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Mercedes SL Class R230 Complete Workshop Service Repair Manual 2003 2004 2005 2006 2007 2008

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: SL-Class Chassis Code: R230 Generation Generation Name: Third Generation SL-Class Codes Covered Years: 2003, 2004, 2005, 2006, 2007, 2008 👋 Introduction Market Position...
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Mercedes SL Class R230 Complete Workshop Service Repair Manual 2003 2004 2005 2006 2007 2008
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
SL-Class
Chassis Code:
R230
Generation
Generation Name:
Third Generation SL-Class
Codes
Covered Years:
2003, 2004, 2005, 2006, 2007, 2008
👋 Introduction
Market Position
Positioning:
Flagship luxury grand tourer roadster, known for advanced technology, sophisticated design, and powerful performance.
Competitive Analysis
Competitors:
Porsche 911 Carrera Cabriolet, BMW 6 Series Convertible, Jaguar XK Convertible, Aston Martin DB9 Volante.
Key Features
Features:
Retractable vario-roof (hardtop convertible), Active Body Control (ABC) suspension, bi-xenon headlights, advanced safety systems, luxurious interior appointments.
Target Audience
Audience:
Affluent buyers seeking a high-performance, stylish, and technologically advanced luxury convertible.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Workshop Service and Repair
Page Count
Estimated Page Count:
Extensive (typically 1000+ pages for comprehensive coverage)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable Digital Format (likely PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, engine electrical, fuel system, cooling system, exhaust system, transmission (automatic), drivetrain (rear-wheel drive)
Chassis:
Suspension (active suspension system), steering, brakes (hydraulic, ABS, ESP), wheels and tires
Body And Interior:
Body structure, exterior panels, interior trim, seats, airbags, climate control, power accessories (windows, locks, mirrors, convertible top)
Electrical And Electronics:
Battery, charging system, lighting, instrumentation, infotainment, body control module (BCM), engine control module (ECM), transmission control module (TCM), diagnostic systems (OBD-II)
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, inspections
Repair And Overhaul:
Engine component removal/installation, transmission overhaul, brake caliper replacement, suspension component repair, convertible top mechanism servicing
Diagnostics And Troubleshooting:
Fault code interpretation, diagnostic procedures for various systems, electrical circuit testing, component testing
Technical Depth
Depth:
Comprehensive; covers basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and electrical schematics
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable (allows for quick navigation to specific topics)
Print Quality
Quality:
High-resolution scans of original manufacturer documentation, featuring clear diagrams and text
Binding Type
Binding:
Not Applicable (Digital Download)
Paper Type
Paper:
Not Applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code Sl500:
M113 (4.7L V8)
Engine Code Sl55 Amg:
M113 ML (5.4L Supercharged V8)
Engine Code Sl600:
M275 (5.5L Twin-Turbocharged V12)
Performance Sl500 2003
Horsepower:
302 hp @ 6000 rpm
Torque:
339 lb-ft @ 3250 rpm
Performance Sl55 Amg 2003
Horsepower:
469 hp @ 6100 rpm
Torque:
516 lb-ft @ 2650 rpm
Performance Sl600 2004
Horsepower:
493 hp @ 5000 rpm
Torque:
590 lb-ft @ 1800 rpm
Fuel System
Injection Type:
Electronic Fuel Injection (EFI)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Engine Management
ECU:
Bosch Motronic (specific variant depending on engine and year)
🔧 Transmission
Standard
Transmission Type:
5-speed automatic (722.6 series) for SL500, SL600 (later models might have 7-speed)
Transmission Type Amg:
5-speed AMG Speedshift automatic for SL55 AMG
Optional
Optional Transmission:
7-speed automatic (7G-TRONIC) became available on some models in later years of this generation.
Features
Shifting Modes:
Comfort (C), Sport (S), and Manual (M) modes available on most transmissions.
Fluid Specification
Transmission Fluid:
MB Approved Automatic Transmission Fluid (e.g., ATF 3403 or equivalent, consult manual for exact specification based on transmission type)
📐 Dimensions
Exterior
Length:
Approx. 4537 mm (178.6 in)
Width:
Approx. 1803 mm (71.0 in) (excluding mirrors)
Height:
Approx. 1300 mm (51.2 in)
Wheelbase:
Approx. 2560 mm (100.8 in)
Weights
Curb Weight Sl500:
Approx. 1820 kg (4012 lbs)
Curb Weight Sl55 Amg:
Approx. 1900 kg (4189 lbs)
Tires And Wheels
Wheel Bolt Pattern:
5x112
Standard Tire Size Sl500:
255/40 R18 (front), 285/35 R18 (rear)
Standard Tire Size Sl55 Amg:
255/40 R18 (front), 285/35 R18 (rear) (often with wider wheels)
🛡️ Safety Features
Ratings
NHTSA Rating:
Not explicitly rated by NHTSA in modern standards for this era, but designed to high Mercedes-Benz safety standards.
Active Features
Active Safety:
Anti-lock Braking System (ABS), Electronic Stability Program (ESP), Brake Assist (BAS), Tire Pressure Monitoring System (TPMS - on later models).
Passive Features
Passive Safety:
Front and side airbags, knee airbags (driver), rollover protection system (pop-up roll bars), reinforced chassis structure, seatbelt pretensioners.
Convertible Top Safety
Rollover Protection:
Automatic pop-up roll bars deploy in milliseconds if a rollover is detected by onboard sensors.
💡 Technology Features
Infotainment
Infotainment System:
COMAND (Cockpit Management and Navigation) system, typically featuring a central display, radio, CD player, and optional navigation, often with early forms of voice control.
Driver Assistance
Assistance Systems:
Adaptive Cruise Control (Distronic), Bi-Xenon headlights with cornering function, rain-sensing wipers, automatic climate control.
Connectivity
Connectivity Features:
Tele Aid (emergency calling system), optional Bluetooth phone integration (often requires a specific cradle).
Convertible Top Technology
Varioroof Operation:
Fully automatic electro-hydraulic operation, capable of opening or closing the hardtop in under 20 seconds.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 10,000 miles or 1 year, whichever comes first, under normal driving conditions (confirm with vehicle's onboard service indicator - 'Assyst').
Transmission Service:
Recommended every 30,000-60,000 miles, depending on driving conditions. Consult manual for precise interval and procedures.
Fluid Specifications
Engine Oil Sl500:
SAE 0W-40 or 5W-40 synthetic, MB 229.5 specification (e.g., Mobil 1 0W-40).
Engine Oil Sl55 Amg:
SAE 0W-40 or 5W-40 synthetic, MB 229.5 specification (often with higher temperature stability requirements).
Coolant:
Mercedes-Benz approved coolant (e.g., ZEREX G-05 or equivalent), mixed 50/50 with distilled water.
Brake Fluid:
DOT 4 Plus or DOT 4 LV (Low Viscosity) approved brake fluid.
Known Issues
Abc Suspension:
Leaking ABC hydraulic lines, pump failure, strut leaks, and accumulator issues can occur, often related to age and mileage. Requires specialized knowledge and fluid.
Varioroof Mechanism:
Hydraulic leaks, pump issues, and sensor faults within the complex convertible top mechanism can lead to operational problems.
Ignition Coils:
Misfires can be attributed to failing ignition coils, especially on the M113 V8 and M275 V12 engines.
Electronics:
Various electronic module failures (e.g., SAM, ABC control module, COMAND system) can occur due to age, water ingress, or component failure.
Spark Plugs
Spark Plug Replacement Interval:
Varies by engine: M113 approx. 100,000 miles, M113 ML and M275 often similar. Consult manual for specific model.
📚 Vehicle History
Brand Heritage
Heritage:
Mercedes-Benz has a long history of producing luxurious and technologically advanced roadsters, dating back to iconic models like the 300 SL 'Gullwing'.
Model Evolution
R230 Introduction:
The R230 generation replaced the R129 and introduced a revolutionary retractable hardtop (Vario-roof), significantly changing the roadster landscape.
Facelift 2002:
Introduced in late 2001 for the 2003 model year, featuring the Vario-roof, Active Body Control (ABC), and standard bi-xenon headlights. Initial models included the SL500 and the high-performance SL55 AMG.
Facelift 2006:
A significant facelift for the 2007 model year brought updated styling (new grille, headlights, bumpers), revised Active Body Control (ABC), improved interior, and new powertrain options including the SL550 (replacing SL500 with a 5.5L V8) and a more powerful SL55 AMG.
Production
Manufacturing Location:
Bremen, Germany
🏆 Awards & Recognition
Recognitions
Performance Awards:
The SL55 AMG model, in particular, was often lauded for its blistering performance and supercar-rivaling acceleration in automotive reviews of its era.
Ratings
Design Appreciation:
Consistently praised for its elegant and timeless design, both as a coupe and a roadster.
Certifications
Engineering Acclaim:
The integration of features like Active Body Control and the complex Vario-roof system earned praise for Mercedes-Benz engineering prowess.
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