1989 Mercedes-Benz 560SL Service & Repair Manual (P/N 1160501120)

• Built for owners and professional workshops servicing the 1989 Mercedes-Benz 560SL, 420SEL, 560SEL, and 560SEC variants equipped with the 4.2L or 5.6L V8 engines.
• Official Mitchell Repair Information Company publication (PN 1160501120, copyright 1998) documenting 1989 engine and climate control systems.
• Contains 14 detailed technical diagrams. Visuals highlight critical tasks like cylinder head tightening sequences and A/C compressor clutch assemblies.
• Delivers detailing component identification, removal and installation (R&I) outlines, and system diagnostics.
• Serves as the foundational technical reference for the 116.965, 117.968, and 117.967 engine families.

Engine and Component Service Overview

This documentation outlines essential service parameters for the 1989 M116 and M117 V8 engine lineup. It provides a detailed look at the removal and installation workflows for the engine assembly, manifolds, and cylinder heads. Working on high-voltage ignition components or pressurized climate systems carries inherent risks; always verify system depressurization and disconnect power sources before initiating tear-downs to ensure shop safety.

The manual highlights specialized tooling requirements, such as the specific Allen wrenches needed for head bolt servicing. You will find extensive data covering timing chain maintenance, valve timing adjustments via offset Woodruff keys, and crankshaft bearing inspections. Rather than just a superficial overview, the text breaks down specifications for a wide range of engine block components. This includes the distributor drive gear, rocker arms, hydraulic valve lifters, piston assemblies, and the complete engine oiling system.

Climate control maintenance is another major focus. The reference material details compressor servicing across Nippondenso, Diesel Kiki, Harrison, and Hitachi units. It covers clutch R&I, shaft seal replacement, and precise refrigerant oil capacities required for proper system operation. For the automatic heater setup, the guide outlines system diagnostics. This features impulse readout testing for sensors, airflow vacuum diagrams, and comprehensive wiring schematics.

Specification Highlights and Data

Reliable data is the backbone of any successful rebuild. This manual delivers specific torque values and comprehensive clearances for rotating components. Cylinder head bolt torque is mapped out in a strict multi-stage sequence. Main bearing clearances are precisely documented at 0.0018 to 0.0033 inches (0.045 to 0.084 mm). The text also notes the 8.5-quart coolant system capacity alongside baseline reference values for the TDC transmitter and ignition sensors.

Intake valve clearance parameters are established for checks involving hydraulic lifter removal. Valve spring pressure data is clearly defined for both open and closed positions. Firing order information and coil specifications round out the ignition system data. Ultimately manual deliver the exact engine, chassis, and climate control specifications needed to accurately service this classic V8 family.