2004 Mercedes-Benz C240 Service & Repair Manual Software
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🏷️ Basic Information Identification Make: Mercedes-Benz Model: C240 Year: 2004 Codes Chassis Code: W203 👋 Introduction Market Position Segment: Entry-level luxury compact executive sedan Competitive Analysis Key Competitors 2004: BMW 3 Series (E46), Audi A4 (B6), Lexus IS 300, Acura TL. Key Features Brand Philosophy: Mercedes-Benz's reputation for engineering excellence, safety, and luxury at a more accessible price point within the brand's lineup. Vehicle Strengths: Comfortable ride, refined interior, strong safety features, sophisticated styling. Manual Value Proposition Benefit To Owner: Empowers owners and independent repair shops with detailed, accurate information for efficient and correct maintenance and repair, potentially saving on dealership labor costs. 📋 Manual Details Coverage Areas Engine Coverage: M112.912 (2.6L V6) Transmission Coverage: 722.6 (5G-TRONIC Automatic) Body Style Coverage: Sedan Page Count Estimated Pages: 1500+ Manual Type Type: Official Service and Repair Manual Software Language Language: English Format Format: Software (Digital) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, emissions control, cooling system, lubrication system, starter, charging system, automatic transmission. Chassis: Front suspension, rear suspension, steering system, brake system (hydraulic, ABS, ESP), wheels, tires. Electrical: Body electrical systems, lighting, instrumentation, climate control, power accessories, CAN bus communication, diagnostic trouble codes (DTCs). Body And Trim: Body panels, doors, windows, interior trim, seats, exterior trim. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, brake pad replacement, spark plug replacement. Repair: Engine component repair and replacement, transmission overhaul, suspension component repair, brake caliper overhaul, electrical component diagnosis and repair. Diagnostics: Troubleshooting guides, diagnostic flowcharts, symptom-based diagnostics, OBD-II diagnostics. Specifications: Torque specifications, clearances, fluid capacities, electrical schematics, wiring diagrams. Technical Depth Depth: Comprehensive diagnostic and repair procedures, including detailed component removal and installation, internal component repair, and system calibration. 📊 Manual Specifications File Format Software Type: Executable application or PDF viewer-compatible file Searchability: Full text search functionality Print Quality Print Capability: Printable sections and diagrams Binding Type Binding: N/A (Software) Paper Type Paper Type: N/A (Software) ⚙️ Engine Specifications Primary Engine Engine Code: M112.912 Configuration: V6 Displacement: 2.6 Liters (2597 cc) Bore X Stroke: 89.9 mm x 68.2 mm Compression Ratio: 10.5:1 Performance Horsepower: 168 hp @ 5700 rpm Torque: 177 lb-ft (240 Nm) @ 4500 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Sequential Port Injection Fuel Type: Premium Unleaded Gasoline (91 octane recommended) Engine Management ECU Type: ME 2.8.x or later variants Emissions Control: Dual catalytic converters, secondary air injection, EGR (where applicable). 🔧 Transmission Standard Type: 5G-TRONIC Automatic (722.6) Gear Ratios: 1: 3.59, 2: 2.19, 3: 1.41, 4: 1.00, 5: 0.73, R: 3.41 Features Shift Modes: Comfort (C) and Sport (S) modes Transmission Fluid: MB 236.10 or MB 236.12 Specification Automatic Transmission Fluid Transmission Fluid Fluid Capacity: Approximately 7.5 - 8.0 Liters (dry fill), 6.5 Liters (pan drop and fill). 📐 Dimensions Exterior Length: 177.9 inches (4519 mm) Width: 68.0 inches (1727 mm) Height: 55.9 inches (1420 mm) Wheelbase: 106.7 inches (2710 mm) Interior Front Headroom: 37.8 inches (960 mm) Rear Headroom: 37.2 inches (945 mm) Front Legroom: 41.7 inches (1059 mm) Rear Legroom: 33.4 inches (848 mm) Cargo Trunk Volume: 13.1 cubic feet (370 liters) Weights Curb Weight: 3395 lbs (1540 kg) Gross Vehicle Weight Rating: 4553 lbs (2065 kg) 🛡️ Safety Features Ratings NHTSA Front Crash Test: 5-Star Driver, 5-Star Passenger IIHS Front Crash Test: Good Active Features Traction Control: ASR (Acceleration Slip Regulation) Electronic Stability Control: ESP (Electronic Stability Program) Braking System: Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Brake Assist (BAS) Passive Features Airbags: Front dual-stage airbags, front side-impact airbags, front and rear side-curtain airbags (optional or standard depending on package). Seatbelts: Pretensioners and force limiters for front seats, three-point belts for all seating positions. Body Structure: High-strength steel safety cage, crumple zones. 💡 Technology Features Infotainment Audio System: Optional Audio 20 or COMAND (Cockpit Management and Navigation Display) system with CD player, AM/FM radio, and optional navigation module. Speaker Configuration: Typically 6-8 speakers, with optional Bose sound system. Driver Assistance Cruise Control: Standard cruise control with speed limiter function. Parking Assistance: Optional Parktronic parking sensors (front and rear). Connectivity Telephone Preparation: Optional UHI (Universal Holder for Integrate Audio) interface for Bluetooth or phone cradle connectivity. Other Features Climate Control: Standard or optional automatic climate control (THERMATIC or THERMATIC with dual-zone control). 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10,000 miles (16,000 km) or 1 year, whichever comes first, using synthetic oil (ASO condition monitoring system can adjust based on driving style). Major Service Interval A: Approx. 15,000 miles (24,000 km) - Oil and filter change, tire rotation, inspection of basic components. Major Service Interval B: Approx. 30,000 miles (48,000 km) - Service A plus cabin air filter, engine air filter, brake fluid flush, spark plug replacement (typically around 100k miles). Fluid Specifications Engine Oil Type: MB 229.5 Specification Synthetic Engine...
Empowers owners and independent repair shops with detailed, accurate information for efficient and correct maintenance and repair, potentially saving on dealership labor costs.
Comprehensive diagnostic and repair procedures, including detailed component removal and installation, internal component repair, and system calibration.
📊 Manual Specifications
File Format
Software Type:
Executable application or PDF viewer-compatible file
Searchability:
Full text search functionality
Print Quality
Print Capability:
Printable sections and diagrams
Binding Type
Binding:
N/A (Software)
Paper Type
Paper Type:
N/A (Software)
⚙️ Engine Specifications
Primary Engine
Engine Code:
M112.912
Configuration:
V6
Displacement:
2.6 Liters (2597 cc)
Bore X Stroke:
89.9 mm x 68.2 mm
Compression Ratio:
10.5:1
Performance
Horsepower:
168 hp @ 5700 rpm
Torque:
177 lb-ft (240 Nm) @ 4500 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Sequential Port Injection
Fuel Type:
Premium Unleaded Gasoline (91 octane recommended)
Engine Management
ECU Type:
ME 2.8.x or later variants
Emissions Control:
Dual catalytic converters, secondary air injection, EGR (where applicable).
MB 236.10 or MB 236.12 Specification Automatic Transmission Fluid
Transmission Fluid
Fluid Capacity:
Approximately 7.5 - 8.0 Liters (dry fill), 6.5 Liters (pan drop and fill).
📐 Dimensions
Exterior
Length:
177.9 inches (4519 mm)
Width:
68.0 inches (1727 mm)
Height:
55.9 inches (1420 mm)
Wheelbase:
106.7 inches (2710 mm)
Interior
Front Headroom:
37.8 inches (960 mm)
Rear Headroom:
37.2 inches (945 mm)
Front Legroom:
41.7 inches (1059 mm)
Rear Legroom:
33.4 inches (848 mm)
Cargo
Trunk Volume:
13.1 cubic feet (370 liters)
Weights
Curb Weight:
3395 lbs (1540 kg)
Gross Vehicle Weight Rating:
4553 lbs (2065 kg)
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
5-Star Driver, 5-Star Passenger
IIHS Front Crash Test:
Good
Active Features
Traction Control:
ASR (Acceleration Slip Regulation)
Electronic Stability Control:
ESP (Electronic Stability Program)
Braking System:
Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Brake Assist (BAS)
Passive Features
Airbags:
Front dual-stage airbags, front side-impact airbags, front and rear side-curtain airbags (optional or standard depending on package).
Seatbelts:
Pretensioners and force limiters for front seats, three-point belts for all seating positions.
Body Structure:
High-strength steel safety cage, crumple zones.
💡 Technology Features
Infotainment
Audio System:
Optional Audio 20 or COMAND (Cockpit Management and Navigation Display) system with CD player, AM/FM radio, and optional navigation module.
Speaker Configuration:
Typically 6-8 speakers, with optional Bose sound system.
Driver Assistance
Cruise Control:
Standard cruise control with speed limiter function.
Parking Assistance:
Optional Parktronic parking sensors (front and rear).
Connectivity
Telephone Preparation:
Optional UHI (Universal Holder for Integrate Audio) interface for Bluetooth or phone cradle connectivity.
Other Features
Climate Control:
Standard or optional automatic climate control (THERMATIC or THERMATIC with dual-zone control).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 miles (16,000 km) or 1 year, whichever comes first, using synthetic oil (ASO condition monitoring system can adjust based on driving style).
Major Service Interval A:
Approx. 15,000 miles (24,000 km) - Oil and filter change, tire rotation, inspection of basic components.
Major Service Interval B:
Approx. 30,000 miles (48,000 km) - Service A plus cabin air filter, engine air filter, brake fluid flush, spark plug replacement (typically around 100k miles).
MB 325.0 Specification Ethylene Glycol Based Coolant (typically a blue or green silicate-free formula)
Brake Fluid Type:
DOT 4 Plus (MB 331.0 Specification)
Known Issues
Common Failures Or Concerns:
Cracked dashboard (especially in hot climates), HVAC blower motor resistor failure, OVP relay issues (older models, less common on W203 but still possible), oil cooler seal leaks, ABS/ESP sensor issues, transmission conductor plate failures (722.6).
Preventative Maintenance Tips:
Regularly inspect and replace PCV valve, clean throttle body, ensure proper cooling system maintenance, use quality fluids and filters.
📚 Vehicle History
Brand Heritage
Founding Year:
1926 (Merger of Benz & Cie. and Daimler-Motoren-Gesellschaft)
Key Innovations:
Invention of the automobile (Benz Patent-Motorwagen), early development of safety features (crumple zones, ABS, airbags).
Model Evolution
C Class Introduction:
First introduced as the 190 E in 1982 (W201 chassis), later becoming the C-Class.
W203 Generation Launch:
Launched in 1997 (Europe) and 1998 (North America) as the second generation of the C-Class.
W203 Facelift:
Received a significant facelift for the 2005 model year, introducing revised styling and some updated features. The 2004 model represents the pre-facelift W203.
Production
Manufacturing Locations:
Bremen, Germany; East London, South Africa; Tuscaloosa, Alabama, USA (for specific C-Class models and markets).
🏆 Awards & Recognition
Recognitions
IIHS Top Safety Picks:
While specific year awards for the C240 might vary, the W203 platform generally performed well in safety tests, leading to frequent 'Good' ratings from IIHS and 5-star NHTSA ratings for frontal impacts.
Consumer Reports Reliability:
Reliability ratings can vary by model year and specific components; the W203 generation had some known issues but was generally considered competitive within its segment for its era.