method: Instant online access/download, offering convenience and rapid deployment for repair needs. 📋 Manual Details Coverage Areas Primary Coverage: Mechanical, Electrical, Body, Chassis, Maintenance, Diagnostics, Troubleshooting, Repair Additional Coverage: Specifications, Wiring Diagrams, Component Location, Torque Values, Fluid Capacities Page Count Estimated Pages: 1500+ Manual Type Type: Official Factory Service Manual (Digital Software) Language Language: English Format Format: Software (likely PDF or proprietary executable) 📖 Manual Coverage Systems Covered Engine: 4.3L V8 M113 Engine (Engine Mechanical, Engine Cooling, Engine Lubrication, Fuel Delivery, Ignition System, Emissions Control) Transmission: 5-Speed Automatic Transmission (722.6) - Operation, Diagnostics, Repair, Fluid Service Drivetrain: Rear Wheel Drive (RWD), Driveshaft, Differential, Axles Suspension: Front and Rear Suspension Systems (Struts, Springs, Control Arms, Bushings, Anti-Roll Bars) Brakes: Hydraulic Brake System (ABS, ESP), Brake Pad Replacement, Rotor Servicing, Bleeding Procedures Steering: Power Steering System, Steering Gear, Steering Column Electrical: 12V Electrical System, Battery, Alternator, Starter, Fuse Box Diagrams, Lighting System, Horn Body Electrical: Power Windows, Power Locks, Convertible Top System (if applicable), Interior Lighting, Exterior Lighting Climate Control: Automatic Climate Control (A/C System, Heater Core, Blower Motor, Controls) Body And Trim: Exterior Body Panels, Interior Trim Components, Door Panels, Headliner, Bumpers Convertible Top System: Hydraulic and Electrical Components of the Power Convertible Top Safety Systems: Airbag System (SRS), Seatbelt Pretensioners, ABS, ESP Diagnostics: OBD-II (On-Board Diagnostics), Diagnostic Trouble Codes (DTCs), Scan Tool Procedures Procedures Included Preventative Maintenance: Oil Changes, Filter Replacements, Fluid Checks and Replacements, Spark Plug Replacement, Belt Inspection and Replacement Troubleshooting: Step-by-step diagnostic flowcharts for various symptoms (e.g., no-start, poor performance, electrical faults) Engine Repair: Engine Overhaul, Component Replacement (e.g., head gasket, pistons, valves), Timing System Service Transmission Repair: Transmission Disassembly and Reassembly, Valve Body Service, Torque Converter Replacement, Mechatronic Unit Service Brake System Repair: Brake Caliper Replacement, Rotor Machining or Replacement, ABS Modulator Service, Brake Line Replacement Suspension And Steering Repair: Component Replacement (shocks, struts, ball joints, tie rods), Wheel Alignment Specifications Electrical System Diagnostics: Wiring Harness Repair, Component Testing (sensors, actuators), Control Module Diagnosis Climate Control Repair: Refrigerant Servicing, Compressor Replacement, Condenser and Evaporator Service, Blower Motor Replacement Convertible Top Mechanism Repair: Hydraulic Pump and Cylinder Service, Sensor Replacement, Actuator Adjustment, Fabric Top Care Body Repair: Panel Replacement, Dent Repair, Door Hinge and Latch Adjustment, Trim Panel Installation Special Tools: Listing and usage of specialized tools required for specific repairs. Technical Depth Depth: Comprehensive - Covers basic maintenance to complete engine and transmission rebuilds. Diagnostic Capabilities: Advanced diagnostic procedures, including interpretation of sensor data and control module functions. Wiring Diagrams: Detailed electrical schematics for all major systems. Torque Specifications: Precise torque values for all critical fasteners. Component Location: Diagrams showing the location of all major components, sensors, and actuators. 📊 Manual Specifications File Format File Type: Software (Likely PDF or Executable Application) Searchability: High (if PDF with OCR or executable with indexing) Print Quality Print Readability: Excellent (as it's digital, user controls resolution) Binding Type Binding: N/A (Digital Software) Paper Type Paper Quality: N/A (Digital Software) ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated V8 Displacement: 4.3 Liters (4266 cc) Engine Code: M113.983 Bore X Stroke: 97.0 mm x 92.0 mm Compression Ratio: 10.0:1 Valvetrain: SOHC (Single Overhead Camshaft), 3 Valves per Cylinder (2 intake, 1 exhaust) Horsepower: 275 hp @ 5750 rpm Torque: 295 lb-ft @ 3750 rpm Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Premium Unleaded Gasoline (91 Octane or higher recommended) Fuel Tank Capacity: 16.4 gallons (62 liters) Cooling System Coolant Type: Mercedes-Benz specifications, typically silicate-free, ethylene glycol based (e.g., G05 or equivalent) Lubrication Oil Type: Synthetic SAE 0W-40, MB 229.5 approved (e.g., Mobil 1 0W-40) Oil Capacity: 8.5 US quarts (8.0 liters) with filter 🔧 Transmission Standard Type: 5-Speed Automatic Transmission Transmission Code: 722.6 (W5A 580) Optional Optional Transmission: N/A for CLK430 Features Gear Ratios: First: 3.59, Second: 2.19, Third: 1.41, Fourth: 1.00, Fifth: 0.83, Reverse: 3.17 Transmission Fluid Type: MB 236.10 specification ATF (Automatic Transmission Fluid) - typically Dexron III/Mercon or equivalent compatible fluids are NOT recommended without verification of MB approval. Transmission Fluid Capacity: Approximately 7.5 - 8.0 liters (dry fill) Differential Fluid: API GL-5, SAE 75W-90 Synthetic Gear Oil Differential Fluid Capacity: Approximately 1.0 - 1.2 liters 📐 Dimensions Exterior Length: 178.6 inches (4536 mm) Width: 68.2 inches (1732 mm)...

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

CLK430

Year:

Codes

Chassis Code:

Engine Code:

M113.983

👋 Introduction

Market Position

Segment:

Luxury Grand Tourer / Sport Coupe and Convertible

Target Audience:

Owners and independent repair facilities servicing the 2002 Mercedes-Benz CLK430.

Competitive Analysis

Competitors:

BMW 3 Series (E46) Coupe/Convertible, Audi A4 Cabriolet, Lexus SC 430, Porsche Boxster

Key Features Of Vehicle

Design Philosophy:

Elegant styling, powerful V8 performance, comfortable grand touring capabilities, and premium Mercedes-Benz build quality.

Key Features Of Manual

Licensing:

Officially Licensed, ensuring accuracy and completeness aligned with manufacturer specifications.

Delivery Method:

Instant online access/download, offering convenience and rapid deployment for repair needs.

📋 Manual Details

Coverage Areas

Primary Coverage:

Mechanical, Electrical, Body, Chassis, Maintenance, Diagnostics, Troubleshooting, Repair

Additional Coverage:

Specifications, Wiring Diagrams, Component Location, Torque Values, Fluid Capacities

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Official Factory Service Manual (Digital Software)

Language

Language:

English

Format

Format:

Software (likely PDF or proprietary executable)

📖 Manual Coverage

Systems Covered

Engine:

4.3L V8 M113 Engine (Engine Mechanical, Engine Cooling, Engine Lubrication, Fuel Delivery, Ignition System, Emissions Control)

Transmission:

5-Speed Automatic Transmission (722.6) - Operation, Diagnostics, Repair, Fluid Service

Drivetrain:

Rear Wheel Drive (RWD), Driveshaft, Differential, Axles

Suspension:

Front and Rear Suspension Systems (Struts, Springs, Control Arms, Bushings, Anti-Roll Bars)

Brakes:

Hydraulic Brake System (ABS, ESP), Brake Pad Replacement, Rotor Servicing, Bleeding Procedures

Steering:

Power Steering System, Steering Gear, Steering Column

Electrical:

12V Electrical System, Battery, Alternator, Starter, Fuse Box Diagrams, Lighting System, Horn

Body Electrical:

Power Windows, Power Locks, Convertible Top System (if applicable), Interior Lighting, Exterior Lighting

Climate Control:

Automatic Climate Control (A/C System, Heater Core, Blower Motor, Controls)

Body And Trim:

Exterior Body Panels, Interior Trim Components, Door Panels, Headliner, Bumpers

Convertible Top System:

Hydraulic and Electrical Components of the Power Convertible Top

Safety Systems:

Airbag System (SRS), Seatbelt Pretensioners, ABS, ESP

Diagnostics:

OBD-II (On-Board Diagnostics), Diagnostic Trouble Codes (DTCs), Scan Tool Procedures

Procedures Included

Preventative Maintenance:

Oil Changes, Filter Replacements, Fluid Checks and Replacements, Spark Plug Replacement, Belt Inspection and Replacement

Troubleshooting:

Step-by-step diagnostic flowcharts for various symptoms (e.g., no-start, poor performance, electrical faults)

Engine Repair:

Engine Overhaul, Component Replacement (e.g., head gasket, pistons, valves), Timing System Service

Transmission Repair:

Transmission Disassembly and Reassembly, Valve Body Service, Torque Converter Replacement, Mechatronic Unit Service

Brake System Repair:

Brake Caliper Replacement, Rotor Machining or Replacement, ABS Modulator Service, Brake Line Replacement

Suspension And Steering Repair:

Component Replacement (shocks, struts, ball joints, tie rods), Wheel Alignment Specifications

Electrical System Diagnostics:

Wiring Harness Repair, Component Testing (sensors, actuators), Control Module Diagnosis

Climate Control Repair:

Refrigerant Servicing, Compressor Replacement, Condenser and Evaporator Service, Blower Motor Replacement

Convertible Top Mechanism Repair:

Hydraulic Pump and Cylinder Service, Sensor Replacement, Actuator Adjustment, Fabric Top Care

Body Repair:

Panel Replacement, Dent Repair, Door Hinge and Latch Adjustment, Trim Panel Installation

Special Tools:

Listing and usage of specialized tools required for specific repairs.

Technical Depth

Depth:

Comprehensive - Covers basic maintenance to complete engine and transmission rebuilds.

Diagnostic Capabilities:

Advanced diagnostic procedures, including interpretation of sensor data and control module functions.

Wiring Diagrams:

Detailed electrical schematics for all major systems.

Torque Specifications:

Precise torque values for all critical fasteners.

Component Location:

Diagrams showing the location of all major components, sensors, and actuators.

📊 Manual Specifications

File Format

File Type:

Software (Likely PDF or Executable Application)

Searchability:

High (if PDF with OCR or executable with indexing)

Print Quality

Print Readability:

Excellent (as it's digital, user controls resolution)

Binding Type

Binding:

N/A (Digital Software)

Paper Type

Paper Quality:

N/A (Digital Software)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Naturally Aspirated V8

Displacement:

4.3 Liters (4266 cc)

Engine Code:

M113.983

Bore X Stroke:

97.0 mm x 92.0 mm

Compression Ratio:

10.0:1

Valvetrain:

SOHC (Single Overhead Camshaft), 3 Valves per Cylinder (2 intake, 1 exhaust)

Horsepower:

275 hp @ 5750 rpm

Torque:

295 lb-ft @ 3750 rpm

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (91 Octane or higher recommended)

Fuel Tank Capacity:

16.4 gallons (62 liters)

Cooling System

Coolant Type:

Mercedes-Benz specifications, typically silicate-free, ethylene glycol based (e.g., G05 or equivalent)

Lubrication

Oil Type:

Synthetic SAE 0W-40, MB 229.5 approved (e.g., Mobil 1 0W-40)

Oil Capacity:

8.5 US quarts (8.0 liters) with filter

🔧 Transmission

Standard

Type:

5-Speed Automatic Transmission

Transmission Code:

722.6 (W5A 580)

Optional

Optional Transmission:

N/A for CLK430

Features

Gear Ratios:

First: 3.59, Second: 2.19, Third: 1.41, Fourth: 1.00, Fifth: 0.83, Reverse: 3.17

Transmission Fluid Type:

MB 236.10 specification ATF (Automatic Transmission Fluid) - typically Dexron III/Mercon or equivalent compatible fluids are NOT recommended without verification of MB approval.

Transmission Fluid Capacity:

Approximately 7.5 - 8.0 liters (dry fill)

Differential Fluid:

API GL-5, SAE 75W-90 Synthetic Gear Oil

Differential Fluid Capacity:

Approximately 1.0 - 1.2 liters

📐 Dimensions

Exterior

Length:

178.6 inches (4536 mm)

Width:

68.2 inches (1732 mm)

Height:

53.4 inches (1356 mm)

Wheelbase:

106.7 inches (2710 mm)

Front Track:

58.5 inches (1486 mm)

Rear Track:

57.8 inches (1468 mm)

Weights

Curb Weight:

Approximately 3671 lbs (1665 kg)

Gross Vehicle Weight Rating:

Approximately 4740 lbs (2150 kg)

Towing Capacity:

Not Recommended/Not Specified by Manufacturer

Cargo

Trunk Volume:

11.3 cubic feet (320 liters)

Convertible Top Down Trunk Space:

Reduced trunk space when the soft top is stowed.

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4-Star Driver, 4-Star Passenger

IIHS Side Impact:

Good (for vehicles of similar design from the era)

IIHS Rear Impact:

Acceptable (for vehicles of similar design from the era)

Active Features

Traction Control:

ASR (Anti-Slip Regulation) / Traction Control System (TCS)

Stability Control:

ESP (Electronic Stability Program)

Anti Lock Brakes:

ABS (Anti-lock Braking System), 4-wheel disc brakes

Passive Features

Airbags:

Driver and Front Passenger Airbags, Side Airbags (in seats), Roll-Over Protection (for convertible models)

Seatbelts:

Front 3-point Inertia-Reel Seatbelts with Pretensioners and Load Limiters, Rear 3-point Seatbelts

Head Restraints:

Active Head Restraints (NECK-PRO) for front occupants

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD stereo, optional Bose premium sound system.

Navigation:

Optional COMAND (Cockpit Management and Navigation) system.

Climate Control System:

Automatic Climate Control (THERMATIC) or optional THERMOTRONIC dual-zone automatic climate control.

Driver Assistance

Cruise Control:

Standard electronic cruise control.

Parking Assistance:

Optional rear park assist sensors.

Connectivity

Tele Aid:

Optional Tele Aid emergency assistance system (subscription-based).

Instrument Cluster:

Analog gauges with integrated digital multi-function display for trip computer, range, and service reminders.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 10,000 miles (16,000 km) or 12 months, whichever comes first, using approved synthetic oil.

Transmission Service Interval:

Recommended every 40,000 - 60,000 miles (64,000 - 96,000 km) for fluid and filter change, depending on driving conditions.

Coolant Service Interval:

First change at 100,000 miles (160,000 km) or 5 years, then every 2 years or 50,000 miles (80,000 km).

Spark Plug Replacement:

Approximately 100,000 miles (160,000 km) with iridium spark plugs.

Brake Fluid Service:

Every 2 years (24 months) regardless of mileage, to prevent moisture absorption.

Fluid Specifications

Power Steering Fluid:

Mercedes-Benz Power Steering Fluid (MB 343.0) or equivalent.

Brake Fluid:

DOT 4 Plus (MB 331.0 specification) or DOT 4

Windshield Washer Fluid:

Approved washer fluid concentrate or plain water with approved additive.

Known Issues

Common Issues Engine:

Oil leaks from valve cover gaskets and oil cooler seals, potential for MAF sensor issues, catalytic converter failures.

Common Issues Transmission:

Transmission control module (TCM) failures, conductor plate issues within the valve body, 'limp mode' activation.

Common Issues Suspension Steering:

Worn control arm bushings, ball joints, and tie rod ends, power steering pump whine or leaks.

Common Issues Electrical:

Window regulator failures, SAM (Signal Acquisition Module) issues, blower motor resistor failure, CAN bus communication errors.

Common Issues Convertible Top:

Hydraulic hose leaks, pump failure, cylinder seal leaks, micro-switch failures affecting operation.

📚 Vehicle History

Brand Heritage

Manufacturer:

Mercedes-Benz, renowned for engineering excellence, luxury, and safety since 1886.

Model Evolution

Generation:

Second generation CLK (C208/A208) facelift, produced from 2000-2003.

Predecessor:

First generation CLK (C208/A208) introduced in 1997.

Platform Sharing:

Based on the W202 C-Class platform, but with a longer wheelbase and shared components with the W210 E-Class.

Production

Production Years:

1997-2003

Manufacturing Location:

Germany (Sindelfingen plant)

🏆 Awards & Recognition

Recognitions

General Reputation:

The CLK-Class in general was recognized for its blend of luxury, performance, and stylish design, often receiving positive reviews from automotive journalists.

Safety Awards:

While specific awards for the 2002 CLK430 are not prominently cited, Mercedes-Benz vehicles of this era consistently performed well in safety tests.

Ratings

Consumer Reports:

Consumer Reports ratings for this model year and generation often noted average to above-average reliability, with some specific electronic components and suspension wear being potential concerns.