MERCEDES BENZ R107 and C107 350SL, 380 SL, 380 SLC, 450 SL, 450SLC, 560SL 1972-1989 Factory Workshop Manual | PDF Download

MERCEDES BENZ R107 and C107 350SL, 380 SL, 380 SLC, 450 SL, 450SLC, 560SL 1972-1989 Factory Workshop Manual | PDF Download

Factory Mercedes Benz R107 and C107 STAR Classic Shop Manual features easy to follow instructions, photos and diagrams on the service and repair of the Mercedes-Benz 107 series including:

• Repair Information - full component disassembly and assembly instructions
• Diagnostic Manual - Provides test and troubleshoot information

For the following Mercedes Benz Models manufactured from 1972 - 1989:

• Mercedes Benz 350SL
• Mercedes Benz 380SL
• Mercedes Benz 380SLC
• Mercedes Benz 450SL
• Mercedes Benz 450SLC
• Mercedes Benz 560SL

This is an extremely detailed workshop manual covering every aspect of the car and consisting of over 3000 pages.

This Manual includes:

• Complete "Star Classis" R107/C107 Factory Chassis Workshop Manual
• Climate Control Air Conditioning Factory Workshop Manual
• 4.5 Litre V8 Engine Factory Workshop Manual
• 3.8 Litre V8 Engine Factory Workshop Manual
• 5.0 Litre V8 Engine Factory Workshop Manual
• 4.2 Litre V8 Engine Factory Workshop Manual
• 5.6 Litre V8 Engine Factory Workshop Manual

See below for a more detailed list of topics covered in this Factory Mercedes Benz Manual: 

• R107 C107 - Chassis Workshop Manual

• Identification of Vehicle
• Instructions for use of Service Manual
• Technical Data
• Suspension
• Front and Rear Shock Absorbers Removal and installation
• Front and Rear Springs and Rubber Mounts
• Front Torsion Bar Removal and installation
• Rear Torsion Bar Removal and installation
• Front Axle
• Front Axle Removal and Assembly
• Front Wheel Bearings Removal and Assembly
• Front Wheel Hub Removal and Assembly
• Steering Knuckle Removal and installation
• Upper Control Arm Removal and installation
• Lower Control Arm Removal and installation
• Rear Axle
• Rear Axle Complete Removal and installation
• Front Rubber Bearing of rear axle suspension Removal and installation
• Rear Rubber Bearing of rear axle suspension Removal and installation
• Semi Trailing Arm Removal and installation
• Rear Axle Shaft Flange Removal, adjustment of bearings and installation
• Rear Axle Center piece with rear axle shafts Removal and installation 
• Radial Sealing Ring on drive pinion Replacement 
• Radial Sealing Ring of rear axle shaft Replacement
• Differential Reconditioning
• Rear Axle Shaft Removal and installation
• Wheels
• Rims and Tires Survey
• Tire inflation pressure
• Lifting vehicle with vehicle jack
• Removing and mounting of wheels
• Propeller Shaft
• Propeller Shaft Removal and installation
• Propeller Shaft Intermediate Bearing Removal, replacement and installation
• Centering Sleeve Replacement
• Brake System
• Checking the brake system for leaks
• Bleeding the brake system or renewing the brake fluid
• Removal and installation of fixed caliper on front axle
• Removal and installation of fixed caliper on rear axle
• Replacing brake pads
• Removal and installation of brake disc on front axle
• Removal and installation of brake disc on rear axle
• Removal and installation of tandem main cylinder
• Disassembly, inspection and assembly of tandem main cylinder
• Removal, adjustment and installation of brake shoes of parking brake
• Layout and operation of anti-locking brake system (ABS)
• Removal and installation of hydraulic unit
• Removal and installation of electronic control unit
• Removal and installation of rpm sensor on front and Rear axle
• Steering System
• Inspection of oil pressure of power steering pump
• Removal and installation of power steering pump
• Disassembly, checkup and reconditioning of power steering pump
• Adjusting power steering in vehicle
• Renewing radial sealing ring of power steering pump
• Reconditioning of steering coupling
• Removal and installation of pitman arm
• Removal and installation of intermediate steering arm and bearing
• Removal and installation of track rod
• Removal and installation of drag link
• Removal and installation of steering wheel
• Removal and installation of steering shaft
• Removal and installation of steering lock
• Electrical System
• Battery test, service and maintenance
• Removal and installation of instrument cluster
• Removal and installation of combination switch
• Removal, testing and installation of electronic tachometer
• Testing fuel gauge
• Removal and installation of light switch
• Renewing bulb for ashtray light
• Seat belt warning device, ignition key, lamps
• Cruise Control Operation
• Body 
• Body Glass and Windows
• Removal and installation of windshield
• Removal and installation of rear window
• Removal and installation of side window on coupe top
• Removal and installation of shutter
• Body Interior
• Removal and installation of speaker cover, left and right
• Removal and installation of glovebox
• Removal and installation of cover on shift lever
• Removal and installation of headlining on Coupe top
• Removal and installation of paneling in rear center
• Removal and installation of ornamental frame on windshield
• Removal and installation of weather strip on windshield pillar
• Body Doors
• Removal and installation of door lining
• Removal and installation of window crank handle
• Removal and installation of inside sealing strip
• Removal and installation of outer sealing strip
• Removal and installation of window opener
• Removal and installation of door catch
• Removal and installation of door sealing frame
• Removal and installation of outside door handle
• Removal and installation of door lock
• Removal, adjustment and installation of striker 
• Removal and installation of outside rear view mirror
• Body Truck and Top Well Cover
• Removal and installation of trunk lid
• Removal and installation of torsion bar spring
• Removal and installation of tank flap
• Body Sliding Roof
• Removal and installation of sliding roof cover
• Adjustment of sliding roof cover
• Removal and installation of drive cable control
• Removal and installation of holder with motor and gear unit
• Trouble diagnosis, electrical sliding roof
• Body Convertible Top
• Removal and installation of top
• Removal and installation of roadster top cover
• Removal and installation of top lock on top well
• Removal and installation of windshield molding with guide bearing
• Removal and installation of lock on top of coupe top
• Removal and installation of lock on bottom of Coupe top
• Central Locking System
• Removal, adjustment and installation of vacuum switch driver's door
• Removal and installation of vacuum element of front passenger's door
• Removal and installation of vacuum element for trunk lid
• Removal and installation of vacuum supply tank
• Checking central locking system
• Electrical Body System
• Lights
• Removal and installation of headlamp unit
• Removal and installation of fog lamp bulb
• Removal and installation of tail lamp unit
• Removal and installation of license plate lamp
• Dome lamps
• Radio
• Connection for radio
• Function of automatic antenna
• Windshield Wipers
• Removal and installation of wiper arm
• Removal and installation of wiper blade
• Removal and installation of wiper blade rubber profile strip
• Renewing impulse switch on wiper motor
• Heated Seats
• Operation of seat heating system
• Checking seat heating system
• Removal and installation of switch for seat heating system
• Renewing heating pad of seat heating system
• Detachable Body Components
• Front fenders front and rear Removal and installation
• Bumpers front and rear Removal and installation
• Engine Hood Removal and installation
• Radiator Shell and Air Flow Grille Removal and installation
• Seats and Safety belts
• Seats
• Removal and installation of driver's seat
• Removal and installation of front passenger seat
• Removal and installation of seat rail and seat fitting
• Removal and installation of seat height adjuster
• Removal and installation of rear seat and rear seat backrest
• Safety Belts
• Removal and installation of safety belt
• Safety belt - replacement instructions

• Climate Air Conditioning Manual

• Operation, Testing, Removal and installation
• Removal and installation of monovalve
• Removal, installation and disassembly of control unit
• Removal and installation of temperature sensor for heat exchanger
• Removal, installation and testing of switchover valves
• Removal and installation of vacuum elements
• Removal and installation of electronic switching unit for temperature control
• Removal and installation of electronic switching unit for blower control
• Removal, installation and checking of cold engine temperature switch
• Removal and installation of heater box
• Removal and installation of heat exchanger
• Checking vacuum element on heater tap and vacuum switches on control unit for leaks
  
• Removal and installation of heater blower
• Refilling or replenishing air conditioning system
• Draining of air conditioning system
• Cleaning of air conditioning system
• Checking oil level in refrigerant compressor
• Removal and installation of refrigerant compressor
• Reconditioning of refrigerant compressor
• Vacuum function diagrams
• Testing vacuum circuit I and II
• Removal and installation of heating water pump

• Engine-M116.98 (3.5 V8) and M117.98 (4.5 V8) 350SL, 450SL and 450SLC

• Engine Checks
• Checking compression pressure
• Checking cylinders for leaks
• Evaluation of cylinder bores
• Measuring oil consumption
• Engine removal and dismantle
• Removal and installation of engine
• Removal and installation of pistons
• Checking, renewing and tightening connecting rod bolts
• Checking and reconditioning of crankshaft
• Measuring, boring and honing cylinder bores
• Renewing front crankshaft radial sealing ring
• Removal and installation of crankshaft sprocket
• Removing and installing flywheel and driven plate
• Refinishing flywheel
• Renewing ring gear
• Cylinder Heads
• Removal and installation of cylinder head
• Facing cylinder head parting surface
• Pressure testing cylinder head
• Inspection and adjustment of valve clearance
• Inspection and renewal of hydraulic valve clearance compensating elements
• Renewal of threaded bushing with valve adjusting screw
• Checking and adjusting of camshaft timing
• Removal and installation of camshaft
• Grinding camshaft bearing journals
• Removal and installation of rocker arms
• Removal and installation of valve springs
• Removal and installation of valve springs
• Replacement of valve stem seals
• Checking and machining valves
• Inspection and renewal of valve guides
• Renewal of valve seat rings
• Removal and installation, inspection of chain tensioner
• Renewing timing chain
• Removal and installation of tensioning rail
• Removal and installation of slide rails
• Removal and installation of intermediate sprocket distributor drive
• Removal and installation of guide sprocket
• Air cleaner and filter
• Removal and installation of intake pipe, renewing gasket
• Removal and installation of air cleaner
• Removal and installation of air filter
• V Belts
• Notes concerning renewing and tensioning of V-belts
• Replacing and tensioning V-belts
• Ignition Distributor
• Removal and installation of ignition distributor
• Removal and installation of vacuum control unit on ignition distributor
• Testing breakerless transistorized ignition system TSZ 4
• Oil pump
• Oil circuit, oil pressure, pressure relief and bypass valve, oil filter
• Removal and installation of oil pump
• Cooling System
• Draining and filling-in of coolant -anti-freeze table
• Cleaning the cooling system
• Removal and installation of coolant thermostat
• Removal and installation of coolant pump
• Viscofan coupling, temperature-controlled
• Viscofan coupling, speed-controlled
• Removal and installation of radiator
• Checking radiator or expansion tank cap
• Engine Mounts
• Removal and installation of engine mounts
• Removal and installation of engine shock absorber
• Exhaust System
• Removal and installation of exhaust system
• Removal and installation of exhaust manifold
• Fuel System
• Adjustment of idle speed
• Checking fuel pressures and for internal leaks
• Checking choke system
• Checking injection valves
• Removal and installation of injection valves
• Renewing fuel hoses on injection valves
• Adjusting throttle valve switch
• Checking fuel pump relay
• Renewing fuel distributor
• Renewing air flow sensor
• Renewing warm-up compensator
• Removal and installation of fuel filter
• Removal and installation of fuel pump
• Ignition System
• Renewing breaker points
• Renewing breaker points

• Engine M116.96 (3.8 V8) and M117.96 (5.0 V8) 380SL, 380SLC and 500SL

• Technical Data
• Engine and Vehicle Identification
• Technical Data
• Engine Block
• Checking compression pressure
• Checking Cylinders for leaks
• Evaluating cylinder bores
• Removal and installation of engine
• Machining tolerances
• Cylinder Head
• Removal and installation of cylinder head
• Facing cylinder head mating surface
• Pressure-testing cylinder head
• Pistons, Connecting Rods, Crankshaft
• Checking, renewing and tightening connecting rod bolts
• Removal and installation of pistons
• Renewal of piston rings
• Checking and reconditioning of crankshaft
• Mounting of crankshaft
• Replacing front and rear crankshaft radial sealing ring
• Hub, V-Belt Pulley, Ring Gear
• Removal and installation of hub, vibration damper and V-belt pulley
• Checking and correcting adjustment of TDC transmitter
• Removal and installation of driven plates
• Renewing ring gear
• Valves, Camshaft
• Renewing ring gear
• Checking and adjusting camshaft timing
• Removal and installation of camshafts
• Grinding camshaft bearing journals
• Removal and installation of rocker arms
• Removal and installation of valve springs
• Replacing valve stem seals
• Checking and machining valves
• Checking replacing valve guides
• Replacing valve seat rings
• Machining valve seats
• Timing Chain
• Removal and installation of chain tensioner
• Replacing timing chain
• Removal and installation of tension rail
• Removal and installation of slide rails
• Removal and installation of intermediate gear for distributor drive
• Removal and installation of return sprocket
• Fuel, Injection System
• Checking fuel pressure and for internal leaks
• Checking choke system
• Checking fuel pump
• Renewing fuel distributor
• Removal and installation of injection valves
• Renewing air flow sensor
• Removal and installation of throttle valve housing
• Removal and installation of fuel reservoir
• Removal and installation of fuel filter
• Removal and installation of fuel pump
• V-Belt Replacement
• Instructions concerning V-belt replacement and tensioning
• Replacing and tensioning V-belt
• Emission Control System
• Checking emission control system
• Removal and installation of catalytic converter 
• Removal and installation of air pump
• Removal and installation of electromagnetic clutch
• Removal and installation of intake manifold upper and lower, renewing gaskets
• Removal and installation of exhaust manifold
• Checking EGR
• Ignition System
• Testing and adjusting ignition timing (firing point)
• Vacuum adjustment of ignition timing (firing point)
• Removal and installation of ignition distributor
• Testing breakerless transistorized ignition system
• Oil Filter, Oil Pump
• Removal and installation of oil filter
• Removal and installation of oil pump
• Removal and installation of oil pressure relief valve
• Removal and installation of oil level transmitter
• Cooling System
• Draining and filling-in of coolant - antifreeze table
• Cleaning cooling and heating system
• Removal and installation of coolant thermostat
• Removal and installation of coolant pump
• Viscofan clutch
• Removal and installation of radiator
• Repairing radiator
• Checking expansion tank cap
• Engine Mounts
• Removal and installation of front and rear engine mounts
• Removal and installation of engine shock absorber
• Throttle Linkage
• Adjusting regulating linkage
• Removal and installation of longitudinal regulating shaft
• Removal, installation and adjustment of chassis regulating shaft
• Removal and installation of accelerator pedal
• Lubricating regulating linkage and regulating shafts
• Fuel Tank
• Removal and installation of fuel tank
• Removal and installation of fuel expansion tank
• Removal and installation of transmitter for fuel readout
• Operation of fuel evaporation control system
• Checking fuel evaporation control system
• Operation of fuel cooler
• Exhaust System
• Removal and installation of exhaust system

• Engine-M116.96 (4.2 V8) and M117.96 (5.6 V8) 420SL and 560SL

• Technical Data
• Engine and Vehicle Identification
• Technical Data
• Engine Block
• Checking compression pressure
• Checking Cylinders for leaks
• Evaluating cylinder bores
• Removal and installation of engine
• Machining tolerances
• Cylinder Head
• Removal and installation of cylinder head
• Facing cylinder head mating surface
• Pressure-testing cylinder head
• Pistons, Connecting Rods, Crankshaft
• Checking, renewing and tightening connecting rod bolts
• Removal and installation of pistons
• Renewal of piston rings
• Checking and reconditioning of crankshaft
• Mounting of crankshaft
• Replacing front and rear crankshaft radial sealing ring
• Hub, V-Belt Pulley, Ring Gear
• Removal and installation of hub, vibration damper and V-belt pulley
• Checking and correcting adjustment of TDC transmitter
• Removal and installation of driven plates
• Renewing ring gear
• Valves, Camshaft
• Renewing ring gear
• Checking and adjusting camshaft timing
• Removal and installation of camshafts
• Grinding camshaft bearing journals
• Removal and installation of rocker arms
• Removal and installation of valve springs
• Replacing valve stem seals
• Checking and machining valves
• Checking replacing valve guides
• Replacing valve seat rings
• Machining valve seats
• Timing Chain
• Removal and installation of chain tensioner
• Replacing timing chain
• Removal and installation of tension rail
• Removal and installation of slide rails
• Removal and installation of intermediate gear for distributor drive
• Removal and installation of return sprocket
• Fuel, Injection System
• Checking fuel pressure and for internal leaks
• Checking choke system
• Checking fuel pump
• Renewing fuel distributor
• Removal and installation of injection valves
• Renewing air flow sensor
• Removal and installation of throttle valve housing
• Removal and installation of fuel reservoir
• Removal and installation of fuel filter
• Removal and installation of fuel pump
• V-Belt Replacement
• Instructions concerning V-belt replacement and tensioning
• Replacing and tensioning V-belt
• Emission Control System
• Checking emission control system
• Removal and installation of catalytic converter 
• Removal and installation of air pump
• Removal and installation of electromagnetic clutch
• Removal and installation of intake manifold upper and lower, renewing gaskets
• Removal and installation of exhaust manifold
• Checking EGR
• Ignition System
• Testing and adjusting ignition timing (firing point)
• Vacuum adjustment of ignition timing (firing point)
• Removal and installation of ignition distributor
• Testing breakerless transistorized ignition system
• Oil Filter, Oil Pump
• Removal and installation of oil filter
• Removal and installation of oil pump
• Removal and installation of oil pressure relief valve
• Removal and installation of oil level transmitter
• Cooling System
• Draining and filling-in of coolant - antifreeze table
• Cleaning cooling and heating system
• Removal and installation of coolant thermostat
• Removal and installation of coolant pump
• Viscofan clutch
• Removal and installation of radiator
• Repairing radiator
• Checking expansion tank cap
• Engine Mounts
• Removal and installation of front and rear engine mounts
• Removal and installation of engine shock absorber
• Throttle Linkage
• Adjusting regulating linkage
• Removal and installation of longitudinal regulating shaft
• Removal, installation and adjustment of chassis regulating shaft
• Removal and installation of accelerator pedal
• Lubricating regulating linkage and regulating shafts
• Fuel Tank
• Removal and installation of fuel tank
• Removal and installation of fuel expansion tank
• Removal and installation of transmitter for fuel readout
• Operation of fuel evaporation control system
• Checking fuel evaporation control system
• Operation of fuel cooler
• Exhaust System
• Removal and installation of exhaust system

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