Mercedes Benz All Automotive Models Inc. Mercedes C CLass Complete Workshop Service Repair Manual 1993 1994 1995 1996 1997 1998 1999 2000

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: C-Class Model Code Series: W202 Model Years Covered: 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000 Production Generations: First Generation (W202) Product Type: Complete Workshop Service Repair Manual 👋 Introduction Market Position Vehicle Class: Compact Executive Car (CD-segment) Target Audience: Consumers seeking a premium, reliable, and well-engineered compact sedan/wagon. Competitive Analysis Key Competitors: BMW 3 Series (E36), Audi A4 (B5), Lexus IS200/IS300, Alfa Romeo 155/156, Volvo S40/V40. Key Features Design Philosophy: Emphasis on build quality, safety, refined driving dynamics, and classic Mercedes-Benz design cues. Innovation: Introduction of side airbags, integrated child seats, and advancements in engine technology for the era. 📋 Manual Details Coverage Areas Continental Coverage: Global (North America, Europe, Asia, etc. - specifications may vary by region) Technical Coverage Scope: Comprehensive: All models and variants within the specified years Page Count Estimated Page Count: 1500+ pages (estimated for comprehensive coverage of all variants) Manual Type Manual Classification: Workshop Service Repair Manual (WSRM) Language Language: English Format Digital Format: Downloadable PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanicals (M111, M104, OM601, OM602, OM605, OM606), fuel system, ignition system, emissions control, cooling system, exhaust system, engine management (ECU/ECM diagnostics) Drivetrain: Automatic transmission (722.4, 722.6), manual transmission (GETRAG), clutch, driveshafts, differentials, axles, transfer case (if applicable) Chassis And Suspension: Front suspension (MacPherson struts), rear suspension (multi-link independent), steering system (power steering), wheel alignment specifications, shock absorbers, springs Brakes: Front disc brakes, rear disc brakes, ABS (Anti-lock Braking System), brake fluid specifications, hydraulic system, parking brake Electrical Systems: Battery, charging system (alternator), starting system (starter motor), lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, instrument cluster, power windows, power locks, central locking, climate control electronics Body And Interior: Body panel repair, door mechanisms, interior trim, seats, airbags, climate control system (HVAC), body electrical, glass replacement, seals Procedures Included Routine Maintenance: Oil change, filter replacement (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid flush, belt inspection/replacement Engine Repair: Engine overhaul, cylinder head gasket replacement, timing chain/belt replacement, piston/ring replacement, valve adjustments, injector service, turbocharger service (if applicable) Transmission Service: Transmission fluid and filter change, transmission overhaul (automatic and manual), clutch replacement, torque converter service Brake System Repair: Brake pad and rotor replacement, caliper service, brake line repair/replacement, ABS module troubleshooting Suspension And Steering Repair: Ball joint replacement, control arm replacement, strut replacement, power steering pump service, tie rod end replacement Electrical Diagnostics: Troubleshooting electrical faults, wiring harness repair, sensor replacement, module programming (limited, may require specialized tools), ABS/ESP diagnostics Diagnostics And Troubleshooting: Symptom-based troubleshooting charts, diagnostic trouble codes (DTCs) and their meanings, component testing procedures Technical Depth Diagnostic Capabilities: Detailed diagnostic procedures for all major systems, including OBD-II (On-Board Diagnostics II) for later models. Repair Depth: From basic fluid changes and filter replacements to complete engine and transmission rebuilds. Specification Accuracy: Precise torque specifications, clearances, fluid capacities, and alignment data. Wiring Diagrams: Detailed, often color-coded, electrical wiring diagrams for all vehicle systems. 📊 Manual Specifications File Format Digital Format Details: Searchable PDF with bookmark navigation for easy access to sections. Print Quality Digital Resolution: High-resolution scans ensuring clarity of text and diagrams. Binding Type Digital Access: Downloadable file for offline access. Paper Type Digital Medium: Electronic document, suitable for printing individual pages or sections. ⚙️ Engine Specifications Primary Engine Options Engine Codes: M111 (2.0L, 2.2L, 2.3L Inline-4), M104 (2.8L, 3.2L Inline-6), OM601 (2.0L Diesel), OM602 (2.5L Diesel), OM605 (2.5L Turbo Diesel), OM606 (3.0L Diesel, 3.0L Turbo Diesel) Performance Typical Horsepower Range: 95 hp (OM601) to 217 hp (C36 AMG) Typical Torque Range: 111 lb-ft (OM601) to 229 lb-ft (C36 AMG) Fuel System Fuel Injection: Bosch Motronic electronic fuel injection (EFI) for gasoline engines; Bosch mechanical or electronic injection for diesel engines. Fuel Type: Unleaded gasoline (91 RON minimum recommended), Diesel fuel. Engine Management ECU Type: Various Bosch ECUs depending on engine and year (e.g., ME2.0, ME2.1, EDC). Engine Variants Specific Variants: C220, C230, C280, C36 AMG, C200 Diesel, C220 Diesel, C250 Diesel, C250 Turbo Diesel. 🔧 Transmission Standard Transmission Manual Transmission Options: GETRAG 5-speed manual transmission (e.g., 717.400, 717.404). Optional Transmission Automatic Transmission Options: Mercedes-Benz 4-speed automatic (722.4) or 5-speed automatic (722.6 'NAG' - New Automatic Gearbox) for later models. Features Automatic Features: Comfort and Sport modes, electronic control (722.6). 📐 Dimensions Exterior Length: Approximately 4516 mm (177.8 in) Width: Approximately 1720 mm (67.7 in) Height: Approximately 1390 mm (54.7 in) Wheelbase: Approximately 2715 mm (106.9 in) Weights Curb Weight Range: Approximately 1370 kg (3020 lbs) to 1550 kg (3417 lbs) depending on engine and equipment. 🛡️ Safety Features Ratings Frontal Crash Tests: Good ratings in contemporary IIHS frontal offset tests. Achieved 4-star frontal rating in NHTSA tests for some model years. Active Features ABS: Standard Anti-lock Braking System (ABS) across most variants. Traction Control: ASR (Anti-Slip Regulation) available on select models,...

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Tags: 1993 1994 1995 1996 1997 1998 1999 2000 C Class Car Cars Mercedes Mercedes-benz Misc

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

C-Class

Model Code Series:

Model Years Covered:

1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000

Production Generations:

First Generation (W202)

Product Type:

Complete Workshop Service Repair Manual

👋 Introduction

Market Position

Vehicle Class:

Compact Executive Car (CD-segment)

Target Audience:

Consumers seeking a premium, reliable, and well-engineered compact sedan/wagon.

Competitive Analysis

Key Competitors:

BMW 3 Series (E36), Audi A4 (B5), Lexus IS200/IS300, Alfa Romeo 155/156, Volvo S40/V40.

Key Features

Design Philosophy:

Emphasis on build quality, safety, refined driving dynamics, and classic Mercedes-Benz design cues.

Innovation:

Introduction of side airbags, integrated child seats, and advancements in engine technology for the era.

📋 Manual Details

Coverage Areas

Continental Coverage:

Global (North America, Europe, Asia, etc. - specifications may vary by region)

Technical Coverage Scope:

Comprehensive: All models and variants within the specified years

Page Count

Estimated Page Count:

1500+ pages (estimated for comprehensive coverage of all variants)

Manual Type

Manual Classification:

Workshop Service Repair Manual (WSRM)

Language

Language:

English

Format

Digital Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanicals (M111, M104, OM601, OM602, OM605, OM606), fuel system, ignition system, emissions control, cooling system, exhaust system, engine management (ECU/ECM diagnostics)

Drivetrain:

Automatic transmission (722.4, 722.6), manual transmission (GETRAG), clutch, driveshafts, differentials, axles, transfer case (if applicable)

Chassis And Suspension:

Front suspension (MacPherson struts), rear suspension (multi-link independent), steering system (power steering), wheel alignment specifications, shock absorbers, springs

Brakes:

Front disc brakes, rear disc brakes, ABS (Anti-lock Braking System), brake fluid specifications, hydraulic system, parking brake

Electrical Systems:

Battery, charging system (alternator), starting system (starter motor), lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, instrument cluster, power windows, power locks, central locking, climate control electronics

Body And Interior:

Body panel repair, door mechanisms, interior trim, seats, airbags, climate control system (HVAC), body electrical, glass replacement, seals

Procedures Included

Routine Maintenance:

Oil change, filter replacement (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid flush, belt inspection/replacement

Engine Repair:

Engine overhaul, cylinder head gasket replacement, timing chain/belt replacement, piston/ring replacement, valve adjustments, injector service, turbocharger service (if applicable)

Transmission Service:

Transmission fluid and filter change, transmission overhaul (automatic and manual), clutch replacement, torque converter service

Brake System Repair:

Brake pad and rotor replacement, caliper service, brake line repair/replacement, ABS module troubleshooting

Suspension And Steering Repair:

Ball joint replacement, control arm replacement, strut replacement, power steering pump service, tie rod end replacement

Electrical Diagnostics:

Troubleshooting electrical faults, wiring harness repair, sensor replacement, module programming (limited, may require specialized tools), ABS/ESP diagnostics

Diagnostics And Troubleshooting:

Symptom-based troubleshooting charts, diagnostic trouble codes (DTCs) and their meanings, component testing procedures

Technical Depth

Diagnostic Capabilities:

Detailed diagnostic procedures for all major systems, including OBD-II (On-Board Diagnostics II) for later models.

Repair Depth:

From basic fluid changes and filter replacements to complete engine and transmission rebuilds.

Specification Accuracy:

Precise torque specifications, clearances, fluid capacities, and alignment data.

Wiring Diagrams:

Detailed, often color-coded, electrical wiring diagrams for all vehicle systems.

📊 Manual Specifications

File Format

Digital Format Details:

Searchable PDF with bookmark navigation for easy access to sections.

Print Quality

Digital Resolution:

High-resolution scans ensuring clarity of text and diagrams.

Binding Type

Digital Access:

Downloadable file for offline access.

Paper Type

Digital Medium:

Electronic document, suitable for printing individual pages or sections.

⚙️ Engine Specifications

Primary Engine Options

Engine Codes:

M111 (2.0L, 2.2L, 2.3L Inline-4), M104 (2.8L, 3.2L Inline-6), OM601 (2.0L Diesel), OM602 (2.5L Diesel), OM605 (2.5L Turbo Diesel), OM606 (3.0L Diesel, 3.0L Turbo Diesel)

Performance

Typical Horsepower Range:

95 hp (OM601) to 217 hp (C36 AMG)

Typical Torque Range:

111 lb-ft (OM601) to 229 lb-ft (C36 AMG)

Fuel System

Fuel Injection:

Bosch Motronic electronic fuel injection (EFI) for gasoline engines; Bosch mechanical or electronic injection for diesel engines.

Fuel Type:

Unleaded gasoline (91 RON minimum recommended), Diesel fuel.

Engine Management

ECU Type:

Various Bosch ECUs depending on engine and year (e.g., ME2.0, ME2.1, EDC).

Engine Variants

Specific Variants:

C220, C230, C280, C36 AMG, C200 Diesel, C220 Diesel, C250 Diesel, C250 Turbo Diesel.

🔧 Transmission

Standard Transmission

Manual Transmission Options:

GETRAG 5-speed manual transmission (e.g., 717.400, 717.404).

Optional Transmission

Automatic Transmission Options:

Mercedes-Benz 4-speed automatic (722.4) or 5-speed automatic (722.6 'NAG' - New Automatic Gearbox) for later models.

Features

Automatic Features:

Comfort and Sport modes, electronic control (722.6).

📐 Dimensions

Exterior

Length:

Approximately 4516 mm (177.8 in)

Width:

Approximately 1720 mm (67.7 in)

Height:

Approximately 1390 mm (54.7 in)

Wheelbase:

Approximately 2715 mm (106.9 in)

Weights

Curb Weight Range:

Approximately 1370 kg (3020 lbs) to 1550 kg (3417 lbs) depending on engine and equipment.

🛡️ Safety Features

Ratings

Frontal Crash Tests:

Good ratings in contemporary IIHS frontal offset tests. Achieved 4-star frontal rating in NHTSA tests for some model years.

Active Features

Standard Anti-lock Braking System (ABS) across most variants.

Traction Control:

ASR (Anti-Slip Regulation) available on select models, especially with larger engines and automatic transmissions.

Passive Features

Airbags:

Driver and front passenger airbags standard; side airbags (pelvis protection) introduced as an option and later standard on many models.

Seat Belts:

Pretensioner seat belts with force limiters.

Child Seat Anchors:

ISOFIX compatible mounting points introduced on later models.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/Cassette or CD players, optional Becker sound systems with multiple speakers. Later models may have early CD changers.

Navigation:

Optional factory navigation system (APS) available on later models, typically with a trunk-mounted screen and CD-ROM unit.

Driver Assistance

Cruise Control:

Standard cruise control system.

Climate Control:

Manual or optional automatic climate control (Thermatic/Thermotronic), including ASR (Anti-Spin Regulation).

Connectivity

Pre Wiring:

Pre-wiring for optional external phone systems (GSM) in some models, requiring specific cradles.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000-15,000 km (6,000-9,000 miles) or 12 months, depending on driving conditions and oil type.

Major Service Intervals:

Major services (e.g., spark plugs, coolant, brake fluid) typically every 40,000-80,000 km (25,000-50,000 miles).

Fluid Specifications

Engine Oil Specification:

MB 229.1 or MB 229.3 approved synthetic oils (e.g., 0W-40, 5W-40, 10W-40 depending on climate).

Coolant Specification:

Mercedes-Benz approved G48 coolant (blue) or equivalent HOAT coolant, mixed 50/50 with distilled water.

Transmission Fluid Automatic:

MB 236.10 or MB 236.12 approved ATF for 722.6; MB 236.6 for 722.4.

Brake Fluid Specification:

DOT 4 (e.g., MB 331.0) brake fluid.

Known Issues

Common Wear Items:

Front control arm bushings, sway bar links, engine mounts, transmission mounts, blower motor resistor, MAF sensor (later models).

Electrical Gremlins:

Occasional issues with door lock actuators, window regulators, and fuse box corrosion.

Cooling System:

Plastic coolant expansion tanks can become brittle and crack; thermostat housing leaks.

Oil Leaks:

Valve cover gasket, oil pan gasket, and rear main seal are common leak points with age.

📚 Vehicle History

Brand Heritage

Manufacturer Reputation:

Mercedes-Benz, renowned for engineering excellence, safety, and luxury since its inception.

Model Evolution

W202 Introduction:

Introduced in 1993 as the successor to the 190E (W201), marking a significant step towards modern Mercedes-Benz design and technology.

Facelift:

Received a significant facelift in 1997 (model year 1998) with revised bumpers, side skirts, grille, and interior enhancements.

Production

Production Period:

1993-2000 (for W202 generation).

Production Locations

Manufacturing Plants:

Primary production in Sindelfingen, Germany. Assembly also occurred in other global locations.

🏆 Awards & Recognition

Recognitions

General Reputation:

Consistently praised for its build quality, safety features, and long-term durability, earning Mercedes-Benz a strong reputation in the compact executive segment.

Ratings

Consumer Reports Historical:

Often received good ratings for predicted reliability and owner satisfaction in contemporary reviews, though some specific powertrain components were noted for potential issues as they aged.

Certifications

Safety Certifications:

Met all relevant European and North American safety standards for its production era.