2002 Mercedes C-Class (W203) Service and Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: C-Class Model Code: W203 Year: 2002 Generation Generation Code: Second Generation (W203) Generation Years: 2000-2007 Codes Chassis Designation: W203 👋 Introduction Market Position...

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

C-Class

Model Code:

Year:

Generation

Generation Code:

Second Generation (W203)

Generation Years:

2000-2007

Codes

Chassis Designation:

👋 Introduction

Market Position

Class Segment:

Compact Executive Sedan/Coupe/Wagon

Target Market:

Premium compact car segment, competing with BMW 3 Series, Audi A4, Lexus IS.

Competitive Analysis

Key Competitors:

BMW 3 Series (E46), Audi A4 (B6), Lexus IS (XE10)

Key Features

Design Philosophy:

Modern, aerodynamic, and sophisticated design with signature Mercedes-Benz build quality.

Powertrain Options:

Range of inline-4 and V6 gasoline engines, plus diesel options in some markets.

Innovations:

Introduction of the modular MRA platform, advanced safety features, and improved interior comfort.

📋 Manual Details

Coverage Areas

Coverage Scope:

All Models & All Repairs A-Z

Coverage Type:

Vehicle Specific

Target Audience:

Dealership Technicians, Independent Repair Shops, Advanced DIYers

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF) - Searchable and Printable

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, timing, valve train, pistons, crankshaft, lubrication system, cooling system, engine management, emissions control.

Engine Electrical:

Ignition system, fuel injection system (EIS, ECU), starter, alternator, battery, wiring diagrams for engine components.

Transmission Manual:

Clutch, gearbox internal components, shifting mechanisms, maintenance, repair.

Transmission Automatic:

722.6 (5-Speed Automatic) - Overhaul, valve body, torque converter, electronic control, fluid and filter service.

Drivetrain:

Front-wheel drive system, driveshafts, CV joints, differentials (if applicable to specific models).

Suspension:

Front and rear suspension components, shock absorbers, struts, springs, control arms, bushings, alignment specifications.

Steering:

Power steering system, steering rack, column, tie rods, fluid specifications, repair procedures.

Brakes:

Front and rear brake systems (disc brakes), ABS, ESP, brake fluid specifications, rotor and pad replacement, caliper overhaul, bleeding procedures.

Electrical System:

Comprehensive wiring diagrams, fuse box locations and functions, lighting systems (headlights, taillights, interior), power windows, mirrors, seats, central locking.

Body And Interior:

Body panel removal and installation, door mechanisms, interior trim, seats, dashboard, climate control system, airbags, body repair.

HVAC:

Air conditioning system, heater core, blower motor, control modules, refrigerant specifications, service and repair.

Diagnostics:

On-board diagnostics (OBD-II), trouble codes (DTCs), diagnostic scan tool procedures, troubleshooting flowcharts.

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flushes, brake fluid replacement, transmission fluid service.

Repair Procedures:

Component replacement (alternator, starter, water pump, fuel pump), suspension and steering component repair, brake caliper rebuild, exhaust system repair, bodywork.

Troubleshooting:

System-specific diagnostic trees and flowcharts for common and uncommon problems across all major vehicle systems.

Technical Specifications:

Torque specifications for fasteners, engine data, electrical component resistance values, fluid capacities, diagnostic parameter ranges.

Special Tools:

Identification and usage instructions for specialized Mercedes-Benz tools required for specific repairs.

Technical Depth

Depth Of Coverage:

Comprehensive, from basic maintenance to full engine and transmission rebuilds, including electrical diagnostics and body repair.

📊 Manual Specifications

File Format

Format:

Searchability:

Fully searchable by keywords and phrases.

Printability:

Printable pages for physical reference.

Print Quality

Image Clarity:

High-resolution diagrams, schematics, and photographs.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code Example Gasoline 1:

M111 (2.0L Supercharged I4 - C200 Kompressor)

Engine Code Example Gasoline 2:

M112 (2.6L V6 - C240, 3.2L V6 - C320)

Engine Code Example Diesel:

OM611 (2.1L CDI I4 - C200 CDI, C220 CDI)

Performance

Horsepower Range:

115 hp to 215 hp (depending on engine variant)

Torque Range:

200 Nm to 310 Nm (depending on engine variant)

Fuel System

Fuel Delivery Gasoline:

Multi-point fuel injection (MPI) or Electronic Fuel Injection (EFI) with Sequential Fuel Injection (SFI).

Fuel Delivery Diesel:

Common Rail Direct Injection (CDI).

Maintenance

Oil Type Recommendation:

MB 229.5 / 229.51 (e.g., Mobil 1 0W-40, Castrol Edge 0W-40)

Oil Capacity Example:

Approx. 5.5 - 6.5 liters (depending on engine)

🔧 Transmission

Standard

Standard Transmission Type:

5-Speed Manual (rare on US models)

Optional

Optional Transmission Type:

5-Speed Automatic (722.6 - NAG)

Features

Automatic Features:

TouchShift (manual shifting mode), electronically controlled.

Maintenance

Automatic Transmission Fluid Type:

MB 236.14 (ATF 722.6, e.g., Pentosin ATF1)

Automatic Transmission Fluid Capacity:

Approx. 7-8 liters for complete service.

📐 Dimensions

Exterior

Length Sedan:

Approx. 4526 mm (178.2 in)

Width Sedan:

Approx. 1728 mm (68.0 in)

Height Sedan:

Approx. 1407 mm (55.4 in)

Wheelbase:

Approx. 2715 mm (106.9 in)

Weights

Curb Weight Range:

Approx. 1400 - 1550 kg (3086 - 3417 lbs)

🛡️ Safety Features

Ratings

NHTSA Front Impact Rating:

5-Star (for models tested)

IIHS Top Safety Pick:

Good (for models tested)

Active Features

Stability Control:

Standard ESP (Electronic Stability Program)

Braking Features:

ABS (Anti-lock Braking System), Brake Assist (BAS)

Passive Features

Airbags:

Front airbags, side airbags, front and rear head curtain airbags (optional).

Seat Technology:

Pretensioner seatbelts, active headrests (optional).

💡 Technology Features

Infotainment

Infotainment System:

COMAND (Cockpit Management and Navigation) or Audio 20 options.

Navigation:

Optional integrated GPS navigation system with CD-ROM maps.

Audio Features:

AM/FM radio, CD player, optional CD changer, cassette player (early models).

Driver Assistance

Cruise Control:

Standard Cruise Control with Speedtronic speed limiter.

Parking Assistance:

Optional Parktronic parking sensors (front and rear).

Connectivity

Phone Integration:

Optional UHI (Universal Hands-free Interface) for Bluetooth or cradle phone integration.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Variable (Assyst system), typically 10,000 - 15,000 miles or 1 year, whichever comes first.

Major Service Interval:

Service B (approx. 20,000-26,000 miles or 2 years) includes checks of suspension, brakes, fluid levels, filters, etc.

Fluid Specifications

Coolant Type:

MB 325.0 / 326.0 (Glysantin G48 Blue/Green Ethylene Glycol)

Brake Fluid Type:

DOT 4 Plus (or MB Spec 331.0)

Power Steering Fluid Type:

Pentosin CHF 11S (Green) or equivalent MB specification.

Known Issues

Common Problem 1:

Mass Air Flow (MAF) sensor failures leading to rough idle or stalling.

Common Problem 2:

Front SAM (Signal Acquisition Module) water ingress causing electrical issues.

Common Problem 3:

Cracked plastic intake manifolds on some V6 engines.

Common Problem 4:

Failure of the secondary air injection pump and system on some gasoline engines.

Common Problem 5:

Oil cooler seal leaks on M112 and M111 engines.

📚 Vehicle History

Brand Heritage

Brand Legacy:

Mercedes-Benz, founded in 1926, renowned for luxury, engineering, and safety.

Model Evolution

W203 Introduction:

Introduced in 1997 in Europe and 2000 in North America as the successor to the W202 C-Class.

W203 Facelift:

Facelift occurred for the 2005 model year, with updated styling and technology.

Production

Manufacturing Locations:

Bremen, Germany; Rastatt, Germany; Tuscaloosa, Alabama, USA.

🏆 Awards & Recognition

Recognitions

Award Example 1:

Ward's 10 Best Engines list (for certain engine variants, e.g., C320 V6).

Award Example 2:

Automobile Magazine All-Stars (for C-Class models).

Ratings

Consumer Reports Reliability:

Generally average to above average reliability, with specific model years and engines showing variations.

Certifications

Certification Standard:

Adherence to Mercedes-Benz's stringent internal quality and safety standards.