🏷️ Basic Information

Make:

Mercedes-Benz

Model:

C-Class

Model Code:

W202

Model Year:

1997

Chassis Code:

W202

Engine Codes Covered:

Various M111, M104, OM60x series (specific codes to be confirmed by manual content)

👋 Introduction

Positioning:

The Mercedes-Benz C-Class (W202) represented Mercedes-Benz's entry into the compact executive car segment, offering a blend of luxury, comfort, and Mercedes-Benz engineering at a more accessible price point than its larger siblings.

Competitors:

Competed against key luxury compact sedans like the BMW 3 Series (E36), Audi A4 (B5), and Lexus ES 300 (though the ES was slightly larger).

Distinctive Features:

Known for its solid build quality, comfortable ride, refined interior, and the characteristic Mercedes-Benz driving experience. Introduced advanced safety features for its class.

Value For Buyers:

This manual is invaluable for W202 owners, providing the same authoritative information used by dealership technicians. It empowers owners to perform their own maintenance, diagnostics, and repairs, saving money and ensuring proper care of a sophisticated vehicle.

📋 Manual Details

Covered Models:

All 1997 Mercedes-Benz C-Class (W202) variants, including Sedan and Wagon (Estate) body styles and all engine configurations.

Estimated Page Count:

Likely several hundred pages, typical for factory-level service manuals.

Type:

Factory Service and Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Engine assembly, cylinder head, valve train, pistons, crankshaft, camshafts, lubrication system, cooling system, engine overhaul.

Engine Management:

Engine control unit (ECU), fuel injection system, ignition system, sensors, actuators, emission control systems.

Transmission:

Automatic Transmission (e.g., 722.6 '5G-TRONIC' depending on engine), Manual Transmission, clutch system, torque converter, transmission overhaul, fluid service.

Drivetrain:

Driveshafts, propeller shafts, universal joints, differentials, axles, CV joints, wheel bearings.

Suspension And Steering:

Front and rear suspension components, shock absorbers, springs, control arms, ball joints, steering gear, power steering system, steering column.

Brakes:

Brake system diagnostics, brake pads, rotors, calipers, brake lines, ABS (Anti-lock Braking System) components and troubleshooting, parking brake.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting system, power windows, power seats, central locking, cruise control.

Climate Control:

Air conditioning (AC) system, heater, ventilation, climate control unit, refrigerant service, blower motor, evaporator, condenser.

Safety Systems:

Supplemental Restraint System (SRS) - airbags and seat belt pretensioners, diagnostic procedures for SRS faults.

Body And Interior:

Body panels, doors, hood, trunk/tailgate, glass, mirrors, interior trim, seats, instrument panel, dashboard, door locks, wiper and washer systems.

Multiplex Communication:

CAN (Controller Area Network) communication systems, multiplex wiring systems, diagnostic information for these networks.

Maintenance Procedures:

Routine maintenance, oil changes, filter replacements, fluid checks and top-offs, belt inspections and replacements, spark plug replacement.

Diagnostic Procedures:

Troubleshooting guides for common and uncommon faults, diagnostic trouble codes (DTCs) and their meanings, testing procedures for sensors and actuators.

Repair Procedures:

Detailed step-by-step instructions for virtually all repair tasks, from simple component replacements to complex engine and transmission overhauls.

Component Testing:

Procedures for testing electrical components, mechanical assemblies, and control modules.

Wiring Schematics:

Complete and detailed wiring diagrams for all vehicle systems, crucial for electrical troubleshooting and repairs.

Torque Specifications:

Precise torque values for all critical fasteners to ensure proper assembly and prevent component damage.

Special Tools:

Identification and usage of special tools required for specific Mercedes-Benz W202 repairs.

Fuel System Service:

Fuel pump testing and replacement, fuel filter replacement, injector diagnostics, fuel pressure specifications.

Emission Control Service:

Catalytic converter information, EGR system (if applicable), oxygen sensor testing, secondary air injection system (if equipped).

Engine Immobilizer:

Information on the engine immobilizer system, its operation, and potential troubleshooting steps.

Meter Audio Visual:

Diagnosis and repair of instrument cluster (meters), audio systems, and other electronic displays.

Horn:

Horn system diagnosis and repair, including relay and switch testing.

Windshield Glass Mirror:

Windshield replacement procedures, mirror adjustment and replacement, wiper blade replacement.

Instrument Panel:

Removal and installation of the instrument panel, dashboard components, and associated wiring.

Engine Hood Door:

Adjustments and repairs for the engine hood, doors, hinges, latches, and related mechanisms.

Exterior Interior Trim:

Removal and installation of exterior and interior trim pieces, body moldings, and fasteners.

Tire Wheel Service:

Tire pressure specifications, wheel torque recommendations, wheel alignment procedures, tire rotation.

Engine Immobilizer System:

Details on the function and troubleshooting of the vehicle's anti-theft system.

Wiper Washer System:

Troubleshooting and repair of the windshield wiper motor, linkages, washer pump, and fluid reservoir.

Door Lock System:

Diagnosis and repair of central locking systems, power door locks, and keyless entry (if equipped).

Depth:

Factory-level, comprehensive coverage suitable for professional technicians and highly skilled DIY enthusiasts. Includes detailed diagnostic procedures, component removal/installation, and repair specifications.

📊 Manual Specifications

Format:

PDF (Portable Document Format)

Printability:

All pages are printable, allowing users to print only the necessary sections or diagrams at enlarged sizes.

Binding:

Not Applicable (Digital PDF format). Users can print and bind as needed.

Paper Type:

Not Applicable (Digital PDF format). Users can print on their preferred paper type.

Text Searchability:

Likely includes searchable text, enabling quick finding of specific topics or keywords.

Operating Systems:

Compatible with Windows (Vista 32/64, XP, ME, 98, NT, 2000) and Mac operating systems.

Software Requirements:

Adobe PDF Reader and Winzip (or equivalent unzipping software), both freely available online.

⚙️ Engine Specifications

Engine Options 1997:

For 1997, common engines included the M111 2.0L and 2.3L inline-4 (e.g., C220, C230) and potentially the M104 2.8L or 3.2L inline-6 (e.g., C280, C36 AMG).

Typical Hp Range:

Horsepower typically ranged from approximately 120 hp for base models to over 270 hp for AMG variants.

Typical Torque Range:

Torque figures varied significantly by engine, generally from around 170 Nm to over 380 Nm.

Fuel Delivery:

Bosch Motronic electronic fuel injection (EFI) system, often with multi-point injection (MPI).

Diesel Options:

Diesel variants like the C220 Diesel (OM602.912) and C250 Diesel (OM605.912) were also available, featuring indirect injection.

🔧 Transmission

Standard Transmission:

A 5-speed manual transmission was often standard on lower trims.

Optional Transmission:

A 4-speed or 5-speed automatic transmission (e.g., the 722.4 or the newer 722.6 '5G-TRONIC') was widely available and popular.

Automatic Features:

Automatic transmissions often featured a 'Comfort' and 'Sport' mode for altered shift characteristics.

Automatic Transmission Fluid:

Specific ATF (Automatic Transmission Fluid) such as MB 236.2, MB 236.3, or MB 236.6 (depending on transmission type) is critical. Manual transmissions typically used gear oil like MB 235.0.

📐 Dimensions

Wheelbase Mm:

Approximately 2715 mm

Length Mm:

Approximately 4488 mm (Sedan)

Width Mm:

Approximately 1720 mm

Curb Weight Kg:

Curb weight typically ranged from 1350 kg to 1550 kg depending on engine and equipment.

Gross Vehicle Weight Rating Kg:

GVWR varied by model, generally in the 1850 kg to 2050 kg range.

🛡️ Safety Features

Crash Test History:

While official NHTSA/IIHS ratings for this specific year might be limited, the W202 was engineered with Mercedes-Benz's renowned safety focus, featuring a robust chassis and progressive crumple zones.

ABS:

Standard Anti-lock Braking System (ABS) on most models.

Traction Control:

ASR (Anti-Slip Regulation) traction control was available on many models.

Airbags:

Driver and front passenger airbags were standard. Side airbags were an optional feature.

Seat Belts:

Front seat belts with pretensioners and force limiters, rear seat belts.

💡 Technology Features

Audio System:

Factory radio/cassette players or early CD players. Optional premium sound systems available.

Cruise Control:

Standard cruise control system integrated into the steering column stalk.

Early Integration:

Limited in-car connectivity by modern standards; however, features like power windows, central locking, and electrically adjustable mirrors were common.

🔧 Maintenance

Oil Change Interval:

Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first, using synthetic oil meeting MB 229.1 specification.

Air Filter Replacement:

Recommended every 30,000-60,000 km (18,600-37,200 miles) or as needed based on driving conditions.

Spark Plug Replacement:

For M111 engines, typically around 100,000 km (62,000 miles) with iridium plugs; older recommendations for standard plugs were lower.

Engine Oil Specification:

MB 229.1 (synthetic) or MB 229.3 (for extended intervals), typically 5W-40 or 0W-40 viscosity.

Coolant Specification:

MB 325.0 (Ethylene Glycol based coolant), typically a 50/50 mix with distilled water.

Brake Fluid Specification:

DOT 4 (or DOT 4 Plus) brake fluid meeting MB 331.0 specification.

Common W202 Issues:

Common issues can include sagging headliner, failing blower motor resistors, premature wear on certain suspension components (e.g., control arm bushings), minor oil leaks, and potential issues with the SRS system warning light (often due to faulty seat occupancy sensors or connector issues).

📚 Vehicle History

Mercedes Benz Legacy:

The C-Class inherited Mercedes-Benz's long-standing reputation for engineering excellence, durability, and comfort.

W202 Introduction:

The W202 generation was introduced in 1993 in Europe and 1994 in North America, replacing the 190 (W201) as Mercedes-Benz's compact executive offering. The 1997 model year falls within its initial production run.

Manufacturing Locations:

Primarily produced in Germany (Sindelfingen and Bremen) and also assembled in South Africa and other locations.

🏆 Awards & Recognition

Class Accolades:

The W202 C-Class was generally well-received by automotive press for its comfort, refinement, and build quality, often winning 'best compact luxury car' comparisons in its early years.