Positioning:
The Mercedes-Benz C220 (W202) represented Mercedes-Benz's entry into the compact executive sedan segment, offering a more accessible yet premium option compared to the E-Class.
Competitors:
Competed against vehicles like the BMW 3 Series (E36), Audi A4 (B5), Lexus IS200/IS300, and Volvo S40.
Vehicle Features:
Known for Mercedes-Benz build quality, comfort, safety, and refined driving experience, albeit with a focus on luxury and durability over outright sportiness.
Purpose:
To provide comprehensive technical information for the diagnosis, maintenance, and repair of the 1996 Mercedes-Benz C220, empowering owners and technicians with factory-level knowledge.
Engine Mechanical:
Engine disassembly, assembly, timing, valve train, piston/ring inspection, crankshaft, camshaft, cylinder head, block, seals, gaskets, lubrication system, cooling system.
Engine Management:
Fuel injection system (Bosch EDC/MPI), ignition system, emissions control, sensors, actuators, ECU diagnostics, fault codes.
Transmission Mechanical:
Manual and Automatic transmission overhaul, clutch, torque converter, gear sets, shifting mechanisms, seals, fluid service.
Drivetrain:
Driveshafts, constant velocity (CV) joints, differential, rear axle assembly, wheel bearings.
Suspension:
Front and rear suspension components, struts, shock absorbers, springs, control arms, bushings, steering knuckles, alignment specifications.
Steering:
Power steering system, steering rack, steering column, tie rods, power steering pump, fluid service.
Brakes:
Hydraulic brake system, ABS system, brake calipers, master cylinder, brake lines, brake pads, rotors, drum brakes (if applicable), parking brake.
Electrical System:
Battery, charging system (alternator), starter motor, lighting system (headlights, taillights, interior), fuses, relays, wiring diagrams.
Body And Interior:
Body panel removal/installation, doors, hood, trunk, bumpers, interior trim, seats, dashboard, HVAC system (heating, ventilation, air conditioning).
Comfort And Convenience:
Power windows, power locks, mirrors, sunroof, central locking system, cruise control.
Maintenance Procedures:
Oil changes, filter replacements, fluid flushes, spark plug replacement, belt replacement, tune-ups, air filter replacement, cabin air filter replacement.
Repair Procedures:
Component removal and installation for all major systems, engine rebuild, transmission overhaul, brake system repair, suspension component replacement.
Troubleshooting:
Diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides, electrical system diagnostics, engine performance issues.
Diagnostics:
OBD-II system basics (though limited in this era compared to modern vehicles), using diagnostic tools, interpreting sensor data, fault code lookup.
Special Tools:
Listing and explanation of necessary special tools for specific repair procedures.
Depth:
Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic fluid changes to complete engine and transmission rebuilds.
Oil Change Interval:
Typically every 10,000 - 15,000 km (6,000 - 9,000 miles) or 12 months, whichever comes first, depending on driving conditions and oil used.
Air Filter Replacement:
Every 30,000 - 60,000 km (18,000 - 36,000 miles) or as per manual recommendation.
Fuel Filter Replacement:
Typically every 40,000 - 60,000 km (24,000 - 36,000 miles) for diesel models.
Coolant Flush:
Every 2-3 years or 40,000-60,000 km.
Engine Oil:
Refer to manual for specific MB-Approval specification (e.g., MB 229.1 or MB 228.3 for diesel, depending on oil formulation). Viscosity typically 5W-40 or 10W-40 for diesel.
Transmission Fluid Manual:
Gear Oil API GL-4, SAE 75W-90 (specific MB approval might apply).
Transmission Fluid Automatic:
MB Automatic Transmission Fluid (ATF) specification (e.g., MB 236.6 or similar for 722.4 transmission).
Brake Fluid:
DOT 3 or DOT 4.
Coolant:
Mercedes-Benz Antifreeze/Coolant (MB 325.0 or MB 326.0) or equivalent silicate-free coolant.
Engine Mbl:
OM604 diesels are generally robust, but injector pump issues (EDC system), glow plug failures, and vacuum leaks can occur. Turbocharged versions (C250 TD) may have turbocharger-related wear.
Suspension Mbl:
Worn control arm bushings, ball joints, and tie rod ends are common wear items. Rear self-leveling suspension (if equipped) can have pump or strut issues.
Electrical Mbl:
Wiring harness issues (particularly around engine bay), headlight switch failures, window regulator problems, and blower motor resistor failures.
Cooling Mbl:
Plastic coolant expansion tanks can become brittle and crack. Thermostat housing leaks.