🏷️ Basic Information

Make:

Mercedes-Benz

Model:

C240

Year:

2005

Chassis Code:

W203

Engine Code:

M272.910

👋 Introduction

Positioning:

The 2005 Mercedes-Benz C240 (W203) represented Mercedes-Benz's entry-level luxury sedan, targeting a younger demographic and competing with models like the BMW 3 Series and Audi A4. This manual provides the essential technical data for maintaining and repairing this sophisticated vehicle.

Comparison:

Competed strongly in its segment with a focus on comfort, build quality, and a refined driving experience, often surpassing rivals in interior materials and ride sophistication, though sometimes perceived as less dynamically engaging than its German counterparts.

Vehicle Features:

Known for its robust engineering, high-quality interior, and comfortable ride. Offered a balance of luxury and performance, making it a popular choice for executive and family use.

Value:

This software manual is an indispensable resource for Mercedes-Benz owners and independent workshops, offering access to precise factory-level repair procedures, specifications, and diagnostic information, enabling cost-effective and accurate maintenance and repairs.

📋 Manual Details

Coverage Description:

Comprehensive service and repair information for the 2005 Mercedes-Benz C240, covering all mechanical, electrical, and body systems.

Estimated Pages:

Over 1000 (typical for comprehensive factory service manuals)

Type:

Official Factory Service Manual (Software)

Language:

English

Format:

Software (likely digital download, potentially with interactive diagrams and search functionality)

📖 Manual Coverage

Engine:

Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, engine management system (ECU/DME), performance tuning, and diagnostics.

Transmission:

Automatic transmission (5G-TRONIC 722.6), torque converter, shift control, hydraulics, electronics, and diagnostics. Manual transmission information may be included if applicable to specific markets or sub-models.

Drivetrain:

Front axle, rear axle, drive shafts, CV joints, differentials, and related components.

Suspension:

Front and rear suspension, struts, shocks, springs, control arms, ball joints, bushings, sway bars, and wheel alignment specifications.

Brakes:

Brake system hydraulic components, ABS (Anti-lock Braking System), ESP (Electronic Stability Program), brake pads, rotors, calipers, lines, master cylinder, and bleeding procedures.

Steering:

Power steering system, steering rack, tie rods, power steering pump, fluid specifications, and diagnosis.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), fuses, relays, wiring diagrams, and component location.

Body And Chassis:

Body panels, doors, hood, trunk, bumpers, interior trim, glass, mirrors, structural components, and corrosion protection.

Climate Control:

HVAC (Heating, Ventilation, and Air Conditioning) system, A/C compressor, refrigerant, evaporator, condenser, blower motor, climate control unit, and troubleshooting.

Infotainment And Comfort:

Audio system, navigation system (if equipped), central locking, power windows, power seats, sunroof operation, and interior electronics.

Safety Systems:

Airbag system (SRS), seat belt pre-tensioners, and related sensor components.

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, fluid flushes (coolant, brake fluid, transmission fluid), and general upkeep.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting guides, error code interpretation, and common problem diagnosis.

Repair And Overhaul:

Detailed step-by-step instructions for component removal, installation, repair, and rebuilding for all major vehicle systems.

Diagnostics:

Use of diagnostic tools (e.g., STAR Diagnosis system), reading and clearing fault codes, live data stream analysis, and component testing.

Special Tools:

Identification and usage instructions for specialized tools required for specific repair and maintenance procedures.

Wheel Alignment Specs:

Includes detailed front and rear wheel alignment specifications (camber, caster, toe) for optimal handling and tire wear.

Timing Chain Replacement:

Covers procedures for inspecting and replacing the timing chain and associated components, a critical maintenance item for the M272 engine series.

Exhaust System Repair:

Includes guidance on diagnosing and repairing exhaust leaks, replacing mufflers, catalytic converters, and exhaust hangers.

Cooling Fan And Clutch Service:

Details on servicing the engine's cooling fan assembly and associated components.

Depth:

Expert level, covering routine maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics, and body repair.

Wiring Diagrams:

Comprehensive and detailed electrical wiring diagrams for all vehicle systems, color-coded and clearly labeled.

Diagnostic Trouble Codes:

Extensive lists of OBD-II (On-Board Diagnostics) and proprietary Mercedes-Benz diagnostic trouble codes (DTCs), along with their definitions and troubleshooting steps.

Torque Specifications:

Precise torque values for all critical fasteners and bolts throughout the vehicle.

📊 Manual Specifications

File Type:

Digital Software

Searchability:

Likely fully searchable text, allowing quick access to specific topics.

Printability:

High-resolution, suitable for printing individual pages or sections.

Binding:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

2.6L V6 (M272 family predecessor)

Engine Displacement Liters:

2.58

Bore X Stroke Mm:

82.0 x 81.0

Compression Ratio:

10.5:1

Horsepower Hp:

168

Torque Lb-Ft:

177

Fuel Delivery:

Electronic Fuel Injection (EFI) with Sequential Port Injection.

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended).

Engine Control Unit:

ME 2.8.3 (likely) or similar Bosch Motronic variant.

Ignition System:

Distributorless Ignition System (DIS) with Coil-on-Plug (COP) ignition coils.

🔧 Transmission

Type:

5-speed Automatic (722.6 '5G-TRONIC')

Type:

6-speed Manual (less common in North America for this model)

Automatic Modes:

Comfort (C) and Sport (S) modes, offering different shift points and throttle response.

Automatic Transmission Fluid:

MB-Approval 236.10 or 236.12 (e.g., Shell ATF 134, Mobil ATF 134).

Automatic Transmission Fluid Capacity Liters:

Approx. 7.5 - 8.0 (dry fill), 3.5 - 4.0 (drain and refill)

📐 Dimensions

Length Mm:

4526

Width Mm:

1728

Height Mm:

1425

Wheelbase Mm:

2715

Curb Weight Kg:

1480 - 1520 (depending on equipment)

Gross Vehicle Weight Rating Kg:

Approx. 2000

🛡️ Safety Features

NHTSA Frontal Driver Rating:

5-Star (for 2005 model year, typical for W203)

NHTSA Frontal Passenger Rating:

5-Star (for 2005 model year, typical for W203)

IIHS Front Crash Rating:

Good (for 2005 model year, typical for W203)

Esp Stability Control:

Standard, integrates with ABS and traction control.

ABS Brakes:

Standard, 4-wheel Anti-lock Braking System.

Traction Control:

Standard, ASR (Anti-Slip Regulation).

Airbags:

Front airbags (driver/passenger), side airbags (front), window curtain airbags (front/rear).

Seatbelts:

Pre-tensioning front seat belts with force limiters, rear 3-point seat belts.

Child Seat Anchors:

ISOFIX/LATCH system compatibility.

💡 Technology Features

Audio System:

Factory AM/FM/CD player with options for premium sound systems (e.g., Harman Kardon) and optional CD changer.

Navigation:

Optional COMAND (Cockpit Management and Navigation) system with DVD-based navigation.

Cruise Control:

Standard cruise control, potentially with DISTRONIC adaptive cruise control on higher trims/optional.

Bluetooth Handsfree:

Optional, depending on the COMAND system and telematics package.

Keyless Go:

Optional keyless entry and ignition system.

Rain Sensing Wipers:

Optional feature.

🔧 Maintenance

Oil Change Interval:

Flexible Service System (ASSYST), typically every 10,000 miles or 12 months, whichever comes first, depending on driving conditions.

Major Service Interval:

Variable based on ASSYST indicators, but common points include spark plug replacement around 60,000-100,000 miles and transmission fluid service around 40,000-70,000 miles.

Engine Oil Specification:

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

Engine Oil Capacity Liters:

Approx. 6.5

Coolant Specification:

MB-Approval 325.0 (typically a long-life silicate-free antifreeze/coolant).

Coolant Capacity Liters:

Approx. 8.0

Brake Fluid Specification:

DOT 4 (MB-Approval 331.0 recommended).

Common Problems:

Cracked intake manifold (plastic component), vacuum leaks, electronic throttle body issues, crank position sensor failure, premature wear of serpentine belt tensioner and idler pulleys, potential for oil leaks from valve cover gaskets and oil filter housing.

Troubleshooting Tips:

The manual will detail diagnostic procedures for these common issues, including component testing and recommended repair sequences.

📚 Vehicle History

Heritage:

Mercedes-Benz, founded in 1926, is renowned for its engineering excellence, luxury, and safety innovations, with a long history of producing premium vehicles.

W203 Generation:

The W203 C-Class generation (1997-2007) represented a significant modernization for Mercedes-Benz's compact executive sedan, offering improved styling, technology, and driving dynamics compared to its predecessors.

Production Years:

W203 C-Class: 1997-2007 (facelifted in 2004)

Manufacturing Locations:

Primary assembly in Bremen, Germany, with production also occurring in other global facilities.

🏆 Awards & Recognition

Segment Awards:

While specific individual awards for the 2005 C240 might be scarce, the W203 generation generally received positive reviews for its build quality, safety, and refinement, contributing to Mercedes-Benz's consistent reputation for excellence in the luxury sedan segment.

Consumer Reports Ratings:

Consumer Reports typically rated Mercedes-Benz vehicles, including the C-Class, as average to above average in reliability, with specific model years and components having varying reliability scores.