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Mercedes Benz C240 1994-2005 Full Service & Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: C-Class Model Variant: C240 Chassis Code: W202 Codes Engine Code: M112 E26 (2.6L V6) Production Start Year: 1994 Production End Year: 2005 👋 Introduction Market Position Segment: Compact Executive Sedan (entry-level luxury) Target Audience: Professionals, families seeking a blend of comfort, safety, and luxury from a reputable German manufacturer Competitive Analysis Key Competitors: BMW 3 Series (E36/E46), Audi A4 (B5/B6), Lexus IS200/IS300, Acura TL Key Features Brand Reputation: Mercedes-Benz known for build quality, safety, and sophisticated engineering Powertrain Philosophy: Smooth, refined V6 engine providing a balance of performance and efficiency for its era Interior Design: Focus on driver ergonomics, premium materials, and a classic Mercedes-Benz aesthetic Manual Value Proposition: Comprehensive, factory-level documentation enabling in-depth maintenance and repair, saving on dealership labor costs. 📋 Manual Details Coverage Areas Covered Years: 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Covered Models: C240 (specific to this engine variant) Page Count Page Count Estimate: Hundreds of pages (exact count not specified, but described as very detailed) Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English (assumed based on product description) Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, repair, troubleshooting, timing, cooling, lubrication, fuel injection, emissions control Transmission: Automatic transmission (likely 5G-Tronic 722.6), repair, servicing, diagnostics, fluid specifications Drivetrain: Rear-wheel drive system, differential, driveshafts, axle shafts, bearing service Suspension: Front and rear suspension components, shock absorbers, springs, control arms, bushings, wheel alignment Brakes: Hydraulic brake system, ABS, brake pads, rotors, calipers, lines, master cylinder, bleeding procedures Steering: Power steering system, steering rack, pump, fluid, steering column Electrical System: Battery, charging system (alternator), starting system (starter), ignition system, lighting, fuses, relays, wiring diagrams Climate Control: HVAC system, A/C compressor, refrigerant, blower motor, heater core, climate control unit Body And Trim: Exterior body panels, interior trim, door mechanisms, window regulators, locks, mirrors, bumpers Body Electronics: Power windows, power locks, remote keyless entry, central locking system, instrument cluster Procedures Included Maintenance: Routine maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt replacement Troubleshooting: Diagnostic procedures for common and complex issues, fault code interpretation (if applicable to the era) Repair: Step-by-step repair instructions for all major vehicle systems Overhaul: Engine and transmission overhaul procedures Component Replacement: Detailed instructions for replacing specific parts and components Wiring Diagrams: Comprehensive electrical wiring diagrams for all systems Torque Specifications: Torque values for all critical fasteners Technical Depth Depth: Full factory level repair and diagnostic information, suitable for professional mechanics and advanced DIY enthusiasts 📊 Manual Specifications File Format File Format: PDF Searchability: Likely text-searchable PDF (standard for professional manuals) Print Quality Print Capability: Printable (single pages or entire manual) Binding Type Binding Type: N/A (Digital Download PDF) Paper Type Paper Type: N/A (Digital Download PDF) Compatibility Operating Systems: Compatible with Windows and MAC computers Licensing Licensing Model: Lifetime use, no expiry or renewal fees ⚙️ Engine Specifications Primary Engine Engine Type: V6, SOHC (Single Overhead Camshaft, though M112 is DOHC with 3 valves per cylinder) Displacement: 2597 cc (2.6 Liters) Bore X Stroke: 83.2 mm x 78.5 mm (typical for M112 E26) Compression Ratio: 10.5:1 (typical) Performance Horsepower: 168 hp @ 5500 rpm (approximate for C240) Torque: 177 lb-ft @ 3500 rpm (approximate for C240) Fuel System Fuel Induction: Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (premium recommended) Engine Features Valvetrain: SOHC with 3 valves per cylinder (2 intake, 1 exhaust), Two spark plugs per cylinder (dual ignition) Cooling System: Liquid-cooled, pressurized system with electric fan Emission Controls: Catalytic converter, EGR (Exhaust Gas Recirculation) system (depending on market/year) 🔧 Transmission Standard Transmission Type: 5-speed Automatic (722.6 '5G-TRONIC') Optional Transmission Type Optional: 5-speed Manual (less common, might be available on some earlier models or specific trims) Features Transmission Features: Electronic control unit (TCU), torque converter lock-up clutch, adaptive shift programs Fluid Specifications Transmission Fluid Type: MB 236.10 or MB 236.14 (ATF - Automatic Transmission Fluid) Fluid Capacity Transmission Fluid Capacity: Approximately 8-9 liters for a complete fluid change (including torque converter drain, if applicable) 📐 Dimensions Exterior Length: Approx. 4489 mm (176.7 in) Width: Approx. 1718 mm (67.6 in) Height: Approx. 1402 mm (55.2 in) Wheelbase: Approx. 2717 mm (107.0 in) Weights Curb Weight: Approx. 1450 - 1550 kg (3197 - 3417 lbs) depending on equipment Gross Vehicle Weight Rating: Typically around 2000 kg (4409 lbs) 🛡️ Safety Features Ratings NHTSA Rating: No specific NHTSA ratings readily available for this era, but Mercedes-Benz vehicles of this period were designed to high safety standards. Euro Ncap Rating: Not applicable for North American market launch years; Euro NCAP started in 1997. Early W202 models may not have undergone formal testing. Active Features Traction Control: Often equipped with ASR (Anti-Slip Regulation) traction control. Anti Lock Brakes: Standard...
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Mercedes Benz C240 1994-2005 Full Service & Repair ManualMercedes Benz C240 1994-2005 Full Service & Repair ManualMercedes Benz C240 1994-2005 Full Service & Repair ManualMercedes Benz C240 1994-2005 Full Service & Repair Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
C-Class
Model Variant:
C240
Chassis Code:
W202
Codes
Engine Code:
M112 E26 (2.6L V6)
Production Start Year:
1994
Production End Year:
2005
👋 Introduction
Market Position
Segment:
Compact Executive Sedan (entry-level luxury)
Target Audience:
Professionals, families seeking a blend of comfort, safety, and luxury from a reputable German manufacturer
Competitive Analysis
Key Competitors:
BMW 3 Series (E36/E46), Audi A4 (B5/B6), Lexus IS200/IS300, Acura TL
Key Features
Brand Reputation:
Mercedes-Benz known for build quality, safety, and sophisticated engineering
Powertrain Philosophy:
Smooth, refined V6 engine providing a balance of performance and efficiency for its era
Interior Design:
Focus on driver ergonomics, premium materials, and a classic Mercedes-Benz aesthetic
Manual Value Proposition:
Comprehensive, factory-level documentation enabling in-depth maintenance and repair, saving on dealership labor costs.
📋 Manual Details
Coverage Areas
Covered Years:
1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Covered Models:
C240 (specific to this engine variant)
Page Count
Page Count Estimate:
Hundreds of pages (exact count not specified, but described as very detailed)
Manual Type
Manual Type:
Factory Service Repair Workshop Manual
Language
Language:
English (assumed based on product description)
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, repair, troubleshooting, timing, cooling, lubrication, fuel injection, emissions control
Transmission:
Automatic transmission (likely 5G-Tronic 722.6), repair, servicing, diagnostics, fluid specifications
Drivetrain:
Rear-wheel drive system, differential, driveshafts, axle shafts, bearing service
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, wheel alignment
Brakes:
Hydraulic brake system, ABS, brake pads, rotors, calipers, lines, master cylinder, bleeding procedures
Steering:
Power steering system, steering rack, pump, fluid, steering column
Electrical System:
Battery, charging system (alternator), starting system (starter), ignition system, lighting, fuses, relays, wiring diagrams
Climate Control:
HVAC system, A/C compressor, refrigerant, blower motor, heater core, climate control unit
Body And Trim:
Exterior body panels, interior trim, door mechanisms, window regulators, locks, mirrors, bumpers
Body Electronics:
Power windows, power locks, remote keyless entry, central locking system, instrument cluster
Procedures Included
Maintenance:
Routine maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt replacement
Troubleshooting:
Diagnostic procedures for common and complex issues, fault code interpretation (if applicable to the era)
Repair:
Step-by-step repair instructions for all major vehicle systems
Overhaul:
Engine and transmission overhaul procedures
Component Replacement:
Detailed instructions for replacing specific parts and components
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all systems
Torque Specifications:
Torque values for all critical fasteners
Technical Depth
Depth:
Full factory level repair and diagnostic information, suitable for professional mechanics and advanced DIY enthusiasts
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Likely text-searchable PDF (standard for professional manuals)
Print Quality
Print Capability:
Printable (single pages or entire manual)
Binding Type
Binding Type:
N/A (Digital Download PDF)
Paper Type
Paper Type:
N/A (Digital Download PDF)
Compatibility
Operating Systems:
Compatible with Windows and MAC computers
Licensing
Licensing Model:
Lifetime use, no expiry or renewal fees
⚙️ Engine Specifications
Primary Engine
Engine Type:
V6, SOHC (Single Overhead Camshaft, though M112 is DOHC with 3 valves per cylinder)
Displacement:
2597 cc (2.6 Liters)
Bore X Stroke:
83.2 mm x 78.5 mm (typical for M112 E26)
Compression Ratio:
10.5:1 (typical)
Performance
Horsepower:
168 hp @ 5500 rpm (approximate for C240)
Torque:
177 lb-ft @ 3500 rpm (approximate for C240)
Fuel System
Fuel Induction:
Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (premium recommended)
Engine Features
Valvetrain:
SOHC with 3 valves per cylinder (2 intake, 1 exhaust), Two spark plugs per cylinder (dual ignition)
Cooling System:
Liquid-cooled, pressurized system with electric fan
Emission Controls:
Catalytic converter, EGR (Exhaust Gas Recirculation) system (depending on market/year)
🔧 Transmission
Standard
Transmission Type:
5-speed Automatic (722.6 '5G-TRONIC')
Optional
Transmission Type Optional:
5-speed Manual (less common, might be available on some earlier models or specific trims)
Features
Transmission Features:
Electronic control unit (TCU), torque converter lock-up clutch, adaptive shift programs
Fluid Specifications
Transmission Fluid Type:
MB 236.10 or MB 236.14 (ATF - Automatic Transmission Fluid)
Fluid Capacity
Transmission Fluid Capacity:
Approximately 8-9 liters for a complete fluid change (including torque converter drain, if applicable)
📐 Dimensions
Exterior
Length:
Approx. 4489 mm (176.7 in)
Width:
Approx. 1718 mm (67.6 in)
Height:
Approx. 1402 mm (55.2 in)
Wheelbase:
Approx. 2717 mm (107.0 in)
Weights
Curb Weight:
Approx. 1450 - 1550 kg (3197 - 3417 lbs) depending on equipment
Gross Vehicle Weight Rating:
Typically around 2000 kg (4409 lbs)
🛡️ Safety Features
Ratings
NHTSA Rating:
No specific NHTSA ratings readily available for this era, but Mercedes-Benz vehicles of this period were designed to high safety standards.
Euro Ncap Rating:
Not applicable for North American market launch years; Euro NCAP started in 1997. Early W202 models may not have undergone formal testing.
Active Features
Traction Control:
Often equipped with ASR (Anti-Slip Regulation) traction control.
Anti Lock Brakes:
Standard ABS (Anti-lock Braking System).
Passive Features
Airbags:
Driver and front passenger airbags. Side airbags (optional or standard on later models).
Body Structure:
Reinforced safety cage, crumple zones designed to absorb impact energy.
Seatbelts:
Pre-tensioning seatbelts with force limiters.
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM stereo with cassette or CD player. Optional COMAND (Cockpit Management and Navigation) system on later models with integrated navigation and display.
Speaker System:
Standard 4 or 6 speaker system. Bose sound system often optional.
Driver Assistance
Cruise Control:
Standard cruise control.
Parking Assistance:
Rear parking sensors (Parktronic) became available on later models.
Connectivity
Auxiliary Input:
Not typically available on factory head units from this era. Aftermarket solutions may exist.
Bluetooth:
Not typically available on factory systems. Aftermarket kits or adapters are required.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000-15,000 miles or 12-24 months, depending on driving conditions and oil type used (consult manual for specific recommendation).
Transmission Fluid Change Interval:
Recommended every 40,000-60,000 miles for the 722.6 transmission. Crucial for longevity.
Spark Plug Replacement:
Often around 60,000-100,000 miles, depending on spark plug type (e.g., iridium or platinum).
Coolant Flush:
Recommended every 2-3 years or 30,000-50,000 miles.
Fluid Specifications
Engine Oil Type:
MB 229.1 or MB 229.5 specifications, typically a 0W-40 or 5W-40 synthetic viscosity.
Engine Oil Capacity:
Approximately 6.5 liters (6.9 US quarts) for the 2.6L V6 with filter change.
Coolant Type:
MB 325.0 or MB 326.0 (Ethylene Glycol based, usually blue or green)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Issues Engine:
Vacuum leaks (affecting idle and performance), PCV valve issues, oil leaks (e.g., valve cover gaskets), crankshaft position sensor failures.
Common Issues Transmission:
Torque converter seal leaks, transmission control module (TCM) issues, electro-hydraulic connector seal leaks (K1/K2 seals in 722.6).
Common Issues Suspension:
Worn control arm bushings, ball joints, and tie rod ends leading to alignment issues and noise.
Common Issues Electrical:
Failing blower motor resistor (HVAC), SAM module issues (Signal Acquisition Module), Mass Air Flow (MAF) sensor inaccuracies, CAN bus communication errors.
Common Issues Body:
Rust formation (especially in wheel wells, rocker panels), sagging headliner, worn door seals.
Filters
Oil Filter Part Number:
OEM part numbers vary, but common aftermarket equivalents include Mann-Filter HU 833/1, Bosch 3310, K&N HP-1010.
Air Filter Part Number:
OEM part numbers vary, but common aftermarket equivalents include Mann-Filter C35152, Bosch 244245, K&N 33-2143.
📚 Vehicle History
Brand Heritage
Brand Origin:
Germany, founded by Gottlieb Daimler and Carl Benz, pioneers of the automobile.
Brand Legacy:
Long history of innovation in automotive engineering, safety, and luxury.
Model Evolution
W202 Introduction:
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.
W202 Facelift:
Received a facelift for the 1997 model year, which included updated styling, interior refinements, and powertrain improvements.
C240 Engine Introduction:
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.
Production
Production Locations:
Primarily manufactured in Germany (Sindelfingen and Bremen) and also assembled in other countries through CKD (Completely Knocked Down) kits.
🏆 Awards & Recognition
Recognitions
Initial Reception:
The W202 C-Class was generally well-received for its Mercedes-Benz quality, comfort, and safety, though some criticized its styling compared to competitors.
Safety Awards:
While specific awards for the C240 variant may not be widely documented, Mercedes-Benz vehicles of this period consistently performed well in safety evaluations due to their robust engineering.
Certifications
Emissions Certification:
Compliant with relevant emissions standards for the model year and market of sale (e.g., EPA in the US).
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