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Mercedes Benz C Class Complete Workshop Service Repair Manual 2001 2002 2003 2004 2005 2006 2007

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The C-Class, codenamed W203, represents the compact executive luxury segment, known for its elegant styling, refined interior, and a strong emphasis on safety and comfort. Produced from 2001 to 2007, this generation offered a range of efficient and powerful gasoline and diesel engines, including supercharged variants, paired with either manual or automatic transmissions. The C-Class was designed to be a competitive and modern vehicle, building upon a legacy of engineering excellence and longevity. Its sophisticated design philosophy, coupled with innovative technologies like advanced safety systems and climate control, made it a popular choice for individuals seeking premium quality and performance in a compact luxury package. This comprehensive workshop service and repair manual provides detailed information for the diagnosis, repair, and maintenance of the C-Class (W203) models from 2001 to 2007. It covers all gasoline and diesel engine variants, automatic and manual transmissions, and sedan, coupe, and wagon body styles. The manual includes extensive coverage of engine mechanicals, fuel and ignition systems, brakes, suspension, steering, and the complete electrical system, along with detailed procedures for routine maintenance, component removal and installation, troubleshooting, and rebuilds. This resource is invaluable for owners, mechanics, and technicians aiming to maintain and repair the vehicle with accuracy and efficiency. 🏷️ Basic Information Identification Make: Mercedes-Benz Model: C-Class Generation Codename: W203 Model Years Covered By Manual: 2001, 2002, 2003, 2004, 2005, 2006, 2007 👋 Introduction Market Position Segment: Compact Executive / Entry-Level Luxury Target Audience: Individuals seeking premium quality, comfort, and performance in a compact luxury vehicle Competitive Analysis Key Competitors: BMW 3 Series (E46), Audi A4 (B6), Lexus IS, Volvo S60 Key Features Of Vehicle Design Philosophy: Elegant styling, refined interior, strong emphasis on safety and comfort Powertrain Options: Range of efficient and powerful inline-4 and V6 gasoline engines, and common-rail diesel engines Innovative Technologies: Advanced safety systems (e.g., ESP, PRE-SAFE availability), sophisticated climate control 📋 Manual Details Coverage Areas Comprehensive Coverage: Yes Engine Coverage: All gasoline and diesel variants for the specified years Transmission Coverage: Automatic and Manual transmissions Body Style Coverage: Sedan, Coupe, and Wagon (T-Model) Page Count Estimated Page Count: Extensive (typically 2000+ pages for a complete workshop manual) Manual Type Type: Complete Workshop Service and Repair Manual Purpose: Diagnosis, repair, maintenance, and overhaul procedures Language Language: English Format Format: Downloadable Digital Format (typically PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, pistons, crankshaft, camshafts, timing, lubrication, cooling Engine Management: Fuel injection, ignition system, electronic control unit (ECU), sensors, emission control Transmission Mechanical: Automatic transmission (e.g., 722.6 '5G-TRONIC') overhaul, manual transmission overhaul, clutch Transmission Electronic: Transmission control module (TCM) diagnostics, shifting solenoids, mechatronics unit Brakes: Hydraulic system, ABS, ESP (Electronic Stability Program), brake pads, rotors, calipers, parking brake Suspension: Front and rear suspension components, shock absorbers, springs, bushings, alignment Steering: Power steering system, steering rack, steering column, tie rod ends Electrical System Overview: 12V battery, alternator, starter, wiring diagrams, fuses, relays Body Electrical: Lighting, wipers, power windows, door locks, mirrors, seats, interior trim Climate Control: HVAC system, A/C compressor, refrigerant, heater core, climate control module Infotainment Audio: COMAND system, Audio 20, speaker systems, antenna module (coverage may vary) Safety Systems: Airbags (SRS), seatbelt pretensioners, crash sensors Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs Component Removal Installation: Engine, transmission, suspension components, brake assemblies, body panels, interior components Troubleshooting Diagnostics: Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, electrical testing procedures Rebuild Procedures: Engine and transmission overhaul procedures, detailed step-by-step instructions Electrical Diagnostics: Wiring diagrams interpretation, component testing, signal tracing Bodywork Repair: Panel replacement, dent repair, rust prevention (general guidelines) Specifications Data: Torque specifications, clearances, fluid capacities, electrical parameters Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission rebuilds Diagnostic Tools: Information to guide the use of Mercedes-Benz diagnostic tools (e.g., STAR Diagnosis) 📊 Manual Specifications File Format Format: PDF Searchability: Fully searchable text content Printability: Printable pages for ease of use in a workshop environment Print Quality Image Resolution: High-resolution diagrams and illustrations Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Codes Examples: M271 (1.8L/2.0L Supercharged I4), M111 (2.0L Supercharged I4), M112 (2.6L/3.2L V6), OM611 (2.1L Diesel I4), OM646 (2.1L Diesel I4) Performance Horsepower Range: Approx. 120 HP (C200 CDI) to 272 HP (C350) Torque Range: Approx. 200 Nm (C200 CDI) to 350 Nm (C320 CDI) Fuel System Fuel Delivery Gasoline: Electronic Fuel Injection (EFI) / Sequential Multipoint Fuel Injection (SMPI) Fuel Delivery Diesel: Common Rail Direct Injection (CDI) Engine Features Supercharging: Availability of supercharged engines (e.g., M271 Kompressor) Valvetrain: DOHC (Double Overhead Camshafts), 4 valves per cylinder Emission Control: Catalytic converters, EGR (Exhaust Gas Recirculation) for diesel models 🔧 Transmission Standard Standard Transmission Type: 5-speed or 6-speed Manual Transmission (RWD) Optional Optional Transmission Type: 5-speed or 7-speed Automatic...
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Mercedes Benz C Class Complete Workshop Service Repair Manual 2001 2002 2003 2004 2005 2006 2007Mercedes Benz C Class Complete Workshop Service Repair Manual 2001 2002 2003 2004 2005 2006 2007Mercedes Benz C Class Complete Workshop Service Repair Manual 2001 2002 2003 2004 2005 2006 2007Mercedes Benz C Class Complete Workshop Service Repair Manual 2001 2002 2003 2004 2005 2006 2007
The C-Class, codenamed W203, represents the compact executive luxury segment, known for its elegant styling, refined interior, and a strong emphasis on safety and comfort. Produced from 2001 to 2007, this generation offered a range of efficient and powerful gasoline and diesel engines, including supercharged variants, paired with either manual or automatic transmissions. The C-Class was designed to be a competitive and modern vehicle, building upon a legacy of engineering excellence and longevity. Its sophisticated design philosophy, coupled with innovative technologies like advanced safety systems and climate control, made it a popular choice for individuals seeking premium quality and performance in a compact luxury package. This comprehensive workshop service and repair manual provides detailed information for the diagnosis, repair, and maintenance of the C-Class (W203) models from 2001 to 2007. It covers all gasoline and diesel engine variants, automatic and manual transmissions, and sedan, coupe, and wagon body styles. The manual includes extensive coverage of engine mechanicals, fuel and ignition systems, brakes, suspension, steering, and the complete electrical system, along with detailed procedures for routine maintenance, component removal and installation, troubleshooting, and rebuilds. This resource is invaluable for owners, mechanics, and technicians aiming to maintain and repair the vehicle with accuracy and efficiency.
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
C-Class
Generation Codename:
W203
Model Years Covered By Manual:
2001, 2002, 2003, 2004, 2005, 2006, 2007
👋 Introduction
Market Position
Segment:
Compact Executive / Entry-Level Luxury
Target Audience:
Individuals seeking premium quality, comfort, and performance in a compact luxury vehicle
Competitive Analysis
Key Competitors:
BMW 3 Series (E46), Audi A4 (B6), Lexus IS, Volvo S60
Key Features Of Vehicle
Design Philosophy:
Elegant styling, refined interior, strong emphasis on safety and comfort
Powertrain Options:
Range of efficient and powerful inline-4 and V6 gasoline engines, and common-rail diesel engines
Innovative Technologies:
Advanced safety systems (e.g., ESP, PRE-SAFE availability), sophisticated climate control
📋 Manual Details
Coverage Areas
Comprehensive Coverage:
Yes
Engine Coverage:
All gasoline and diesel variants for the specified years
Transmission Coverage:
Automatic and Manual transmissions
Body Style Coverage:
Sedan, Coupe, and Wagon (T-Model)
Page Count
Estimated Page Count:
Extensive (typically 2000+ pages for a complete workshop manual)
Manual Type
Type:
Complete Workshop Service and Repair Manual
Purpose:
Diagnosis, repair, maintenance, and overhaul procedures
Language
Language:
English
Format
Format:
Downloadable Digital Format (typically PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, pistons, crankshaft, camshafts, timing, lubrication, cooling
Engine Management:
Fuel injection, ignition system, electronic control unit (ECU), sensors, emission control
Transmission Mechanical:
Automatic transmission (e.g., 722.6 '5G-TRONIC') overhaul, manual transmission overhaul, clutch
Transmission Electronic:
Transmission control module (TCM) diagnostics, shifting solenoids, mechatronics unit
Brakes:
Hydraulic system, ABS, ESP (Electronic Stability Program), brake pads, rotors, calipers, parking brake
Suspension:
Front and rear suspension components, shock absorbers, springs, bushings, alignment
Steering:
Power steering system, steering rack, steering column, tie rod ends
Electrical System Overview:
12V battery, alternator, starter, wiring diagrams, fuses, relays
Body Electrical:
Lighting, wipers, power windows, door locks, mirrors, seats, interior trim
Climate Control:
HVAC system, A/C compressor, refrigerant, heater core, climate control module
Infotainment Audio:
COMAND system, Audio 20, speaker systems, antenna module (coverage may vary)
Safety Systems:
Airbags (SRS), seatbelt pretensioners, crash sensors
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs
Component Removal Installation:
Engine, transmission, suspension components, brake assemblies, body panels, interior components
Troubleshooting Diagnostics:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, electrical testing procedures
Rebuild Procedures:
Engine and transmission overhaul procedures, detailed step-by-step instructions
Electrical Diagnostics:
Wiring diagrams interpretation, component testing, signal tracing
Bodywork Repair:
Panel replacement, dent repair, rust prevention (general guidelines)
Specifications Data:
Torque specifications, clearances, fluid capacities, electrical parameters
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds
Diagnostic Tools:
Information to guide the use of Mercedes-Benz diagnostic tools (e.g., STAR Diagnosis)
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Fully searchable text content
Printability:
Printable pages for ease of use in a workshop environment
Print Quality
Image Resolution:
High-resolution diagrams and illustrations
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Codes Examples:
M271 (1.8L/2.0L Supercharged I4), M111 (2.0L Supercharged I4), M112 (2.6L/3.2L V6), OM611 (2.1L Diesel I4), OM646 (2.1L Diesel I4)
Performance
Horsepower Range:
Approx. 120 HP (C200 CDI) to 272 HP (C350)
Torque Range:
Approx. 200 Nm (C200 CDI) to 350 Nm (C320 CDI)
Fuel System
Fuel Delivery Gasoline:
Electronic Fuel Injection (EFI) / Sequential Multipoint Fuel Injection (SMPI)
Fuel Delivery Diesel:
Common Rail Direct Injection (CDI)
Engine Features
Supercharging:
Availability of supercharged engines (e.g., M271 Kompressor)
Valvetrain:
DOHC (Double Overhead Camshafts), 4 valves per cylinder
Emission Control:
Catalytic converters, EGR (Exhaust Gas Recirculation) for diesel models
🔧 Transmission
Standard
Standard Transmission Type:
5-speed or 6-speed Manual Transmission (RWD)
Optional
Optional Transmission Type:
5-speed or 7-speed Automatic Transmission (RWD, 4MATIC AWD available on select models)
Features
Automatic Features:
Tiptronic (manual shifting capability), Comfort/Sport modes
Manual Gear Ratios:
Specific ratios provided in the manual for each engine variant
Fluid Specifications
Automatic Transmission Fluid:
MB-Approval 236.10 or 236.14 (e.g., ATF LT 71141 or equivalent)
Manual Transmission Fluid:
MB-Approval 235.10 or equivalent GL-4/GL-5 gear oil (specific viscosity to be checked)
📐 Dimensions
Exterior
Wheelbase:
Approx. 2715 mm (106.9 in)
Length:
Approx. 4526 mm (178.2 in) for Sedan
Width:
Approx. 1729 mm (68.1 in)
Height:
Approx. 1407 mm (55.4 in) for Sedan
Cargo
Trunk Volume:
Approx. 455 liters (16.1 cu ft) for Sedan
Weights
Curb Weight Range:
Approx. 1450 kg - 1650 kg (3200 lbs - 3630 lbs) depending on engine and options
Towing Capacity:
Generally not specified for standard passenger models, check local regulations and manual
🛡️ Safety Features
Ratings
NHTSA Rating:
Good in frontal offset and side impact tests (IIHS, based on available data for the era)
Euro Ncap Rating:
4 stars (for early W203 models, updated ratings might apply)
Active Features
Stability Control:
Standard ESP (Electronic Stability Program) across most models
Traction Control:
Standard TCS (Traction Control System)
Braking Systems:
ABS (Anti-lock Braking System), Brake Assist (BAS)
Passive Features
Airbags:
Frontal airbags, side airbags, optional curtain airbags
Seatbelts:
3-point inertia-reel seatbelts with pretensioners and force limiters
Structural Safety:
High-strength steel passenger cell, crumple zones
💡 Technology Features
Infotainment
Audio Systems:
Audio 20 (basic radio/CD), COMAND 2.0/2.5 (enhanced system with navigation, color screen)
Navigation:
Optional COMAND navigation system (CD-ROM based)
Driver Assistance
Parking Assist:
Optional Parktronic parking sensors
Cruise Control:
Standard cruise control and speed limiter (TEMPOMAT)
Connectivity
Phone Integration:
Optional integrated hands-free telephone systems, Bluetooth interface (later models)
Comfort Features
Seating:
Electrically adjustable seats with memory functions (optional)
Lighting:
Xenon headlamps with automatic leveling (optional)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first (based on 'FlexService' interval, can vary)
Major Service Interval:
e.g., 'Service B' at approx. 30,000 km (18,600 miles) or 24 months, including air filter, cabin filter, spark plugs (depending on engine)
Transmission Service:
Automatic: Typically around 60,000 km (37,000 miles) for fluid and filter change. Manual: Less frequent, check clutch wear.
Brake Fluid Change:
Every 2 years, regardless of mileage
Fluid Specifications
Engine Oil Specification:
MB-Approval 229.3, 229.5, or 229.51 (e.g., SAE 0W-40, 5W-30, 5W-40 depending on engine and climate)
Coolant Specification:
MB-Approval 325.0 or 326.0 (Antifreeze/Coolant - typically blue or green)
Power Steering Fluid:
MB-Approval 343.0 (Pentosin CHF 11 S equivalent) or MB-Approval 345.0
Known Issues
Common Wear Items:
Front control arm bushings, ball joints, blower motor resistor, MAF sensor (certain engines)
Electrical Concerns:
Window regulator failures, SAM unit issues (Signal Acquisition Module), CAN bus communication problems
Engine Specific:
M271 Kompressor: Timing chain stretch, oil leaks from valve cover gasket. OM646/OM611: Glow plug issues, potential turbocharger problems.
Transmission Specific:
722.6 (5-speed auto): Conductor plate failure, torque converter seal leaks, solenoids.
📚 Vehicle History
Brand Heritage
Mercedes Benz Legacy:
Renowned for engineering excellence, luxury, safety, and longevity
Model Evolution
W203 Introduction:
Introduced in 2000, succeeding the W202 C-Class. Designed to be more modern and competitive.
Facelift:
Received a significant facelift in 2004, introducing revised styling, interior enhancements, and updated technology.
Performance Variants:
Included AMG variants like the C32 AMG and C55 AMG, offering enhanced performance.
Production
Production Period:
2000 - 2007
Manufacturing Locations:
Primarily Germany (Sindelfingen, Bremen), also South Africa, and other international locations.
🏆 Awards & Recognition
Recognitions
Previous Generation Acclaim:
The W202 C-Class (predecessor) was highly acclaimed, setting a high bar for the W203.
Design Awards:
While specific awards for the W203 might be varied, its design was generally well-received for its modern and sophisticated appeal.
Safety Acclaim:
Consistently ranked well in safety tests for its era, contributing to Mercedes-Benz's reputation for safety.
Ratings
Customer Satisfaction:
Generally high customer satisfaction for build quality, comfort, and driving dynamics, despite some noted mechanical and electrical quirks.
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