🏷️ Basic Information

Make:

Mercedes-Benz

Model:

C-Class

Body Style:

Wagon (S202)

Model Years Covered:

1996, 1997, 1998, 1999, 2000

Chassis Code:

S202

👋 Introduction

Market Position:

The Mercedes-Benz C-Class (W202/S202) represented Mercedes-Benz's entry into the compact executive segment, offering premium features and build quality in a more accessible package than the E-Class or S-Class. The S202 wagon variant provided increased practicality and versatility.

Competitors:

Competed against vehicles like the BMW 3 Series Touring (E36/E46), Audi A4 Avant, Volvo V70, and Saab 900/9-3 Combi.

Key Features Vehicle:

Renowned Mercedes-Benz build quality, comfortable ride, sophisticated engineering, available with a range of refined 4-cylinder, 6-cylinder gasoline, and diesel engines. The S202 wagon offered a spacious and flexible cargo area.

Key Features Manual:

Provides detailed step-by-step repair instructions, diagnostic flowcharts, torque specifications, and wiring diagrams essential for maintaining and repairing the S202 C-Class effectively.

📋 Manual Details

Coverage Scope:

Complete Workshop Service and Repair

All Engine Variants Covered:

Yes, the manual covers all engine variants offered for the S202 chassis during the specified model years.

All Transmission Variants Covered:

Yes, includes both manual and automatic transmissions fitted to the S202 wagon.

Body And Chassis Coverage:

Comprehensive coverage of body panels, structural components, suspension, steering, brakes, and wheels.

Electrical Schematics Detail:

Provides detailed, system-by-system wiring diagrams, including component locations and connector pinouts.

Estimated Pages:

Extensive (Specific count not provided, typical for comprehensive workshop manuals)

Manual Type:

Workshop Service and Repair Manual

Language:

English

Format:

Downloadable Digital Format (Likely PDF)

File Format:

Likely PDF, optimized for digital viewing and printing

Print Quality:

High-resolution, clear diagrams and text for ease of understanding

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

📖 Manual Coverage

Engine Systems:

Engine mechanical (M111, M104, M112, OM60x, OM611), lubrication, cooling, fuel injection (KE-Jetronic, EIS), ignition, emissions control, exhaust systems

Transmission Systems:

Automatic transmissions (722.4, 722.6), manual transmissions, clutch, driveshafts, differentials

Chassis Systems:

Front and rear suspension, steering (power steering, steering column), brakes (ABS, ESP), wheel alignment, chassis components

Electrical Systems:

Wiring diagrams, starter, alternator, battery, lighting, instrumentation, body electronics (FBS, CEM), comfort features, diagnostic connectors (OBD-II)

Body And Interior:

Body panels, doors, windows, glass, sunroof, seats, interior trim, HVAC system, climate control, body sealing

Powertrain Control:

Engine control modules (ECU), transmission control modules (TCU), sensor inputs (crankshaft position, camshaft position, throttle position, etc.), actuator outputs (injectors, ignition coils, throttle body).

Comfort And Convenience:

HVAC system operation and repair, power windows, power seats, central locking, sunroof mechanisms, interior lighting, wipers and washers.

Exhaust System:

Catalytic converters, mufflers, exhaust pipes, oxygen sensors, exhaust manifold gaskets. Includes procedures for replacement and diagnosis of exhaust leaks.

Maintenance Procedures:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement, brake pad and rotor replacement, tire rotation

Repair Procedures:

Engine overhaul, transmission overhaul/replacement, suspension component replacement, brake caliper rebuild/replacement, steering rack replacement, electrical component diagnosis and repair, body panel repair and replacement

Diagnostic Procedures:

Troubleshooting guides, symptom-based diagnosis, fault code interpretation, electrical system testing, component testing

Troubleshooting Flowcharts:

Detailed diagnostic flowcharts for common drivability, electrical, and mechanical issues. These are invaluable for efficient fault diagnosis.

Torque Specifications:

Comprehensive list of all critical torque specifications for engine components, suspension parts, chassis fasteners, wheel lug bolts, etc.

Wiring Diagrams:

Detailed electrical schematics for all vehicle systems, including engine, transmission, chassis, body, and comfort electronics. Crucial for electrical troubleshooting.

Technical Depth:

Comprehensive from basic maintenance to advanced diagnostics and complete unit overhauls

Engine Rebuild Detail:

Instructions for engine disassembly, cleaning, inspection, measurement of wear tolerances (e.g., cylinder bore, piston ring gap, bearing clearances), and reassembly.

Transmission Overhaul Detail:

Detailed procedures for the disassembly, inspection, repair, and reassembly of both manual and automatic transmissions, including torque converter replacement and valve body diagnostics.

⚙️ Engine Specifications

Engine Options:

Includes coverage for various 4-cylinder (M111) and 6-cylinder (M104, M112) gasoline engines, and 4-cylinder (OM60x, OM611) diesel engines.

Example Engine M111:

M111.920/921 (2.0L Inline-4): Approx. 136 HP @ 5500 rpm, 190 Nm (140 lb-ft) torque @ 3700 rpm

Example Engine M104:

M104.910 (2.8L Inline-6): Approx. 193 HP @ 5500 rpm, 265 Nm (195 lb-ft) torque @ 4000 rpm

Example Engine Om611:

OM611.961 (2.1L I4 Diesel - CDI): Approx. 102 HP @ 4200 rpm, 235 Nm (173 lb-ft) torque @ 1800-2600 rpm

Fuel System Gasoline:

Electronic Fuel Injection (EFI) - Bosch Motronic (ME, ME-S) and potentially older KE-Jetronic for earlier models. Includes distributors, injectors, fuel pump, pressure regulator.

Fuel System Diesel:

Direct injection (CDI - Common Rail Direct Injection) for later models, older models may use indirect injection or mechanical injection pumps.

🔧 Transmission

Standard Transmission:

Often a 5-speed manual transmission was standard on lower-end models. Automatic transmissions were widely popular.

Optional Transmission:

4-speed automatic (722.4) and 5-speed automatic (722.6 'NAG') transmissions were available, depending on engine and model year.

Automatic Transmission Features:

The 722.6 transmission featured electronic control for smoother shifts and better efficiency.

📐 Dimensions

Exterior Dimensions S202:

Length: ~4517 mm, Width: ~1720 mm, Height: ~1475 mm (Figures are approximate and may vary slightly by year/trim).

Interior Features:

Spacious cabin for its class, comfortable seating for five, premium materials consistent with Mercedes-Benz standards.

Cargo Volume S202:

Significant cargo capacity for a wagon, with folding rear seats for expanded storage. Exact volume figures vary by configuration but typically exceed sedan counterparts.

Curb Weight Range:

Approx. 1450 - 1650 kg depending on engine and equipment.

🛡️ Safety Features

Safety Ratings:

Likely achieved good safety ratings for its era in independent crash tests, reflecting Mercedes-Benz's commitment to safety engineering. Specific NHTSA/Euro NCAP ratings for S202 may be available.

Active Safety Features:

Optional ABS (Anti-lock Braking System), available ESP (Electronic Stability Program) on later models.

Passive Safety Features:

Front airbags, side airbags (optional on some models), front and rear crumple zones, reinforced passenger cell, seatbelt pre-tensioners.

💡 Technology Features

Infotainment Features:

Basic audio systems with radio and cassette/CD players. Optional climate control systems with manual or automatic temperature regulation. Early versions of Mercedes-Benz's telematics systems might be present on later models.

Driver Assistance Features:

ABS was standard, and ESP became available on later models. Cruise control was a common option.

Connectivity Features:

Limited connectivity by modern standards. Features like remote central locking and immobilizer (FBS - Fahrzeug-Batterie-System) were integrated.

🔧 Maintenance

Typical Oil Change Interval:

Every 10,000 - 15,000 km or 12 months, whichever comes first, using synthetic oil. Refer to the manual for specific intervals based on engine and driving conditions.

Transmission Fluid Interval:

Automatic transmission fluid and filter change typically recommended every 60,000 - 100,000 km. Manual transmission fluid changes less frequently, often at 100,000 km.

Engine Oil Specification:

Refer to the manual for specific API service categories and viscosity grades (e.g., MB 229.1, MB 229.3, SAE 0W-40, 5W-40, 5W-30 depending on engine and temperature).

Coolant Specification:

Mercedes-Benz approved coolant concentrate (e.g., G48 or similar ethylene glycol based) mixed with distilled water, typically a 50/50 ratio. Capacity varies by engine, but approx. 7-9 liters.

Automatic Transmission Fluid:

MB 236.1, MB 236.2, or MB 236.10/12 for the 722.6 transmission (Dexron III or equivalent for 722.4). Capacity approx. 8-9 liters for a full change with torque converter.

Brake Fluid Specification:

DOT 4 or DOT 4 Plus (MB 331.0) approved brake fluid. Flush and replace every 2 years.

Power Steering Fluid:

Mercedes-Benz specified power steering fluid (often a CHF-type fluid or MB 236.3). Refer to manual for exact type.

Rear Axle Differential Fluid:

GL-5 gear oil, with specific viscosity grades (e.g., 75W-90 or 80W-90) as per Mercedes-Benz specifications. Capacity approx. 1.5 - 2 liters.

Common Issues Overview:

Typical issues for this era of Mercedes-Benz can include: head gasket leaks on some engines, transmission conductor plate issues (722.6), MAF sensor faults, biodegradable wiring insulation degradation, rust in common areas (wheel arches, sills), suspension component wear (bushings, ball joints), and HVAC blower motor resistor failures.

Specific Issue Biodegradable Wiring:

Older Mercedes-Benz models used wiring insulation that degrades over time. The manual will detail identification and replacement procedures for affected harnesses.

Specific Issue Rust:

The S202 wagon is susceptible to rust, particularly around the rear wheel arches, tailgate, and rocker panels. The manual may offer guidance on inspection and repair.

Common Issue Mas Sensor:

Mass Airflow (MAF) sensor failures can lead to poor engine performance, rough idling, and check engine lights. The manual will cover diagnosis and replacement.

📚 Vehicle History

Brand Heritage:

Mercedes-Benz has a long-standing reputation for engineering excellence, safety, and luxury, dating back to the invention of the automobile. This heritage is reflected in the C-Class.

W202 Evolution:

The W202 generation (including the S202 wagon) was introduced in 1993 as the successor to the 190E. It marked a significant step in modernizing Mercedes-Benz's compact offerings. Mid-cycle updates occurred, including engine revisions and feature upgrades. The S202 wagon variant was introduced in 1996.

Production Period:

1993-2000 for W202 sedan, 1996-2000 for S202 wagon. The manual covers the latter half of this production run.

🏆 Awards & Recognition

General Recognition:

The W202/S202 generation was well-received for its blend of comfort, durability, and the prestige associated with the Mercedes-Benz brand. It helped Mercedes-Benz solidify its presence in the entry-level luxury market.

Customer Satisfaction:

Generally received positive ratings for build quality and ride comfort, though maintenance costs can be higher than non-premium brands.