1998–2004 Mercedes-Benz SLK Repair Manual (P/N 6515 3238 13, 170 584 189)

• Covers 1998–2004 Mercedes-Benz R170 SLK roadsters, with model-specific repair material for the SLK230 Kompressor (170.447/170.449), SLK320 (170.465), and SLK32 AMG Kompressor (170.466), including 111.973/111.983, 112.947, and 112.960 engine applications.
• Contains 6,720 PDF pages in 132 files: 6,447 pages of system-organized repair information plus a separate 273-page Mercedes-Benz USA SLK230 Kompressor/SLK320 Operator’s Manual, Order No. 6515 3238 13, Part No. 170 584 1896, USA Edition C 2001.
• Engine sections cover compression and cylinder-leak testing, engine removal, cylinder-head and valve-train work, crankshaft and piston service, timing-chain procedures, lubrication diagnosis, cooling-system repair, and Kompressor charge-air cooling components.
• Transmission material combines 722.6 automatic diagnosis, adaptation, removal, electrohydraulic control-unit work, and internal clutch/brake repair with 717.460 five-speed overhaul, 716.6 six-speed service data, clutch bleeding, and shift-linkage adjustment.
• Chassis coverage includes rear differential teardown and gear-set adjustment, axle shafts, suspension, wheel bearings, power-steering testing and bleeding, mechanical brake repair, and ABS, BAS, ETS, ASR, and ESP fault diagnosis.
• Vario-roof, body, and HVAC files address trunk-lid and tubular-frame adjustment, hydraulic pressure release and cylinder setup, doors and windows, bonded glass, body-panel repair, corrosion protection, restraints, R134a climate control, and engine/A/C fan operation.
• Electrical support includes 83 labeled system-wiring figures—38 for the 1999 SLK230 and 45 for the 2003 SLK320—supplemented by fuse layouts, component locations, starter and charging tests, connector views, and system-specific diagnostic material.

Coverage and Powertrain Identification

The model survey separates the early and later SLK230 configurations from the V6 SLK320 and supercharged SLK32 AMG. It identifies the applicable 722.605, 722.616, 722.618, 722.633, and 722.641 automatic transmissions together with the related 716- and 717-series manual transmissions. That distinction is important when selecting engine-control, cooling, starting, charging, and driveline procedures.

The 717.460 five-speed overhaul article includes a production break that directly affects parts identification: units through serial 6141000 use tapered roller bearings in the intermediate plate, while serial 6141001 and later units use ball bearings. The 716.667 section covers assembly-stand mounting, transmission design, shift operation, multiple-cone synchronization, and the reverse-lamp switch. Separate clutch files cover removal, installed wear inspection, hydraulic bleeding, and master- and slave-cylinder service.

Engine, Fuel, and Cooling Systems

Engine repair ranges from in-vehicle compression, leakage, oil-pressure, and cooling-system tests to engine removal, cylinder-head service, crankcase machining references, piston and connecting-rod work, crankshaft bearing measurement, timing-chain replacement, camshaft and hydraulic lash-compensator work, and seal replacement. Kompressor material covers the mechanical supercharger, electromagnetic clutch, intake manifold, charge-air cooler, low-temperature cooler, and circulation pump.

ME-SFI sections provide connector assignments, signal patterns, DTC memory information, and fault isolation for the hot-film mass-air sensor, coolant-temperature input, oxygen sensors, misfire detection, secondary-air injection, fuel-tank ventilation, electric cooling fan, thermostat, throttle actuator, and CAN-linked control units. Fuel-pressure and injector tests, tank and pump service, cooling-system draining and bleeding, water-pump and thermostat repair, radiator work, and fan/shroud diagnosis are also included.

Transmission, Driveline, Brakes, and Steering

The 722.6 material covers ETC connector and 13-pin plug assignments, electrical testing, adaptation, emergency-running functions, shift complaints, delayed engagement, and leak diagnosis. Internal repair sections address the electrohydraulic control unit, shift plate, oil pump, gearset, K1/K2/K3 multi-disc clutches, B1/B2/B3 brakes, torque converter, transmission cooler flushing, and selector mechanisms.

Rear axle coverage goes beyond complete-unit replacement. It includes differential disassembly, pinion-bearing setup, pinion depth, ring-and-pinion backlash, differential bearing adjustment, seals, flange play, and axle-shaft service. Brake and steering files cover calipers, pads, rotors, parking brakes, master cylinder and booster work, wheel-speed sensors, hydraulic units, steering-angle and yaw-related inputs, steering gear, power-steering pump, pressure testing, and bleeding.

Vario Roof, Body, Climate Control, and Electrical

Vario-roof repair centers on the trunk lid, tubular frame, catches, striker alignment, hydraulic pressure release, cylinder adjustment, side stops, roof paneling, rear glass, seals, and power-top circuit. Body files extend into door and window mechanisms, bumpers, fenders, front structure, rear body panels, welding references, gap dimensions, cavity preservation, corrosion protection, locking systems, seats, and restraint components. Climate-control sections cover system diagnosis, blower and regulator replacement, heater and evaporator housings, expansion valve, receiver/drier, condenser, compressor, refrigerant checks, and fan control.

Representative schematics include 2.3L and 3.2L engine-performance wiring, anti-lock brake circuits, Automatic A/C, D2B/data-link communication, power-top circuits, and starting/charging layouts. The two complete-vehicle wiring books are specific to the 1999 SLK230 and 2003 SLK320. SLK32 AMG electrical coverage is distributed through the broader engine, transmission, component-location, and model-specific diagnostic files rather than supplied as a separate full-car AMG wiring book.

Specifications, Tools, and Repair Cautions

Component-specific torque tables, test and adjustment data, fluid specifications, capacities, inspection limits, electrical test values, and technical modification notes are distributed throughout the set. Referenced service tools include support plate 140 589 34 63 00 and assembly stand 116 589 06 59 00 for the 716.6 transmission, plus feeler gauge 129 589 03 21 00 for Vario-roof and trunk adjustment.

Several procedures flag component-specific damage risks. The Vario-roof emergency valve is opened only when the roof is fully open and stowed or fully closed, with the ignition switched off; incorrect handling can damage the valve seal and prevent hydraulic pressure from building. The 722.6 torque converter must seat fully without being forced, or the axial stop and primary pump can be damaged. During timing work, rotating the engine backward after positioning can jam the chain.

Battery isolation, hydraulic-pressure release, secure vehicle support, and the specified precautions for fuel, refrigerant, cooling-system, and restraint-system work remain part of the repair process.