🏷️ Basic Information

Make:

Mercedes-Benz

Model:

W202

👋 Introduction

Target Audience:

DIY enthusiasts, independent repair shops, and Mercedes-Benz owners seeking detailed technical information to perform maintenance and repairs themselves.

Advantage:

Provides professional-level diagnostic and repair data equivalent to what authorized Mercedes-Benz workshops utilize, often at a fraction of the cost of official documentation. Its comprehensiveness is a key differentiator.

Detail Level:

Extremely detailed, with step-by-step instructions and diagrams, making complex procedures accessible.

Content Scope:

Covers all major vehicle systems, including electrical schematics, torque settings, fluid capacities, and spare parts illustrations.

📋 Manual Details

Manual Type:

Service and Repair Manual

Language:

Russian

Format:

PDF

📖 Manual Coverage

Engine:

Detailed coverage including M111 (2.0L), M104 (2.8L, 3.2L), OM601 (2.0L Diesel), OM602 (2.5L Turbo Diesel), OM605 (2.5L Turbo Diesel), OM606 (3.0L Turbo Diesel) engine families. Includes engine mechanicals, cylinder head, crankshaft, pistons, timing system, lubrication, cooling, and fuel injection systems.

Injection Ignition System:

Comprehensive details on fuel injection (e.g., Bosch KE-Jetronic, LH-Jetronic, HFM) and ignition systems, including component testing, troubleshooting, and adjustments.

Clutch:

Service and repair procedures for clutch actuation, clutch disc, pressure plate, and flywheel for manual transmissions.

Gearbox:

Detailed repair and maintenance for both manual (e.g., Getrag 717.4xx) and automatic transmissions (e.g., 722.4, 722.5, 722.6). Includes shift linkage, internal components, torque converter, and hydraulic control.

Suspension System:

Front and rear suspension repair, including struts, shock absorbers, control arms, bushings, and spring replacement. Geometry and alignment specifications.

Wheels:

Wheel bearing replacement, tire fitment, and wheel specifications. Includes information on alloy and steel wheels.

Braking System:

Front and rear brake system diagnostics, including disc brake service, drum brake service (where applicable), hydraulic components (master cylinder, calipers, wheel cylinders), ABS system troubleshooting, and bleeding procedures.

Control Driving Instructions:

While not a primary focus of a service manual, may include references to basic operational checks or adjustments relevant to maintenance.

Air Temp Control System:

Service and repair of the HVAC system, including refrigerant handling (where applicable), blower motor, evaporator, condenser, heater core, climate control modules, and cabin air filter replacement.

Electrical System:

Extensive coverage of the W202 electrical system. Includes detailed wiring diagrams for various circuits (engine management, lighting, power windows, central locking, etc.), component testing, fuse/relay identification, diagnostic procedures, and troubleshooting for common electrical faults.

Bodywork:

Information on body panel repair, door mechanisms, window regulators, seat adjustments, interior trim removal, and basic body sealant procedures.

Exploded Views Diagrams:

Abundant exploded view diagrams illustrating component relationships and assembly sequences for various systems, crucial for correct reassembly.

Maintenance:

Routine maintenance tasks such as oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, and belt inspections/replacements.

Repair:

Detailed step-by-step repair procedures for virtually all mechanical and electrical components, from minor adjustments to major component overhauls like engine rebuilding or transmission repair.

Diagnostics:

Troubleshooting guides and diagnostic procedures for identifying common faults and failures across all vehicle systems.

Depth:

Complete workshop level. Covers everything from basic preventative maintenance to complex engine and transmission rebuilds, including in-depth electrical system troubleshooting and component-level diagnostics.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable PDF, allowing users to quickly find specific terms or procedures.

Printability:

All pages are printable, allowing users to create physical copies of specific sections or the entire manual for workshop use.

Binding:

N/A (Digital Format)

Paper Quality:

N/A (Digital Format - printable on user's choice of paper)

⚙️ Engine Specifications

Engine Families:

M111 (Inline-4 petrol), M104 (Inline-6 petrol), OM601 (Inline-4 diesel), OM602 (Inline-5 diesel), OM605 (Inline-5 diesel), OM606 (Inline-6 diesel). Specific engine codes such as M111.920, M111.921, M104.900, M104.904, M104.910, OM601.912, OM602.910, OM602.912, OM605.910, OM605.911, OM606.910, OM606.912 are typically covered.

Typical Power Output Petrol:

Range from 120 hp (M111.920) to 279 hp (M104.923 AMG variants, though standard M104 were around 193-217 hp).

Typical Power Output Diesel:

Range from 75 hp (OM601.912) to 177 hp (OM606.962 Turbo Diesel).

Petrol Injection:

Electronic fuel injection systems, including Bosch KE-Jetronic (older models), Bosch LH-Jetronic, and Bosch HFM (Hot Film Mass Airflow) control.

Diesel Injection:

Mechanical injection pumps (e.g., Bosch VE, EDC) for naturally aspirated and turbo-diesel variants.

🔧 Transmission

Manual Availability:

Available with 5-speed manual transmissions (e.g., Getrag 717.4xx series) on many variants.

Automatic Availability:

Optional 4-speed (e.g., 722.4) and 5-speed (e.g., 722.5, 722.6) automatic transmissions.

Automatic Features:

Lock-up torque converter, electronic or hydraulic control depending on the transmission variant.

📐 Dimensions

Body Styles:

Sedan (4-door) and Estate/Wagon (S202, 5-door).

Wheelbase:

Approximately 2715 mm (106.9 inches).

Length:

Sedan: Approx. 4488 mm (176.7 inches); Estate: Approx. 4516 mm (177.8 inches).

Curb Weight Range:

Approximately 1350 kg to 1650 kg, depending on engine and equipment.

🛡️ Safety Features

Euro Ncap Era:

The W202 predates rigorous Euro NCAP testing as we know it today, but was designed with Mercedes-Benz's established safety principles, including a strong body structure.

ABS:

Standard Anti-lock Braking System (ABS) on most, if not all, variants.

Airbags:

Driver and passenger front airbags became standard over the production run. Side airbags were optional on later models.

Crumple Zones:

Designed with front and rear crumple zones for improved crash energy absorption.

💡 Technology Features

Audio Systems:

Various factory-installed audio systems, often with cassette or CD players. Later models had improved sound systems and integrated displays.

Cruise Control:

Cruise control was a common option on many W202 models.

Traction Control:

ASR (Acceleration Skid Control) was available as an option on many variants.

🔧 Maintenance

Oil Change Interval Petrol:

Typically every 10,000-15,000 km or 12 months, depending on service indicator ('Service A' or 'Service B').

Oil Change Interval Diesel:

Typically every 7,500-10,000 km or 12 months, depending on service indicator.

Transmission Fluid Interval:

Automatic transmissions often recommended fluid and filter change at 60,000 km, though manual transmissions typically do not require regular fluid changes unless issues arise.

Engine Oil Type Petrol M111:

MB 229.1 or 229.3 specification, typically 0W-40, 5W-40, or 10W-40 depending on climate.

Engine Oil Type Diesel Om60X:

MB 229.1 specification, typically 5W-40 or 10W-40 depending on climate. Turbocharged models may require specific specs.

Coolant Type:

MB 325.0 (Ethylene Glycol based) coolant, mixed with distilled water in a 50/50 ratio.

Brake Fluid Type:

DOT 4 (MB 331.0 specification).

Common Failures M111:

Mass airflow sensor (MAF) issues, lambda sensor failures, idle control valve problems, occasional head gasket issues on high-mileage vehicles.

Common Failures M104:

Head gasket failures, particularly around the thermostat housing; distributor issues; oil leaks from valve cover gaskets.

Common Failures Diesel:

Glow plug issues, injector pump seals, turbocharger wear on higher mileage units, vacuum line leaks affecting engine performance.

Common Failures Electrical:

Cracked wiring insulation (especially in engine bay), instrument cluster failures (pixelation), ABS sensor failures, blower motor resistor failure.

Common Failures Suspension Body:

Front suspension sagging (strut mounts, control arm bushings), rear axle bushings (H-frame bushings), rust on wheel arches and sills, rear window seal leaks (Estate).

📚 Vehicle History

Legacy:

The W202 succeeded the highly successful W201 (190E) and was Mercedes-Benz's entry into the compact executive sedan market, aimed at a younger demographic and a more accessible price point.

Production Years:

Produced from 1993 to 2000.

Facelift:

Received a significant facelift in 1997, introducing revised bumpers, side skirts, wheel designs, updated interior trim, and engine improvements (e.g., introduction of the M111 with Variocam).

Manufacturing Locations:

Primarily manufactured in Germany (Sindelfingen) and South Africa.

🏆 Awards & Recognition

Historical Recognition:

While specific 'awards' might not be widely documented for this model in isolation, the W202 was a crucial model for Mercedes-Benz, expanding its market reach and reinforcing its reputation for quality and durability, which is an implicit recognition in itself.