Mercedes 500SL 1990-1993 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: 500SL Codes Chassis Code: R129 Generation Generation Code: R129 (First Generation) 👋 Introduction Market Position Segment: Luxury Grand Tourer (GT) Convertible Target Audience: Enthusiasts and owners seeking in-depth technical knowledge for maintenance and repair Competitive Analysis Competitors 1990S: BMW 8 Series Convertible, Jaguar XJS, Porsche 911 Targa/Cabriolet Key Features Vehicle Identity: Flagship luxury convertible, blend of performance and comfort, iconic Mercedes-Benz engineering Manual Value Proposition: Empowers owners and independent mechanics with factory-level diagnostic and repair information, crucial for preserving the value and functionality of a classic Mercedes-Benz 📋 Manual Details Coverage Areas Covered Years: 1990, 1991, 1992, 1993 Covered Models: All 500SL variants Page Count Estimated Pages: 1500+ Manual Type Type: Workshop Repair and Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Full disassembly, assembly, timing, lubrication, cooling, fuel injection (Bosch KE-Jetronic) Engine Electrical: Ignition system, starter, alternator, engine control unit (ECU) diagnostics and wiring diagrams Transmission: 4-speed automatic transmission (722.3xx series), hydraulic system, shifting characteristics, repair procedures Suspension: Front and rear suspension components, shock absorbers, springs, bushings, hydraulic systems (e.g., self-leveling rear axle if equipped on some variations) Brakes: Hydraulic system, ABS (Anti-lock Braking System), brake discs, pads, calipers, bleeding procedures Steering: Power steering system, steering column, steering rack, troubleshooting Body: Body panels, doors, hood, trunk, convertible top mechanism (hydraulics, operation), interior trim, glass Electrical System: Lighting, wipers, horn, power windows, power seats, climate control, central locking, diagnostic codes and wiring diagrams Climate Control: Air conditioning system (compressor, condenser, evaporator), heating system, blower motor, HVAC controls Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement, lubrication points Troubleshooting: Diagnosis of common issues, diagnostic trouble codes (DTCs), electrical fault finding, mechanical component diagnosis Repair: Detailed step-by-step...

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

500SL

Codes

Chassis Code:

Generation

Generation Code:

R129 (First Generation)

👋 Introduction

Market Position

Segment:

Luxury Grand Tourer (GT) Convertible

Target Audience:

Enthusiasts and owners seeking in-depth technical knowledge for maintenance and repair

Competitive Analysis

Competitors 1990S:

BMW 8 Series Convertible, Jaguar XJS, Porsche 911 Targa/Cabriolet

Key Features

Vehicle Identity:

Flagship luxury convertible, blend of performance and comfort, iconic Mercedes-Benz engineering

Manual Value Proposition:

Empowers owners and independent mechanics with factory-level diagnostic and repair information, crucial for preserving the value and functionality of a classic Mercedes-Benz

📋 Manual Details

Coverage Areas

Covered Years:

1990, 1991, 1992, 1993

Covered Models:

All 500SL variants

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Workshop Repair and Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full disassembly, assembly, timing, lubrication, cooling, fuel injection (Bosch KE-Jetronic)

Engine Electrical:

Ignition system, starter, alternator, engine control unit (ECU) diagnostics and wiring diagrams

Transmission:

4-speed automatic transmission (722.3xx series), hydraulic system, shifting characteristics, repair procedures

Suspension:

Front and rear suspension components, shock absorbers, springs, bushings, hydraulic systems (e.g., self-leveling rear axle if equipped on some variations)

Brakes:

Hydraulic system, ABS (Anti-lock Braking System), brake discs, pads, calipers, bleeding procedures

Steering:

Power steering system, steering column, steering rack, troubleshooting

Body:

Body panels, doors, hood, trunk, convertible top mechanism (hydraulics, operation), interior trim, glass

Electrical System:

Lighting, wipers, horn, power windows, power seats, climate control, central locking, diagnostic codes and wiring diagrams

Climate Control:

Air conditioning system (compressor, condenser, evaporator), heating system, blower motor, HVAC controls

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement, lubrication points

Troubleshooting:

Diagnosis of common issues, diagnostic trouble codes (DTCs), electrical fault finding, mechanical component diagnosis

Repair:

Detailed step-by-step repair instructions for all major mechanical and electrical components, including rebuild procedures for specific units

Installation:

Guidance on installing replacement parts and components

Adjustments:

Setting ignition timing, idle speed adjustment, brake adjustments

Technical Depth

Depth:

Comprehensive, covering basic to advanced diagnostics and complete overhaul procedures

📊 Manual Specifications

File Format

Type:

Searchable PDF

Quality:

High-resolution scans for clarity

Print Quality

Printability:

Printable for workshop use

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M119 E50

Configuration:

Displacement:

5.0 Liters (4973 cc)

Bore X Stroke:

96.5 mm x 85.0 mm

Compression Ratio:

10.0:1

Performance

Horsepower:

322 hp @ 5750 rpm

Torque:

354 lb-ft @ 3750 rpm

Fuel System

Type:

Bosch KE-Jetronic Electronic Fuel Injection with Air Flow Meter (AFM)

Fuel Type:

Unleaded Premium Gasoline (91 octane or higher recommended)

Engine Management

ECU Type:

Digital Engine Control Unit (DEC)

🔧 Transmission

Standard

Type:

4-Speed Automatic Transmission

Model Code:

722.3xx series

Features

Shift Modes:

Comfort (C) and Sport (S) modes

Fluid Specifications

Fluid Type:

ATF Dexron III or equivalent

Fluid Capacities

Fluid Capacity:

Approximately 8.5 Liters (8.9 US Quarts) for a complete fluid change.

📐 Dimensions

Exterior

Length:

Approx. 4775 mm (188.0 inches)

Width:

Approx. 1810 mm (71.3 inches)

Height:

Approx. 1308 mm (51.5 inches)

Wheelbase

Wheelbase:

Approx. 2600 mm (102.4 inches)

Weights

Curb Weight:

Approx. 1800-1900 kg (3968-4189 lbs)

Wheels Tires

Standard Wheel Size:

16-inch alloy wheels

Standard Tire Size:

225/55 R16

Bolt Pattern:

5x112 mm

🛡️ Safety Features

Passive Features

Airbags:

Driver's side airbag (standard from 1990), Passenger airbag (optional/standard on later models within this range)

Rollover Protection:

Automatic rollover hoops that deploy in the event of a rollover.

Seatbelts:

Pre-tensioning seatbelts

Active Features

Standard Anti-lock Braking System (ABS)

Ratings

NHTSA Ratings:

Not specifically rated by NHTSA for this era in the same way modern vehicles are; built to strict Mercedes-Benz safety standards of the time.

💡 Technology Features

Infotainment

Radio System:

Factory-fitted cassette radio with optional CD changer. Basic analog controls.

Display:

Analog gauges for speed, RPM, temperature, and fuel. Warning lamps for system status.

Driver Assistance

Cruise Control:

Standard electronic cruise control.

Traction Control:

Often equipped with Acceleration Slip Regulation (ASR) in later models or as an option.

Connectivity

External Connectivity:

Limited to power antennas; no modern Bluetooth or USB connectivity from the factory.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500-10,000 miles or 12 months, whichever comes first, depending on driving conditions.

Transmission Fluid Interval:

Recommended at 60,000-100,000 miles, or if fluid shows signs of degradation.

Coolant Change Interval:

Every 2-3 years or 30,000 miles.

Fluid Specifications

Engine Oil Type:

API SG/SH or ACEA A2/A3, viscosity typically 10W-40 or 15W-50 depending on climate.

Coolant Type:

Mercedes-Benz approved coolant (e.g., G48 or equivalent) mixed at a 50/50 ratio with distilled water.

Brake Fluid Type:

DOT 4 low viscosity.

Known Issues

Wiring Harness:

Degradation of wiring harness insulation, particularly in the engine bay, due to age and heat.

Hydraulic Systems:

Leaks in convertible top hydraulics, suspension components, or power steering.

Engine Management Kejetronic:

Issues with the Air Flow Meter (AFM) sensor, fuel distributor, or control pressure regulator can cause drivability problems.

Convertible Top Mechanism:

Potential failures in the hydraulic pump, cylinders, and switches controlling the soft top operation.

📚 Vehicle History

Brand Heritage

Marque Legacy:

Mercedes-Benz is renowned for its engineering excellence, safety innovations, and luxury vehicles dating back to the late 19th century.

Model Evolution

Predecessor:

Mercedes-Benz R107 SL-Class

Introduction Year:

1989 (as a 1990 model year vehicle)

Key Innovations R129:

Introduction of the M119 V8 engine, significantly updated aerodynamics, advanced safety features (rollover protection, ABS), and improved interior comfort.

Production

Manufacturing Location:

Sindelfingen, West Germany (later Germany)

Production Span:

1989-2001 (R129 chassis)

🏆 Awards & Recognition

Recognitions

Auto Magazine Ratings:

Consistently praised by automotive publications of its era for its build quality, performance, and luxurious appointments. Often featured in 'best of' lists for luxury convertibles.

Collector Status:

Highly regarded by collectors and enthusiasts for its timeless design and engineering, appreciating in value as a modern classic.

Certifications

Safety Standards:

Compliant with all applicable European and North American safety standards for its production years.