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Introduction
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Market Position
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Segment:
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Compact Executive Sedan (entry-level luxury)
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Target Audience:
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Professionals, families seeking a blend of comfort, safety, and luxury from a reputable German manufacturer
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Competitive Analysis
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Key Competitors:
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BMW 3 Series (E36/E46), Audi A4 (B5/B6), Lexus IS200/IS300, Acura TL
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Key Features
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Brand Reputation:
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Mercedes-Benz known for build quality, safety, and sophisticated engineering
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Powertrain Philosophy:
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Smooth, refined V6 engine providing a balance of performance and efficiency for its era
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Interior Design:
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Focus on driver ergonomics, premium materials, and a classic Mercedes-Benz aesthetic
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Manual Value Proposition:
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Comprehensive, factory-level documentation enabling in-depth maintenance and repair, saving on dealership labor costs.
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Manual Details
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Coverage Areas
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Covered Years:
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1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
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Covered Models:
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C240 (specific to this engine variant)
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Page Count
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Page Count Estimate:
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Hundreds of pages (exact count not specified, but described as very detailed)
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Manual Type
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Manual Type:
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Factory Service Repair Workshop Manual
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Language
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Language:
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English (assumed based on product description)
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Format
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Format:
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Downloadable PDF
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Manual Coverage
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Systems Covered
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Engine:
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Complete engine overhaul, repair, troubleshooting, timing, cooling, lubrication, fuel injection, emissions control
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Transmission:
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Automatic transmission (likely 5G-Tronic 722.6), repair, servicing, diagnostics, fluid specifications
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Drivetrain:
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Rear-wheel drive system, differential, driveshafts, axle shafts, bearing service
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Suspension:
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Front and rear suspension components, shock absorbers, springs, control arms, bushings, wheel alignment
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Brakes:
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Hydraulic brake system, ABS, brake pads, rotors, calipers, lines, master cylinder, bleeding procedures
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Steering:
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Power steering system, steering rack, pump, fluid, steering column
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Electrical System:
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Battery, charging system (alternator), starting system (starter), ignition system, lighting, fuses, relays, wiring diagrams
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Climate Control:
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HVAC system, A/C compressor, refrigerant, blower motor, heater core, climate control unit
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Body And Trim:
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Exterior body panels, interior trim, door mechanisms, window regulators, locks, mirrors, bumpers
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Body Electronics:
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Power windows, power locks, remote keyless entry, central locking system, instrument cluster
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Procedures Included
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Maintenance:
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Routine maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt replacement
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Troubleshooting:
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Diagnostic procedures for common and complex issues, fault code interpretation (if applicable to the era)
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Repair:
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Step-by-step repair instructions for all major vehicle systems
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Overhaul:
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Engine and transmission overhaul procedures
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Component Replacement:
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Detailed instructions for replacing specific parts and components
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Wiring Diagrams:
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Comprehensive electrical wiring diagrams for all systems
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Torque Specifications:
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Torque values for all critical fasteners
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Technical Depth
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Depth:
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Full factory level repair and diagnostic information, suitable for professional mechanics and advanced DIY enthusiasts
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Engine Specifications
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Primary Engine
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Engine Type:
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V6, SOHC (Single Overhead Camshaft, though M112 is DOHC with 3 valves per cylinder)
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Displacement:
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2597 cc (2.6 Liters)
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Bore X Stroke:
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83.2 mm x 78.5 mm (typical for M112 E26)
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Compression Ratio:
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10.5:1 (typical)
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Performance
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Horsepower:
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168 hp @ 5500 rpm (approximate for C240)
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Torque:
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177 lb-ft @ 3500 rpm (approximate for C240)
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Fuel System
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Fuel Induction:
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Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPI)
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Fuel Type:
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Unleaded Gasoline (premium recommended)
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Engine Features
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Valvetrain:
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SOHC with 3 valves per cylinder (2 intake, 1 exhaust), Two spark plugs per cylinder (dual ignition)
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Cooling System:
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Liquid-cooled, pressurized system with electric fan
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Emission Controls:
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Catalytic converter, EGR (Exhaust Gas Recirculation) system (depending on market/year)
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Maintenance
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Service Intervals
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Oil Change Interval:
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Typically every 10,000-15,000 miles or 12-24 months, depending on driving conditions and oil type used (consult manual for specific recommendation).
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Transmission Fluid Change Interval:
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Recommended every 40,000-60,000 miles for the 722.6 transmission. Crucial for longevity.
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Spark Plug Replacement:
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Often around 60,000-100,000 miles, depending on spark plug type (e.g., iridium or platinum).
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Coolant Flush:
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Recommended every 2-3 years or 30,000-50,000 miles.
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Fluid Specifications
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Engine Oil Type:
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MB 229.1 or MB 229.5 specifications, typically a 0W-40 or 5W-40 synthetic viscosity.
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Engine Oil Capacity:
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Approximately 6.5 liters (6.9 US quarts) for the 2.6L V6 with filter change.
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Coolant Type:
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MB 325.0 or MB 326.0 (Ethylene Glycol based, usually blue or green)
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Brake Fluid Type:
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DOT 3 or DOT 4
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Known Issues
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Common Issues Engine:
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Vacuum leaks (affecting idle and performance), PCV valve issues, oil leaks (e.g., valve cover gaskets), crankshaft position sensor failures.
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Common Issues Transmission:
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Torque converter seal leaks, transmission control module (TCM) issues, electro-hydraulic connector seal leaks (K1/K2 seals in 722.6).
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Common Issues Suspension:
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Worn control arm bushings, ball joints, and tie rod ends leading to alignment issues and noise.
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Common Issues Electrical:
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Failing blower motor resistor (HVAC), SAM module issues (Signal Acquisition Module), Mass Air Flow (MAF) sensor inaccuracies, CAN bus communication errors.
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Common Issues Body:
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Rust formation (especially in wheel wells, rocker panels), sagging headliner, worn door seals.
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Filters
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Oil Filter Part Number:
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OEM part numbers vary, but common aftermarket equivalents include Mann-Filter HU 833/1, Bosch 3310, K&N HP-1010.
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Air Filter Part Number:
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OEM part numbers vary, but common aftermarket equivalents include Mann-Filter C35152, Bosch 244245, K&N 33-2143.
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Vehicle History
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Brand Heritage
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Brand Origin:
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Germany, founded by Gottlieb Daimler and Carl Benz, pioneers of the automobile.
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Brand Legacy:
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Long history of innovation in automotive engineering, safety, and luxury.
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Model Evolution
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W202 Introduction:
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The W202 was Mercedes-Benz's first compact executive car, launched in 1993 for the 1994 model year, aimed at a younger demographic and competing with the BMW 3 Series.
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W202 Facelift:
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Received a facelift for the 1997 model year, which included updated styling, interior refinements, and powertrain improvements.
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C240 Engine Introduction:
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The 2.6L V6 engine (M112 E26) was introduced as part of the facelift, replacing some of the inline-4 and inline-6 engines from earlier models, offering improved smoothness and torque.
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Production
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Production Locations:
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Primarily manufactured in Germany (Sindelfingen and Bremen) and also assembled in other countries through CKD (Completely Knocked Down) kits.
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