Mercedes-Benz 560SL 1989 Service & Repair Manual Collection

The collection combines 560SL-specific service information with shared Mercedes-Benz repair articles and general workshop references. Broader model listings within individual articles do not establish complete vehicle coverage for every listed model.

Transmission coverage: Automatic-transmission material provides symptom diagnosis and removal/installation procedures. The separate overhaul article referenced for vacuum-control tests, hydraulic-pressure tests, and road tests is not included. Full body, convertible-top, upholstery, and paint repair are outside this collection’s scope.

PDF Text Search, Diagrams and File Contents

Search and diagram detail: Article text is searchable, but labels within embedded wiring diagrams and some diagnostic graphics are not searchable. None of the PDFs has embedded bookmarks. Small labels in the CIS-E, ABS, and automatic A/C schematics require zooming.

The ZIP download contains 73 printable English PDFs totaling 1,098 pages. This total includes 16 introductory pages within the general inspection references and five article-ending pages.

V8 Repair, CIS-E Diagnosis and Chassis Service

The following topics are selected coverage highlights, not a complete contents list. Additional references include electrostatic-discharge precautions and symptom-reporting worksheets.

• Engine repair: Step-by-step procedures for engine/transmission assembly removal, cylinder-head work, timing-chain and tensioner replacement, camshaft service, hydraulic lifters, pistons, bearings, seals, and pumps.

• CIS-E and EZL diagnosis: Preliminary checks, fuel-delivery and differential-pressure testing, California/Federal diagnostics, no-code troubleshooting, sensor and relay checks, idle control, and EGR/EVAP testing.

• Transmission and rear axle: W4A020/W4A040 diagnostic references, transmission removal/installation, axle-shaft and CV-joint service, differential disassembly, pinion-depth adjustment, bearing preload, backlash, and gear-contact patterns.

• Brakes and ABS: Brake-pad, caliper, rotor, master-cylinder, and parking-brake service, plus Bosch ABS pre-diagnosis, electrical component testing, and wheel-speed-sensor replacement.

• Steering and suspension: Power-steering pump and recirculating-ball gear overhaul, front and rear suspension removal/installation, wheel-bearing service, ride-height adjustment, and wheel alignment.

• Automatic climate control: Nippondenso compressor application data, compressor service references, impulse-readout diagnosis, temperature-sensor checks, vacuum testing, and climate-control component removal/installation.

• Electrical and restraints: Charging and starting tests, parasitic-load diagnosis, electrical component locations, system wiring diagrams, SRS testing, and post-collision inspection.

The engine-performance introduction expressly addresses professional automotive technicians. Many procedures assume access to a DVOM, model-specific test adapters, refrigerant recovery equipment, and workshop lifting equipment.

Engine Procedures and Valve-Train Details

The shared V8 engine article distinguishes 560SL procedures from other applications, including oil-pan removal. Intake and exhaust manifolds, valve guides and seats, distributor drive components, hydraulic-lifter base settings, and crankshaft seals receive separate treatment.

Valve-timing correction uses offset Woodruff keys, supported by timing specifications and component illustrations. The Cylinder Head Tightening Sequence accompanies the head-installation instructions; general engine-overhaul references supplement the Mercedes-specific article.

Rocker-arm compatibility: Replacement arms require the lifter-end chamfer that prevents contact with the hydraulic-lifter retaining cap. The article also warns against mixing new rocker arms with a used camshaft.

Referenced equipment includes Spring Compressor 123 589 03 61 00 and hydraulic-lifter Test Gauge 100 589 04 23 00. Tools are not supplied.

Driveability Tests and Circuit Tracing

The basic-testing, code-diagnosis, symptom-diagnosis, and component-test articles work together to narrow down no-start, cold-start, rough-idle, and intermittent complaints. Fuel-pressure and electrical checks help distinguish supply, control, and sensor faults before component replacement.

The dedicated 560SL CIS-E wiring diagram and the 420 & 560 Series Vacuum Hose Diagram support circuit and hose-routing checks. Sensor-range charts provide temperature-dependent reference data. A separate injector-waveform tutorial is a general workshop reference.

Rear-Axle Setup and Chassis Repair

Standard and limited-slip differential procedures include side-gear assembly, shim selection, and measuring-fixture use. The Exploded View of Mercedes-Benz Drive Axle Assembly and gear-contact-pattern references support identification and setup. Rear-axle Assembly Mandrel 116 589 18 61 00 is among the specified tools.

Pinion preload: Overtightening the pinion nut can crush the collapsible spacer beyond reuse, requiring pinion removal and spacer replacement.

The steering article includes a Cross Sectional View of the Steering Gear. ABS diagnosis uses Test Adapter 126 589 09 21 00, with a 560 Series ABS Wiring Diagram supporting electrical checks.

Climate Control, Electrical Service and Maintenance

The 560SL automatic A/C wiring diagram accompanies control-system diagnosis. Shared accessory articles address instruments, mirrors, wipers, and cruise control; the cruise-control article does not list the 560SL among its applications.

SRS procedures call for Tester 126 589 10 21 00. A/C service requires approved refrigerant recovery/recycling equipment before the circuit is opened. SRS and ABS work depends on the applicable disabling and pressure-release precautions; SRS testing requires approved equipment to prevent accidental deployment or component damage.

Maintenance references distinguish normal and severe operation and provide fluid specifications, capacities, and scheduled-service labor times for planning maintenance work.

Examples from the Ignition and Sensor Tables

For the 420 and 560 applications, the ignition-coil table specifies primary resistance of 0.2–0.4 ohm and secondary resistance of 7,000–13,000 ohms at 68°F (20°C).

The engine-control coolant-temperature sensor table lists 2,500 ohms at 68°F (20°C) and 325 ohms at 176°F (80°C), measured between the sensor terminal and ground. These temperature-dependent references support sensor evaluation during driveability diagnosis.