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Mercedes Benz C-Class (W202) 1995 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: C-Class Chassis Code: W202 Model Year: 1995 Codes Production Codes Covered: Comprehensive coverage for all W202 variants produced in 1995. 👋 Introduction Market...
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Mercedes Benz C-Class (W202) 1995 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
C-Class
Chassis Code:
W202
Model Year:
1995
Codes
Production Codes Covered:
Comprehensive coverage for all W202 variants produced in 1995.
👋 Introduction
Market Position
Vehicle Segment:
Compact Executive / Compact Car segment.
Brand Perception:
Represents Mercedes-Benz's entry into the more accessible luxury compact market, competing with brands like BMW (3 Series), Audi (A4/80), and Lexus (IS).
Competitive Analysis
Competitors 1995:
BMW 3 Series (E36), Audi A4 (B5), Lexus ES (V30), Volvo S40.
Key Features
Selling Points Of Model:
Mercedes-Benz build quality, safety features, comfort, refinement, rear-wheel-drive dynamics, advanced (for its time) engineering.
Manual Value Proposition
Target User:
DIY enthusiasts, independent repair shops, and professional Mercedes-Benz technicians seeking accurate, detailed service information.
Content Quality:
Highly detailed with photos and diagrams, mirroring factory technician resources for accuracy and completeness.
📋 Manual Details
Coverage Areas
Geographic Regions:
Global specifications applicable to North American, European, and other international markets.
Variant Coverage:
Sedan (W202) body style.
Page Count
Estimated Pages:
Hundreds (exact count not specified, but described as 'very detailed' with 'hundreds of pages').
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English (implied by product description and target audience).
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, fuel system, ignition system, cooling system, exhaust system, engine management, transmission (automatic and manual), drivetrain (rear-wheel drive).
Chassis:
Suspension (front and rear), steering, brakes (front and rear, ABS), wheels and tires.
Electrical:
Wiring diagrams, lighting systems, charging system, starting system, instrument cluster, body electronics, comfort features, diagnostic systems (OBD-II for models equipped).
Body And Interior:
Body panels, doors, windows, seats, interior trim, HVAC (heating, ventilation, and air conditioning) systems, safety restraints.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, brake pad replacement, spark plug replacement, belt inspection and replacement.
Troubleshooting:
Diagnostic procedures for common and complex issues across all major systems, symptom-based troubleshooting guides.
Repair:
Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation for virtually all vehicle systems.
Diagnostics:
Fault code interpretation, sensor testing, actuator testing, component-specific diagnostic routines.
Specifications:
Torque specifications, fluid capacities, electrical component specifications, clearances, alignments.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to full engine and transmission overhauls. Includes detailed component dissections and rebuild procedures.
📊 Manual Specifications
File Format
Compatibility:
Compatible with Windows and MAC operating systems.
Accessibility:
Instant download, usable on multiple computers, no expiry dates, no renewal fees.
Print Quality
Print Option:
Printable by the page or in its entirety.
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Family:
M111 (Inline-4), M104 (Inline-6), OM601/OM602/OM604/OM605 (Diesel and Turbo Diesel).
Engine Variants 1995
Common Engines:
C220 (2.2L M111), C280 (2.8L M104), C200 Diesel (2.0L OM601), C250 Diesel (2.5L OM605), C250 Turbo Diesel (2.5L OM605).
Performance
C220 Horsepower:
Approx. 148 hp (110 kW) @ 5500 rpm (M111.960)
C280 Horsepower:
Approx. 190 hp (142 kW) @ 5700 rpm (M104.941)
C250 Turbodiesel Horsepower:
Approx. 125 hp (93 kW) @ 4400 rpm (OM605.912)
Fuel System
Induction:
Multi-point fuel injection (MPI) for gasoline engines, direct injection for diesel engines.
Fuel Type:
Unleaded gasoline (RON 95 recommended), Diesel fuel.
Cooling System
Coolant Type:
Mercedes-Benz approved Antifreeze/Coolant concentrate (e.g., G05 specification) mixed with distilled water, typically a 50/50 ratio.
🔧 Transmission
Standard
Transmission Type Gasoline:
5-speed manual transmission (e.g., Getrag 260-5).
Optional
Transmission Type Automatic:
4-speed automatic transmission (e.g., 722.4, 722.5).
Features
Transmission Control:
Electronic control for automatic transmissions (e.g., K4/K5 on some models) for shift quality and efficiency.
Fluid Specifications
Automatic Transmission Fluid:
Dexron IIE or Dexron III (refer to specific model/VIN for exact MB approval, e.g., MB 236.2, MB 236.5, MB 236.7).
Manual Transmission Fluid:
SAE 75W-80 or SAE 75W-90 GL-4 or GL-5 gear oil (specific MB approval recommended).
📐 Dimensions
Exterior
Length:
Approx. 4488 mm (176.7 in)
Width:
Approx. 1722 mm (67.8 in)
Height:
Approx. 1399 mm (55.1 in)
Weights
Curb Weight:
Varies by engine and equipment, typically 1300-1450 kg (2866-3197 lbs).
🛡️ Safety Features
Ratings
Crash Test History:
Generally performed well in contemporary crash tests for its class, emphasizing Mercedes-Benz safety standards. Official NHTSA/IIHS ratings from the era may vary.
Active Features
Braking System:
Four-wheel Anti-lock Braking System (ABS) standard on most models.
Traction Control:
Optional Acceleration Skid Control (ASR) available on some models.
Passive Features
Airbags:
Driver's airbag standard, passenger airbag optional on some early 1995 models, becoming more common later in the year or for MY1996.
Seat Belts:
Front and rear seat belts, often with pre-tensioners for front occupants.
Body Structure:
Integrated safety cell design, crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM cassette radio or CD player with basic speaker systems. Options for upgraded sound systems from Becker.
Driver Assistance
Cruise Control:
Electronic cruise control system available as an option or standard on higher trims.
Parking Assistance:
No factory parking sensors or backup cameras on 1995 models. This was a feature introduced much later.
Climate Control
HVAC System:
Manual climate control standard, optional automatic climate control (Thermatic) available on some models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000-15,000 km (6,000-9,000 miles) or annually, whichever comes first, depending on driving conditions and oil used (refer to specific model requirements).
Major Service Interval:
Key intervals around 40,000-60,000 km (25,000-37,000 miles) for spark plugs, filters, and inspections.
Fluid Specifications
Engine Oil Specification:
API SJ/SL, ACEA A2/A3, or MB 229.1 specification. Viscosity grades commonly SAE 0W-30, 5W-30, 5W-40, 10W-30, 10W-40 depending on climate and engine variant. Always consult owner's manual.
Brake Fluid Specification:
DOT 4.
Power Steering Fluid:
MB-approved hydraulic fluid or Pentosin CHF 11S/202 (check specific application).
Known Issues
Common Problems:
Headlight switch failures, blower motor resistor failure, MAF sensor issues (on some gasoline engines), coolant leaks from plastic components (e.g., expansion tank, thermostat housing), aging vacuum lines, rear axle trailing arm bushing wear, rust in common areas (wheel arches, rocker panels).
Diesel Specific Issues:
Glow plug issues, injector pump seals, turbocharger problems (on turbodiesel models).
📚 Vehicle History
Brand Heritage
Heritage:
Continuation of Mercedes-Benz's reputation for engineering, quality, and safety established over decades.
Model Evolution
Introduction Of W202:
The W202 C-Class was introduced in 1993 as a replacement for the 190 (W201) model. The 1995 model year represents an early iteration of this platform.
Facelift Timeline:
The W202 received a significant facelift (known as 'Evolution' or 'Sportline' models externally) in 1997, not applicable to the 1995 model.
Production
Production Period:
1993-2000.
Manufacturing Locations:
Primary manufacturing in Germany (Sindelfingen and Bremen), with some production in South Africa and other international facilities.
🏆 Awards & Recognition
Recognitions
Automotive Awards:
While specific awards for the 1995 model year are not prominently publicized, the W202 platform generally received praise for its refinement, safety, and build quality in its segment, contributing to Mercedes-Benz's overall strong reputation.
Ratings
Reliability Perception:
Reliability perception is mixed. While mechanically robust if well-maintained, the aging electrical components and potential for rust are factors. The manual provides the knowledge to address these.
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