Mercedes Benz CLK Class C209 A209 2002-2010 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: CLK Class Chassis Code Coupe: C209 Chassis Code Convertible: A209 Production Years Covered: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Codes Internal Platform Code: W203 derived platform 👋 Introduction Market Position Market Segment: Entry-level luxury coupe and convertible, positioned as a stylish and performance-oriented alternative to traditional sedans. Competitive Analysis Key Competitors: BMW 3 Series Coupe/Convertible (E46/E92/E93), Audi A4 Cabriolet, Lexus SC, Infiniti G35 Coupe. Key Features Design Philosophy: Combines Mercedes-Benz's signature build quality and comfort with a sportier, more dynamic aesthetic. Known for its elegant lines and refined interior. Target Audience: Individuals seeking a premium coupe or convertible experience with a blend of performance, luxury, and everyday usability. 📋 Manual Details Coverage Areas Primary Coverage: North America & European Markets Secondary Coverage: Global variations where applicable Page Count Estimated Page Count: Over 2500 pages (estimated for comprehensive factory data) Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine management (ECU, sensors, actuators). Drivetrain: Automatic transmission (722.6 5-speed, 722.9 7-speed), transfer case (if applicable), drive shafts, differentials, axles. Chassis: Suspension (front & rear), steering system, brakes (ABS, ESP, SBC - Sensotronic Brake Control for early models), wheels, tires. Body: Exterior body panels, doors, hood, trunk, bumpers, glass, convertible top mechanism (for A209), interior trim, seating. Electrical: Body control module (BCM), instrument cluster, lighting (headlights, taillights, interior), power windows, mirrors, seats, infotainment system (COMAND), climate control, SRS (Airbag) system, CAN bus communication. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections and replacement. Repair Procedures: Engine component repair and replacement (e.g., cylinder head, pistons, camshafts), transmission overhaul and component replacement, brake caliper and rotor replacement, suspension arm and bushing replacement, power steering rack replacement, electrical component diagnosis and repair. Diagnostics: Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) and their meanings, sensor testing, actuator testing, circuit testing. Special Tools: Identification and usage of specialized Mercedes-Benz tools required for specific procedures. Technical Depth Depth: Comprehensive factory-level detail, including schematics, wiring diagrams, torque specifications, component locations, diagnostic flowcharts, and step-by-step repair instructions. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, suitable for printing individual pages or the entire manual. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchability Searchable Text: Yes (typically text-searchable PDF for efficient information retrieval) Licensing Licensing Model: One-time purchase, no expiry dates, instant download. ⚙️ Engine Specifications Primary Engine Engine Variant 1: M271 E18 ML (1.8L Supercharged Inline-4) Engine Variant 1 Power: 184 hp @ 5500 rpm Engine Variant 1 Torque: 250 Nm (184 lb-ft) @ 3000-4300 rpm Engine Variant 2: M112 E32 (3.2L V6) Engine Variant 2 Power: 215 hp @ 6000 rpm Engine Variant 2 Torque: 310 Nm (229 lb-ft) @ 3000-4800 rpm Engine Variant 3: M112 E37 (3.7L V6) Engine Variant 3 Power: 238 hp @ 5750 rpm Engine Variant 3 Torque: 345 Nm (254 lb-ft) @ 3000-4500 rpm Engine Variant 4: M272 E35 (3.5L V6) Engine Variant 4 Power: 268 hp @ 6000 rpm Engine Variant 4 Torque: 350 Nm (258 lb-ft) @ 3500-5000 rpm Engine Variant 5: M113 E50 ML (5.0L V8 - CLK500) Engine Variant 5 Power: 302 hp @ 5600 rpm Engine Variant 5 Torque: 460 Nm (339 lb-ft) @ 2700-4250 rpm Engine Variant 6: M113 E55 ML (5.4L Supercharged V8 - CLK55 AMG) Engine Variant 6 Power: 362 hp @ 6100 rpm Engine Variant 6 Torque: 510 Nm (376 lb-ft) @ 3250-5000 rpm Engine Variant 7: M156 E63 (6.2L Naturally Aspirated V8 - CLK63 AMG) Engine Variant 7 Power: 475 hp @ 6800 rpm Engine Variant 7 Torque: 600 Nm (443 lb-ft) @ 5000 rpm Performance 0 60 Mph Typical: Varies by engine: ~7.0s (CLK320) to ~4.3s (CLK63 AMG) Top Speed Governed: Typically electronically limited to 250 km/h (155 mph) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with multi-point injection (MPI) or direct injection (DI) on some later variants. Fuel Type: Premium Unleaded Gasoline (91 Octane or higher recommended) Emission Controls: Catalytic converters, O2 sensors, secondary air injection (on some models), EVAP system. 🔧 Transmission Standard Transmission Type Standard: 5-speed automatic (722.6) or 7-speed automatic (722.9) depending on model year and engine. Optional Transmission Type Optional: AMG SpeedShift 7-speed automatic (722.3/722.9) for AMG models. Features Shift Modes: Comfort (C), Sport (S), Manual (M) modes available on most automatic transmissions. Transmission Fluid Spec: MB 236.10 or MB 236.14 (e.g., ATF 7G-Tronic) 📐 Dimensions Exterior Length: Approx. 4635-4712 mm (182.5-185.5 in) Width: Approx. 1741-1764 mm (68.5-69.4 in) Height: Approx. 1382-1417 mm (54.4-55.8 in) Wheelbase: Approx. 2717 mm (107.0 in) Cargo Cargo Volume Coupe: Approx. 370-400 liters...

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

CLK Class

Chassis Code Coupe:

Chassis Code Convertible:

Production Years Covered:

2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010

Codes

Internal Platform Code:

W203 derived platform

👋 Introduction

Market Position

Market Segment:

Entry-level luxury coupe and convertible, positioned as a stylish and performance-oriented alternative to traditional sedans.

Competitive Analysis

Key Competitors:

BMW 3 Series Coupe/Convertible (E46/E92/E93), Audi A4 Cabriolet, Lexus SC, Infiniti G35 Coupe.

Key Features

Design Philosophy:

Combines Mercedes-Benz's signature build quality and comfort with a sportier, more dynamic aesthetic. Known for its elegant lines and refined interior.

Target Audience:

Individuals seeking a premium coupe or convertible experience with a blend of performance, luxury, and everyday usability.

📋 Manual Details

Coverage Areas

Primary Coverage:

North America & European Markets

Secondary Coverage:

Global variations where applicable

Page Count

Estimated Page Count:

Over 2500 pages (estimated for comprehensive factory data)

Manual Type

Manual Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine management (ECU, sensors, actuators).

Drivetrain:

Automatic transmission (722.6 5-speed, 722.9 7-speed), transfer case (if applicable), drive shafts, differentials, axles.

Chassis:

Suspension (front & rear), steering system, brakes (ABS, ESP, SBC - Sensotronic Brake Control for early models), wheels, tires.

Body:

Exterior body panels, doors, hood, trunk, bumpers, glass, convertible top mechanism (for A209), interior trim, seating.

Electrical:

Body control module (BCM), instrument cluster, lighting (headlights, taillights, interior), power windows, mirrors, seats, infotainment system (COMAND), climate control, SRS (Airbag) system, CAN bus communication.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections and replacement.

Repair Procedures:

Engine component repair and replacement (e.g., cylinder head, pistons, camshafts), transmission overhaul and component replacement, brake caliper and rotor replacement, suspension arm and bushing replacement, power steering rack replacement, electrical component diagnosis and repair.

Diagnostics:

Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) and their meanings, sensor testing, actuator testing, circuit testing.

Special Tools:

Identification and usage of specialized Mercedes-Benz tools required for specific procedures.

Technical Depth

Depth:

Comprehensive factory-level detail, including schematics, wiring diagrams, torque specifications, component locations, diagnostic flowcharts, and step-by-step repair instructions.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution, suitable for printing individual pages or the entire manual.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Searchability

Searchable Text:

Yes (typically text-searchable PDF for efficient information retrieval)

Licensing

Licensing Model:

One-time purchase, no expiry dates, instant download.

⚙️ Engine Specifications

Primary Engine

Engine Variant 1:

M271 E18 ML (1.8L Supercharged Inline-4)

Engine Variant 1 Power:

184 hp @ 5500 rpm

Engine Variant 1 Torque:

250 Nm (184 lb-ft) @ 3000-4300 rpm

Engine Variant 2:

M112 E32 (3.2L V6)

Engine Variant 2 Power:

215 hp @ 6000 rpm

Engine Variant 2 Torque:

310 Nm (229 lb-ft) @ 3000-4800 rpm

Engine Variant 3:

M112 E37 (3.7L V6)

Engine Variant 3 Power:

238 hp @ 5750 rpm

Engine Variant 3 Torque:

345 Nm (254 lb-ft) @ 3000-4500 rpm

Engine Variant 4:

M272 E35 (3.5L V6)

Engine Variant 4 Power:

268 hp @ 6000 rpm

Engine Variant 4 Torque:

350 Nm (258 lb-ft) @ 3500-5000 rpm

Engine Variant 5:

M113 E50 ML (5.0L V8 - CLK500)

Engine Variant 5 Power:

302 hp @ 5600 rpm

Engine Variant 5 Torque:

460 Nm (339 lb-ft) @ 2700-4250 rpm

Engine Variant 6:

M113 E55 ML (5.4L Supercharged V8 - CLK55 AMG)

Engine Variant 6 Power:

362 hp @ 6100 rpm

Engine Variant 6 Torque:

510 Nm (376 lb-ft) @ 3250-5000 rpm

Engine Variant 7:

M156 E63 (6.2L Naturally Aspirated V8 - CLK63 AMG)

Engine Variant 7 Power:

475 hp @ 6800 rpm

Engine Variant 7 Torque:

600 Nm (443 lb-ft) @ 5000 rpm

Performance

0 60 Mph Typical:

Varies by engine: ~7.0s (CLK320) to ~4.3s (CLK63 AMG)

Top Speed Governed:

Typically electronically limited to 250 km/h (155 mph)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with multi-point injection (MPI) or direct injection (DI) on some later variants.

Fuel Type:

Premium Unleaded Gasoline (91 Octane or higher recommended)

Emission Controls:

Catalytic converters, O2 sensors, secondary air injection (on some models), EVAP system.

🔧 Transmission

Standard

Transmission Type Standard:

5-speed automatic (722.6) or 7-speed automatic (722.9) depending on model year and engine.

Optional

Transmission Type Optional:

AMG SpeedShift 7-speed automatic (722.3/722.9) for AMG models.

Features

Shift Modes:

Comfort (C), Sport (S), Manual (M) modes available on most automatic transmissions.

Transmission Fluid Spec:

MB 236.10 or MB 236.14 (e.g., ATF 7G-Tronic)

📐 Dimensions

Exterior

Length:

Approx. 4635-4712 mm (182.5-185.5 in)

Width:

Approx. 1741-1764 mm (68.5-69.4 in)

Height:

Approx. 1382-1417 mm (54.4-55.8 in)

Wheelbase:

Approx. 2717 mm (107.0 in)

Cargo

Cargo Volume Coupe:

Approx. 370-400 liters (13.1-14.1 cu ft)

Cargo Volume Convertible:

Approx. 270-300 liters (9.5-10.6 cu ft) with top up

Weights

Curb Weight:

Approx. 1500-1750 kg (3300-3850 lbs), varies by engine and body style.

🛡️ Safety Features

Ratings

NHTSA Rating:

Generally rated well in frontal and side impact tests, consult specific year NHTSA reports for precise ratings.

IIHS Rating:

Typically 'Good' or 'Acceptable' in various crashworthiness categories. Consult specific IIHS reports.

Active Features

Active Safety Features:

Anti-lock Braking System (ABS), Electronic Stability Program (ESP), Traction Control System (TCS), optional Brake Assist (BAS), optional Sensotronic Brake Control (SBC) on early models.

Passive Features

Passive Safety Features:

Front and side airbags, curtain airbags (on coupe), seatbelt pretensioners, active head restraints (on some models), reinforced body structure.

Convertible Top Safety A209:

Integrated rollover protection system (pop-up roll bars behind rear headrests activated by sensors).

💡 Technology Features

Infotainment

Infotainment System:

COMAND (Cockpit Management and Navigation) system, featuring CD player, optional GPS navigation, radio, and optional auxiliary input or media interface.

Audio System:

Standard premium audio, optional Harman Kardon surround sound system.

Driver Assistance

Driver Assistance Features:

Cruise control, optional Parktronic parking sensors, rain-sensing wipers, automatic climate control.

Connectivity

Connectivity Options:

Optional Bluetooth hands-free communication system (often integrated into COMAND).

Lighting

Lighting Technology:

Standard Halogen projector headlights, optional Xenon (HID) headlights with dynamic beam control.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000 miles or 12 months, whichever comes first, or as indicated by the Flexible Service System (ASSYST).

Major Service Interval:

Refer to ASSYST or specific mileage intervals for spark plug replacement (e.g., 60,000-100,000 miles depending on plug type), coolant flush, brake fluid flush (every 2 years), transmission fluid and filter service (often around 40,000-60,000 miles).

Fluid Specifications

Engine Oil Spec:

MB 229.5 (e.g., SAE 0W-40, 5W-40, 5W-30 depending on climate and specific engine).

Coolant Spec:

MB 325.0 or MB 326.0 (Antifreeze/Coolant, typically a silicate-free, ethylene glycol-based mixture).

Brake Fluid Spec:

DOT 4 PLUS (MB specification 331.0).

Power Steering Fluid Spec:

MB 343.0 or MB 345.0 (Hydraulic Fluid).

Known Issues

Common Issues Engine:

Balance shaft wear in early M271 engines, oil leaks from valve cover gaskets and oil filter housing, spark plug well oil contamination, potential timing chain issues on higher mileage M272/M273 engines.

Common Issues Transmission:

Leaking transmission cooler lines, conductor plate issues in 722.6 and 722.9 transmissions, torque converter solenoid issues.

Common Issues Chassis:

Worn suspension bushings (control arms, sway bar links), premature wear of ball joints and tie rod ends, ABS/ESP sensor failures, SBC system faults (early models).

Common Issues Electrical:

HVAC blower motor resistor failure, headlight leveling sensor issues, power seat module failures, COMAND system glitches, window regulator failures, convertible top hydraulic leaks or sensor faults (A209).

📚 Vehicle History

Brand Heritage

Brand Heritage:

Mercedes-Benz has a long-standing reputation for automotive engineering excellence, safety, and luxury, established in the early 20th century.

Model Evolution

Generation Codification:

The C209/A209 CLK replaced the C208/A208 and was based on the W203 C-Class platform, offering a more modern chassis and technology.

Facelifts And Updates:

Received a significant facelift for the 2005 model year, featuring updated exterior styling (headlights, grille, bumpers), interior enhancements, and updated powertrain options (e.g., introduction of the M272 V6).

Production

Manufacturing Locations:

Primarily manufactured at Mercedes-Benz's Bremen plant in Germany.

Production End Year:

2010, succeeded by the W207 E-Class Coupe/Convertible.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards may vary by year and region, the CLK Class generally received positive reviews for its styling, comfort, and engineering, contributing to Mercedes-Benz's strong brand perception in the luxury segment.

Ratings

Reliability Ratings:

Reliability varied by specific model year and engine. Early models with the M271 engine and the SBC system required particular attention. Later models with the M272 and M113/M156 engines generally demonstrated better reliability with proper maintenance.