Introduction
This manual provides comprehensive service and repair information for Mercedes-Benz C-Class (W202) models manufactured between 1993 and August 2000. It covers petrol and diesel engine variants, including Saloon and Estate body styles. The content is designed to assist owners and technicians in performing maintenance, repairs, and overhauls with detailed, step-by-step instructions and illustrations.
The manual is structured into logical sections, beginning with routine checks and progressing to more complex repair procedures for various vehicle systems. Adherence to the procedures outlined herein will help ensure the safe and efficient operation of your vehicle.
Image Description: The cover of the Mercedes-Benz C-Class Service and Repair Manual. It features a green Mercedes-Benz C-Class sedan with the hood open, revealing the engine bay. The title "MERCEDES-BENZ C180, C200, C220, C230 & C250" is prominently displayed, along with the years "1993 to August 2000" and "Petrol & Diesel". The Haynes logo is visible in the top right corner.
Safety Information
Always prioritize safety when working on your vehicle. Before commencing any procedure, ensure you have read and understood all relevant instructions. Observe the following general safety guidelines:
- Wear appropriate personal protective equipment (PPE), such as safety glasses and gloves.
- Ensure the vehicle is securely supported on jack stands before working underneath it. Never rely solely on a jack.
- Disconnect the battery's negative terminal before working on electrical components to prevent accidental short circuits.
- Allow the engine and exhaust system to cool down before working on them to avoid burns.
- Be aware of hazardous fluids (e.g., engine oil, coolant, brake fluid) and dispose of them responsibly.
- Work in a well-ventilated area, especially when dealing with fuel or exhaust fumes.
- Keep a fire extinguisher readily available.
Routine Maintenance and Servicing
Regular maintenance is crucial for the longevity and reliable operation of your Mercedes-Benz C-Class. This section outlines routine checks and servicing procedures.
Weekly Checks
- Engine oil level
- Coolant level
- Brake and clutch fluid level
- Power steering fluid level
- Washer fluid level
- Wiper blades condition
- Tyre condition and pressure
- Battery condition
- Bulbs and fuses operation
Maintenance Schedule (Petrol Models)
The following table provides a general overview of maintenance intervals for petrol models. Refer to the detailed manual for specific procedures and intervals.
Image Description: A page from the manual detailing routine maintenance and servicing for petrol models. It includes instructions for checking evaporative emission control charcoal canister renewal, clutch friction disc check, and automatic transmission fluid level check. Diagrams illustrate the clutch friction disc wear checking gauge and the process for checking the automatic transmission fluid level.
Repairs and Overhaul
This section covers detailed procedures for repairing and overhauling various engine and associated systems components.
Engine and Associated Systems
- Petrol engine in-car repair procedures
- Diesel engine in-car repair procedures
- Engine removal and general engine overhaul procedures
- Cooling, heating and ventilation systems
- Fuel system - multipoint petrol injection
- Fuel system - diesel
- Emission control and exhaust systems
- Starting and charging systems
- Ignition system - petrol engines
- Pre-heating system - diesel engines
Image Description: A page from the manual detailing petrol engine in-car repair procedures, specifically for camshafts and hydraulic tappets. It includes step-by-step instructions for removing and refitting the camshaft cover, adjusting the timing chain tensioner, and removing the camshafts. Several small images illustrate these steps, such as "refit the cover", "insert the bolts and tighten to the specified torque", and "removing the oil pump tensioner from the pin on the front of the cylinder block".
Image Description: A page from the manual illustrating petrol engine in-car repair procedures, focusing on the cylinder head. It provides detailed instructions for lowering the cylinder head onto the cylinder block, inserting cylinder head bolts, and the correct tightening sequence for the cylinder head bolts. Multiple diagrams and images accompany the text, showing the cylinder head bolt tightening sequence and various stages of the cylinder head installation.
Specifications (Petrol Models)
The following tables provide key specifications for Mercedes-Benz C-Class petrol models. These values are essential for proper maintenance and repair.
Image Description: A page from the manual titled "Specifications - petrol models". It lists capacities for engine oil, cooling system, transmission, power-assisted steering, and fuel tank. It also provides details for the cooling system (antifreeze mixture), ignition system (spark plugs, electrode gap), brakes (brake pad friction material minimum thickness), and torque wrench settings for various components like engine oil drain plug, transmission fill-level plug, oil filter cap, roadwheel bolts, and spark plugs.
Capacities
| Component | Capacity |
|---|---|
| Engine oil (including oil filter) | 5.8 litres |
| Cooling system (without air conditioning) | 8.0 litres |
| Cooling system (with air conditioning) | 8.5 litres |
| Manual transmission | 1.5 litres |
| Automatic transmission (fluid change) | 5.5 litres |
| Automatic transmission (from dry) | 6.6 litres |
| Final drive unit (all models) | 1.1 litres |
| Power-assisted steering (all models, approximate) | 1.0 litre |
| Fuel tank (total) | 62 litres |
| Fuel tank (reserve) | 7 litres |
Torque Wrench Settings
| Component | Nm | lbf ft |
|---|---|---|
| Engine oil drain plug | 25 | 18 |
| Manual transmission fill-level plug | 60 | 44 |
| Oil filter cap | 25 | 18 |
| Roadwheel bolts | 110 | 81 |
| Spark plugs | 27 | 20 |
Note: Refer to the full manual for complete specifications, including diesel models and additional components.
Wiring Diagrams
This section contains detailed wiring diagrams to assist in diagnosing and repairing electrical systems within the Mercedes-Benz C-Class (W202).
Image Description: A detailed wiring diagram from the manual, labeled "Diagram 2". It shows various electrical components and their connections, including the instrument cluster, battery, terminal 30 feed, and different warning lights. A key to items lists components such as the instrument cluster, brake system warning light, high beam warning light, and oil level switch, along with their corresponding numbers in the diagram. Wire colours are also listed with their abbreviations.
Troubleshooting
This section provides guidance for diagnosing common issues that may arise with your Mercedes-Benz C-Class. It covers various symptoms and potential causes, helping you to identify and resolve problems efficiently.
Common Issues and Solutions
- Engine Cranks but Won't Start: Check fuel supply, ignition system, and battery charge.
- Engine Overheating: Inspect coolant level, radiator, thermostat, and cooling fan operation.
- Brake System Malfunction: Check brake fluid level, brake pad wear, and inspect for leaks.
- Electrical System Problems: Verify battery connections, fuse integrity, and alternator output. Refer to wiring diagrams for specific circuit diagnosis.
- Unusual Noises: Identify the source of the noise (e.g., engine, suspension, brakes) and consult the relevant repair section.
For detailed diagnostic procedures and specific fault codes, refer to the dedicated troubleshooting chapters within the full manual.
Support
For further assistance or specific technical queries not covered in this manual, it is recommended to consult a qualified Mercedes-Benz service technician or an authorized service center. Always ensure that any parts used for replacement are genuine Mercedes-Benz parts or approved equivalents to maintain vehicle integrity and safety.
This manual is a product of Haynes, a reputable publisher of automotive repair manuals. For additional resources or to purchase other related publications, please visit the official Haynes website.
