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Mercedes SLK 230 1996-2004 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: SLK 230 Generation: R170 Codes Engine Code Primary: M111 E23 ML 👋 Introduction Market Position Vehicle Segment: Compact Luxury Sports Roadster Competitive Analysis...
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Mercedes SLK 230 1996-2004 Workshop Service Repair ManualMercedes SLK 230 1996-2004 Workshop Service Repair ManualMercedes SLK 230 1996-2004 Workshop Service Repair ManualMercedes SLK 230 1996-2004 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
SLK 230
Generation:
R170
Codes
Engine Code Primary:
M111 E23 ML
👋 Introduction
Market Position
Vehicle Segment:
Compact Luxury Sports Roadster
Competitive Analysis
Key Competitors:
BMW Z3, Porsche Boxster (early models), Audi TT (later models).
Key Features
Convertible Top:
Vario-roof (retractable hardtop) is a signature feature.
Engine Type:
Supercharged inline-four cylinder engine.
Design Philosophy:
Compact, agile, driver-focused sports car with Mercedes-Benz luxury and engineering.
📋 Manual Details
Coverage Areas
Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
Regions Covered:
Global (based on typical Mercedes-Benz service documentation)
Page Count
Total Pages:
6447
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, diagnosis, tuning, cooling system, lubrication system, fuel injection, intake and exhaust systems.
Engine Electrical:
Ignition system, starting system, charging system, engine control unit (ECU) diagnosis, sensors, actuators.
Transmission Manual:
Removal, installation, overhaul, diagnosis, clutch system.
Transmission Automatic:
Removal, installation, diagnosis, fluid changes, internal component overhaul.
Drivetrain:
Rear axle assembly, driveshafts, CV joints, differential.
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment specifications.
Steering:
Power steering system, steering rack, tie rods, steering column, diagnosis and repair.
Brakes:
Hydraulic system, ABS system diagnosis, brake pads, rotors, calipers, bleeding procedures, parking brake.
Electrical System:
Wiring diagrams, lighting systems, fuses, relays, battery, power windows, mirrors, seats, convenience features.
Body And Chassis:
Frame, body panels, doors, hood, trunk lid, convertible top mechanism, interior trim, corrosion protection.
Climate Control:
Air conditioning system (R134a), heater core, blower motor, control panel, refrigerant handling.
Safety Systems:
Airbag system diagnosis and repair, seatbelt mechanisms.
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, belt inspection and replacement, spark plug replacement.
Troubleshooting:
Systematic diagnosis of common and uncommon issues, diagnostic trouble codes (DTCs) and their meanings.
Repair:
Detailed step-by-step repair procedures for all components and systems.
Disassembly Assembly:
Comprehensive instructions for removing and reinstalling all vehicle parts.
Adjustments:
Precision adjustments for engine timing, idle speed, brakes, clutch, and other systems.
Installation:
Procedures for installing new or reconditioned parts, including torque specifications.
Technical Depth
Depth:
Comprehensive, 'bumper-to-bumper' coverage suitable for professional mechanics and advanced DIY enthusiasts.
Special Tools:
Identification and usage instructions for necessary special service tools.
Wiring Diagrams:
Detailed electrical wiring diagrams for all vehicle systems.
Pictorial Diagrams:
Abundant step-by-step illustrations, exploded diagrams, and photographs.
Specifications:
Extensive service data, factory specifications, allowable limits, and torque values.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text within the PDF document.
Print Quality
Printability:
All pages are printable.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Software Requirement
Reader:
Adobe Reader
Compatibility
Operating Systems:
Windows, Mac, Linux OS
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-4 Cylinder, Supercharged
Displacement:
2.3 Liters (2295 cc)
Bore X Stroke:
90.9 mm x 86.7 mm
Compression Ratio:
8.8:1
Valvetrain:
2 Valves per Cylinder, SOHC (Single Overhead Camshaft)
Performance
Horsepower Est:
192 hp @ 5300 rpm (for most model years)
Torque Est:
200 lb-ft @ 2500-4500 rpm (for most model years)
Fuel System
Fuel Delivery:
Sequential Electronic Fuel Injection (EFI) with Bosch Motronic M3.8/ME2.0 management.
Fuel Type:
Premium Unleaded Gasoline (91+ octane recommended)
Engine Management
ECU Type:
Bosch Motronic
Supercharger Type:
Lysholm Twin-Screw Supercharger
Boost Pressure:
Approx. 0.8 bar (11.6 psi)
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual Transmission
Optional
Transmission Type:
5-Speed Automatic Transmission (with Touchshift)
Features
Gear Ratios Manual:
Specific ratios provided within the manual.
Gear Ratios Automatic:
Specific ratios provided within the manual.
Fluid Specifications
Manual Transmission Fluid:
Refer to manual for specific MB Approval numbers (e.g., MB 235.10 for 5-speed manual).
Automatic Transmission Fluid:
MB 236.10 or equivalent ATF.
📐 Dimensions
Exterior
Length:
Approx. 3995 mm (157.3 in)
Width:
Approx. 1701 mm (67.0 in)
Height:
Approx. 1293 mm (50.9 in)
Wheelbase:
Approx. 2070 mm (81.5 in)
Weights
Curb Weight Est:
Approx. 1390 kg (3064 lbs)
Gross Vehicle Weight Rating Est:
Approx. 1700 kg (3748 lbs)
Towing Capacity:
Not specified/recommended for towing.
🛡️ Safety Features
Ratings
Crash Test Ratings:
Refer to NHTSA/Euro NCAP for specific model year data. Mercedes-Benz vehicles generally prioritize safety.
Active Features
Traction Control:
ASR (Acceleration Slip Regulation) available on some models.
Anti Lock Brakes:
ABS (Anti-lock Braking System) standard.
Passive Features
Airbags:
Driver and passenger front airbags. Side airbags may be optional on some models.
Rollover Protection:
Integrated roll-over protection bars behind the seats.
Seatbelts:
Pre-tensioning seatbelts.
💡 Technology Features
Infotainment
Audio System:
Optional premium audio systems by Becker or Bose.
Navigation:
Optional navigation system available on later models.
Driver Assistance
Cruise Control:
Standard cruise control.
Connectivity
Bluetooth:
Not typically integrated from the factory in early models; aftermarket solutions available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 miles or 12 months, whichever comes first (refer to manual for exact intervals).
Major Service Intervals:
Refer to manual for specific mileage/time-based major service points (e.g., spark plugs, transmission fluid, coolant).
Fluid Specifications
Engine Oil Type:
MB 229.1 or MB 229.3 specification, typically 0W-40 or 5W-40 synthetic.
Engine Oil Capacity:
Approx. 5.5 liters (5.8 US quarts) with filter.
Coolant Type:
MB 325.0 or MB 326.0 specification (ethylene glycol based).
Brake Fluid Type:
DOT 4.
Known Issues
Supercharger Couplings:
Wear on the supercharger snout coupling leading to noise or reduced performance.
Mass Air Flow Sensor:
Can become dirty or fail, leading to rough idling and poor performance.
Crankshaft Position Sensor:
Failure can cause intermittent starting issues or engine stalling.
Variable Timing Solenoids:
Can fail, affecting engine performance and fuel economy.
Convertible Top Hydraulics:
Leaks or pump failures can affect the operation of the Vario-roof.
Window Regulators:
Can fail, causing windows to drop or not operate correctly.
Parts Replacement
Spark Plugs:
NGK PFR5G-11 or equivalent.
Air Filter Part Number Est:
Refer to manual or parts catalog for specific part numbers (e.g., A1110940104).
Oil Filter Part Number Est:
Refer to manual or parts catalog for specific part numbers (e.g., 0001802209).
📚 Vehicle History
Brand Heritage
Brand Focus:
Luxury automobiles, engineering excellence, innovation, safety.
Model Evolution
Introduction Year:
1997 (for model year 1997).
R170 Chassis:
The R170 generation was the first iteration of the SLK-Class.
Facelift:
A significant facelift occurred for the 2000 model year, including updated styling and engine options.
Production
Manufacturing Location:
Bremen, Germany.
Production Years:
1996-2004.
🏆 Awards & Recognition
Recognitions
Value Retention:
Mercedes-Benz vehicles generally have strong value retention.
Design Awards:
Known for its distinctive compact roadster styling.
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