2004 Mercedes C-Class (W203) Service and Repair Manual
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🏷️ Basic Information Identification Make: Mercedes-Benz Model: C-Class Model Code: W203 Model Year: 2004 Codes Chassis Code: W203 Platform: W203 Platform 👋 Introduction Market Position Segment: Compact Executive Sedan/Coupe/Wagon Positioning: Premium compact luxury vehicle offering refined comfort, advanced technology, and strong brand prestige. Competitive Analysis Key Competitors: BMW 3 Series (E46), Audi A4 (B6), Lexus IS300, Infiniti G35 Key Features Design: Modern, flowing lines with signature Mercedes-Benz grille and interior quality. Performance: Responsive engines, refined handling, and comfortable ride quality. Technology: Introduction of advanced features like COMAND infotainment and advanced safety systems. 📋 Manual Details Coverage Areas Coverage: All models and all repairs A-Z Page Count Estimated Page Count: 1500+ Manual Type Type: Factory Service and Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, timing, lubrication, cooling, fuel delivery, emissions control Engine Management: ECU diagnostics, sensor data, ignition system, fuel injection control Transmission Manual: Clutch, gear selection, overhaul, fluid service Transmission Automatic: Control module diagnostics, valve body, torque converter, fluid service, overhaul Drivetrain: Drive shafts, CV joints, differential, axles Suspension: Front and rear suspension components, alignment, shock absorbers, springs, bushings Steering: Power steering system, steering rack, tie rods, steering column Brakes: ABS, ESP, brake discs, pads, calipers, lines, master cylinder, bleeding procedures Electrical System: Battery, alternator, starter, wiring diagrams, fuse boxes, relays Lighting: Headlights, taillights, interior lighting, bulb replacement, aiming HVAC: Air conditioning system, heater core, blower motor, climate control module, refrigerant servicing Body Interior: Door panels, seats, dashboard, trim, headliner, glass replacement Body Exterior: Bumpers, fenders, hood, trunk lid, doors, body panel alignment, rust repair Infotainment: Audio system, navigation, display unit, control modules Comfort Systems: Power windows, power locks, power mirrors, keyless entry, sunroof operation Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs Diagnostics: Troubleshooting guides, fault codes (DTCs), diagnostic procedures for all systems Repair: Step-by-step repair instructions for all major components and systems Rebuilds: Engine and transmission overhaul procedures, component-specific rebuilds Adjustments: Alignment adjustments, electronic system calibrations, clutch adjustments Electrical Repairs: Component replacement, wiring harness repair, circuit troubleshooting Body Repairs: Panel replacement, dent repair, glass installation, sealing procedures Technical Depth Depth: Comprehensive; from basic maintenance to complete engine/transmission rebuilds and advanced electronic diagnostics Detail Level: Factory-level detail with specific torque specifications, clearances, and diagnostic procedures Audience: Professional technicians and advanced DIY enthusiasts 📊 Manual Specifications File Format File Type: PDF Searchability: Fully searchable text for quick information retrieval Print Quality: High-resolution, printable pages for workshop use Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Options: M271 (1.8L Supercharged I4), M111 (2.0L Supercharged I4), M271 (2.0L Turbocharged I4), M112 (2.6L V6), M112 (3.2L V6), M113 (5.4L V8 - C32/C55 AMG) Engine Displacements: 1.8L, 2.0L, 2.6L, 3.2L, 5.4L Performance Horsepower Range: 140 hp - 369 hp (depending on engine) Torque Range: 140 lb-ft - 376 lb-ft (depending on engine) Fuel System Fuel Type: Premium Unleaded Gasoline (91 RON or higher recommended) Injection System: Sequential Multi-Port Fuel Injection (MPI) or Direct Injection (DI) for some later variants not typically in 2004 Engine Codes Common M271 Evo: Commonly found 1.8L (271.940, 271.942) and 2.0L (271.860, 271.941) variants with variable valve timing and supercharging/turbocharging. M112 V6: Robust 2.6L (112.910) and 3.2L (112.912, 112.916) SOHC V6 engines known for smoothness. 🔧 Transmission Standard Transmission Options: 5-speed manual (less common), 5-speed automatic (722.6 '5G-TRONIC'), 6-speed manual (later models) Optional Automatic Transmission: 722.6 5-speed automatic, a highly regarded and durable transmission. Features Automatic Modes: Comfort (C) and Sport (S) modes available on 722.6 transmission. Fluid Specifications 722.6 Fluid: MB 236.10 or MB 236.14 (ATF Dexron III/Mercon equivalent for older specs, newer specs are synthetic) 📐 Dimensions Exterior Length: Approximately 4526 mm (178.2 in) Width: Approximately 1728 mm (68.0 in) Height: Approximately 1407 mm (55.4 in) Wheelbase: Approximately 2715 mm (106.9 in) Weights Curb Weight: Approximately 1450-1600 kg (3200-3520 lbs) depending on engine and trim Gross Vehicle Weight: Approximately 1900-2050 kg (4189-4520 lbs) depending on configuration 🛡️ Safety Features Ratings NHTSA Front Impact: 5-Star (for driver and front passenger) IIHS Frontal Offset: Good (for early W203 models, later updates improved structure) Euroncap Overall: 4-Star (for 2002 models, likely similar for 2004) Active Features Stability Control: Standard ESP (Electronic Stability Program) on most models. Braking System: ABS (Anti-lock Braking System), Brake Assist (BAS) Passive Features Airbags: Front airbags, side airbags, optional curtain airbags. Seatbelts: Pretensioners and force limiters on front seats, ISOFIX child seat anchors. Body Structure: High-strength steel safety cell with crumple zones. 💡 Technology Features Infotainment Infotainment System: COMAND (Cockpit Management and Navigation) system available on higher trims, featuring CD player, radio, navigation, and optional phone integration. Instrument Cluster: Clear, multi-function display providing vehicle status, trip computer, and diagnostic information. Driver Assistance Cruise Control: Standard cruise control, optional DISTRONIC adaptive...
Standard cruise control, optional DISTRONIC adaptive cruise control on some models.
Parking Sensors:
Optional Parktronic parking assist system (front and rear).
Connectivity
Phone Integration:
Optional Bluetooth phone preparation with cradle or integrated system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 15,000 km (9,300 miles) or 12 months, whichever comes first, with synthetic oil. Varies with driving conditions and oil type used.
Major Service:
Major services (e.g., spark plug replacement, transmission fluid change) recommended at higher mileages, often around 60,000-100,000 km (37,000-62,000 miles) depending on specific components.
Fluid Specifications
Engine Oil:
MB 229.5 (e.g., Mobil 1 0W-40, Castrol EDGE 0W-40) is commonly recommended for gasoline engines. Always verify for specific engine. Capacity approx. 5.5-8.5L depending on engine.
Coolant:
MB 325.0 (Antifreeze/Coolant, ethylene glycol-based) or MB 326.0 (Pre-diluted) - typically a pinkish-red color. Capacity approx. 8-9L.
Brake Fluid:
DOT 4 PLUS (MB 331.0 specification)
Known Issues
M271 Timing Chain:
Potential stretching of the timing chain and wear on the tensioner and guides, leading to timing issues and noise. Early warning signs can include rattle on startup.
Oil Cooler Seals:
Leaking oil cooler seals, especially on the M112/M113 V6/V8 engines, can cause coolant contamination.
Evap Canister Purge Valve:
Faulty EVAP purge valve can lead to check engine lights and rough idling, particularly on M271 engines.
Window Regulators:
Plastic components in window regulators can degrade, leading to windows falling down inside the door.
Suspension Bushings:
Wear and tear on control arm bushings, especially front lower control arms, can cause clunks and affect alignment.
Mass Airflow Sensor Maf:
Can become dirty or fail, leading to poor engine performance and check engine lights.
📚 Vehicle History
Brand Heritage
Brand:
Mercedes-Benz: Renowned for engineering excellence, luxury, and safety innovations since the early 20th century.
Model Evolution
W203 Generation:
Second generation of the C-Class, replacing the W202. Introduced in 2000.
Facelift:
The 2004 model year typically corresponds to the pre-facelift W203 (introduced 2000-2003). A significant facelift occurred for the 2005 model year, with styling and feature updates.
Production
Production Years W203:
2000 - 2007
Manufacturing Locations:
Germany (Sindelfingen, Bremen), South Africa, Malaysia, Egypt, Thailand.
🏆 Awards & Recognition
Recognitions
General Reputation:
Consistently praised for ride comfort, build quality, and interior refinement within its segment.
Safety Awards:
Received strong safety ratings from various automotive safety organizations (as detailed in safety section).
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