🏷️ Basic Information

Make:

Mercedes-Benz

Model:

C-Class

Model Code:

W202

Engine Variant:

C220

Model Years Covered:

1996, 1997

Chassis Code:

W202

Engine Code Range:

M111 E22

👋 Introduction

Positioning:

The Mercedes-Benz C-Class (W202) represented Mercedes-Benz's entry into the compact executive sedan market, aiming to compete with models like the BMW 3 Series. The C220 variant offered a balance of performance and fuel efficiency.

Competitors:

BMW 3 Series (E36), Audi A4 (B5), Volvo S40, Lexus ES.

Vehicle Focus:

Known for Mercedes-Benz's characteristic build quality, safety, and refinement, the W202 C-Class was a popular choice in its segment.

Manual Value Proposition:

This manual is essential for owners and independent workshops seeking to perform comprehensive maintenance and repairs on their W202 C220, providing access to manufacturer-level repair information.

📋 Manual Details

Content Scope:

Complete Workshop Service and Repair

Estimated Pages:

1500+

Type:

Workshop Manual / Service Manual / Repair Manual

Language:

English

Format:

Downloadable PDF

📖 Manual Coverage

Engine:

Engine mechanical, cylinder head, block, crankshaft, pistons, camshafts, timing, lubrication, cooling, fuel injection (Bosch Motronic/KE-Jetronic variations), ignition system, emissions control, engine diagnostics and troubleshooting.

Transmission:

Manual and Automatic transmission (e.g., 717.4 Manual, 722.4/722.5 Automatic), clutch, gearbox overhaul, torque converter, hydraulic system, electronic control module (ECM) interfaces, shift linkage, fluid specifications, and troubleshooting.

Drivetrain:

Rear-wheel drive system, driveshaft, universal joints, differential, axle shafts, bearings, and seals.

Suspension:

Front and rear suspension components (struts, shocks, control arms, ball joints, bushings, springs), alignment specifications, wheel bearings, and troubleshooting.

Brakes:

Front and rear disc brakes, ABS (Anti-lock Braking System), brake calipers, rotors, pads, master cylinder, brake lines, parking brake, hydraulic system diagnostics, bleeding procedures, and component replacement.

Steering:

Power steering system, steering rack, steering column, tie rods, power steering pump, fluid types, and troubleshooting.

Electrical:

12V electrical system, battery, alternator, starter motor, lighting (headlights, taillights, interior), ignition system, instrument cluster, relays, fuses, wiring diagrams, diagnostic trouble codes (DTCs), body control modules (BCM), and infotainment system basic troubleshooting.

Climate Control:

HVAC system (heating, ventilation, air conditioning), blower motor, evaporator, condenser, refrigerant system, climate control panel, and troubleshooting.

Body:

Body panels, doors, hood, trunk, bumpers, glass, seals, interior trim, body hardware, anti-corrosion treatment, and basic body repair procedures.

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, fluid checks and changes (coolant, brake fluid, power steering fluid, transmission fluid, differential fluid), lubrication points, and battery maintenance.

Repair:

Engine component removal and installation (e.g., alternator, starter, fuel injectors), brake caliper and rotor replacement, suspension component replacement, exhaust system repair, cooling system repair, fuel system component replacement, and electrical component troubleshooting and replacement.

Diagnostics:

Troubleshooting guides based on symptoms, diagnostic trouble code (DTC) interpretation and clearing, component testing procedures, use of diagnostic tools (e.g., OBD-II scanners for post-1996 models where applicable), and electrical circuit tracing.

Overhaul Rebuild:

Detailed procedures for engine overhaul, cylinder head reconditioning, transmission rebuilding (manual and automatic), differential overhaul, and brake system overhauls.

Technical Specifications:

Torque specifications for all fasteners, engine timing specifications, valve clearances, fluid capacities, electrical system voltages, diagnostic parameters, and alignment settings.

Depth:

Comprehensive, from basic maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and electrical schematics.

📊 Manual Specifications

Format Details:

High-resolution, searchable PDF document for easy navigation and printing. Optimized for digital viewing.

Quality:

Designed for clarity with sharp text and diagrams, suitable for printing specific pages for workshop use.

Binding:

N/A (Digital Download - PDF)

Paper:

N/A (Digital Download - PDF)

⚙️ Engine Specifications

Engine Type:

Inline-4 Cylinder, DOHC (Double Overhead Camshaft)

Engine Code:

M111 E22

Displacement:

2.2 Liters (2199 cc)

Horsepower:

Approx. 148-150 PS (146-148 hp) at 5500 rpm (depending on market and specific variant)

Torque:

Approx. 210-215 Nm (155-159 lb-ft) at 4000 rpm (depending on market and specific variant)

Fuel Delivery:

Bosch KE-Jetronic (Mechanical-Electronic Fuel Injection) or later Bosch Motronic (Electronic Fuel Injection) variations.

Fuel Type:

Unleaded Petrol (Gasoline)

Ignition Type:

Electronic Ignition (Distributorless Ignition System - DIS or Coil-on-Plug variants)

Coolant Type:

Mercedes-Benz approved G48 Coolant (Blue/Green) or equivalent ethylene glycol based coolant with corrosion inhibitors.

🔧 Transmission

Standard Transmission:

5-speed Manual Transmission

Optional Transmission:

4-speed Automatic Transmission (e.g., 722.4, 722.5)

Automatic Features:

Selectable modes (e.g., Economy/Sport), torque converter lock-up.

Manual Transmission Fluid:

API GL-4 or GL-5 rated, SAE 75W-90 or 80W-90 gear oil (refer to specific chassis codes for exact MB approval numbers).

Automatic Transmission Fluid:

MB Approved ATF (Automatic Transmission Fluid) such as MB 236.1, 236.2, or 236.3 depending on transmission variant. Typically Dexron III compatible fluids if MB approved.

📐 Dimensions

Length:

Approx. 4488 mm (176.7 in)

Width:

Approx. 1717 mm (67.6 in)

Height:

Approx. 1390 mm (54.7 in)

Wheelbase:

Approx. 2717 mm (107.0 in)

Curb Weight:

Approx. 1350-1450 kg (2976-3197 lbs) depending on equipment.

Gross Vehicle Weight:

Approx. 1850-1950 kg (4079-4300 lbs).

🛡️ Safety Features

Crash Test Performance:

While specific NHTSA/Euro NCAP ratings for these exact years may vary, the W202 was designed with a strong focus on safety, incorporating Mercedes-Benz's signature safety cell and crumple zones.

ABS:

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional ASR (Anti-Slip Regulation) traction control on some models.

Airbags:

Driver and front passenger airbags standard. Side airbags available as an option on later models or higher trims.

Seatbelts:

Pretensioner seatbelts with force limiters, rear seat belt reminders.

Body Structure:

Reinforced safety cell, side impact protection beams, energy-absorbing steering column.

💡 Technology Features

Audio System:

Factory-fitted radio/cassette player with potential for CD changer integration. Speaker configurations varied by trim level.

Climate Control Options:

Manual HVAC system or optional automatic climate control (ACC) on higher trims.

Cruise Control:

Standard or optional cruise control system.

Parking Assistance:

Rear parking sensors were an optional feature on some models.

Vehicle Diagnostics:

On-board diagnostics (OBD) capabilities, with OBD-II port for diagnostic scanners on 1996 and later models (though interpretation might differ from later standards).

🔧 Maintenance

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 quality.

Air Filter Replacement:

Every 30,000 - 45,000 km (18,000 - 27,000 miles) or as needed based on inspection.

Spark Plug Replacement:

Intervals vary significantly by spark plug type (e.g., copper vs. platinum). Consult manual for specific recommendation, often in the 50,000-100,000 km range.

Coolant Flush:

Every 2-3 years or 50,000 - 75,000 km (30,000 - 45,000 miles).

Engine Oil Capacity:

Approx. 5.0 - 5.5 Liters (5.3 - 5.8 Quarts) with filter change. Specific grade: SAE 5W-40 or 5W-30 Synthetic/Semi-Synthetic recommended for optimal performance, meeting MB 229.1 or MB 229.3 specifications.

Brake Fluid Type:

DOT 3 or DOT 4, meeting Mercedes-Benz specification 331.0. Must be replaced every 2 years to prevent moisture absorption.

Common Problems:

Cracked vacuum lines, failing MAF sensor (on later Motronic systems), sagging headliner, worn suspension bushings, rear axle mounting bracket failure (subframe mounts), power seat module failure, SRS warning light due to seat occupancy sensor or clock spring issues, early fuel pump failures.

Preventative Maintenance:

Regular inspection of rubber hoses and bushings, checking for coolant leaks, timely replacement of fuel filters and air filters, and monitoring for any unusual noises or warning lights are crucial for longevity.

📚 Vehicle History

Mercedes Benz Legacy:

Mercedes-Benz has a long-standing reputation for engineering excellence, safety, and luxury automotive manufacturing, dating back to the late 19th century.

W202 Introduction:

The W202 chassis C-Class was introduced in 1993, replacing the 190E (W201). It marked a significant step towards modernizing the Mercedes-Benz sedan lineup, offering more aerodynamic styling and updated technology.

Mid Cycle Updates:

While the core design remained consistent, minor updates occurred during the W202's lifecycle, including potential revisions to engine management, interior trim, and feature availability for the 1996-1997 model years covered by this manual.

Production Years:

1993-2000

Manufacturing Locations:

Primary production in Germany (Sindelfingen), with additional plants in South Africa and other international locations.

🏆 Awards & Recognition

Safety Awards:

While specific awards for the 1996-1997 C220 are not widely publicized as standalone entities, the W202 chassis generally received positive reviews for its build quality and safety features, consistent with Mercedes-Benz's established reputation for safety engineering.

Consumer Reports:

Consumer reports from the period often highlighted the C-Class's comfortable ride, solid construction, and reliable powertrains, although some noted higher maintenance costs compared to some competitors.