🏷️ Basic Information

Make:

Mercedes-Benz

Model:

C-Class

Chassis Code:

W202

Model Year:

1996

Manual Product Name:

Mercedes Benz C-Class (W202) 1996 Service Repair Workshop Manual

Manual Format Code:

PDF Download

👋 Introduction

Vehicle Class:

Compact Executive Car (E-segment in some markets)

Target Audience:

Professionals seeking a reliable, comfortable, and premium compact sedan.

Key Competitors:

BMW 3 Series (E36), Audi A4 (B5), Lexus IS200, Volvo S40.

Brand Philosophy:

Emphasizes build quality, safety, refinement, and technological advancement characteristic of Mercedes-Benz.

Manual Value Proposition:

Provides professional-level repair and maintenance information, empowering owners and independent workshops to service the W202 effectively.

📋 Manual Details

Primary Market Focus:

Global

Language:

English

Estimated Pages:

Hundreds (exact count not specified, but described as extensive)

Type:

Factory Service Repair Workshop Manual

File Type:

PDF

Accessibility:

Downloadable for instant access on computer, tablet, or smartphone

Usage Rights:

Unlimited usage on multiple devices, no expiry date, no renewal fees

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, overhaul, cylinder head, pistons, crankshaft, camshafts, valve train, timing system, lubrication system, cooling system, fuel system (injection/carburetion - dependent on specific engine variant), exhaust system, engine management sensors and actuators.

Engine Electrical:

Ignition system, starter motor, alternator, battery, engine control unit (ECU) diagnostics, wiring diagrams for engine systems.

Transmission:

Manual transmission (clutch, gearbox, shift linkage), Automatic transmission (torque converter, valve body, planetary gears, hydraulic control, electronic control unit, fluid service).

Drivetrain:

Driveshafts, CV joints, differential, rear axle assembly.

Suspension:

Front suspension (struts, control arms, ball joints, bushings, stabilizer bar), Rear suspension (multi-link, shock absorbers, springs, bushings, stabilizer bar), wheel alignment specifications.

Brakes:

Front and rear brake systems (disc brakes, calipers, pads, rotors, brake lines, master cylinder, brake booster), Anti-lock Braking System (ABS) components, diagnostics, and bleeding procedures.

Steering:

Power steering system (pump, reservoir, lines, steering rack/gearbox), steering column, linkage, alignment.

Electrical System:

Chassis electrical systems, interior and exterior lighting, power windows, power seats, central locking, climate control system, audio system, instrument cluster, fuse box locations, relay assignments, comprehensive wiring diagrams.

Body And Interior:

Exterior body panels, doors, hood, trunk lid, bumpers, interior trim, dashboard, seats, headliner, glass replacement.

Heating Ventilation Air Conditioning:

HVAC system components, refrigerant handling, blower motor, evaporator, condenser, heater core, climate control module.

Maintenance:

Scheduled maintenance procedures (oil changes, filter replacements, fluid checks and changes), brake pad replacement, spark plug replacement, belt replacement, coolant flush, air filter replacement.

Repair:

Component removal and installation, engine rebuild, transmission overhaul, suspension component replacement, brake system repair, electrical component diagnosis and replacement.

Troubleshooting:

System-specific diagnostic procedures, common fault finding, diagnostic trouble codes (DTCs) interpretation (where applicable for the era), symptom-based troubleshooting.

Diagnostics:

On-board diagnostics (OBD-II for later models, proprietary diagnostics for earlier), component testing procedures, sensor data interpretation.

Depth Level:

Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds.

Visuals:

Hundreds of detailed photos and exploded diagrams.

Instruction Style:

Step-by-step instructions, suitable for professional mechanics and advanced DIY enthusiasts.

📊 Manual Specifications

Quality:

High-resolution PDF, allowing for clear viewing and printing.

Searchability:

Likely text-searchable PDF (standard for professional manuals).

Reproducibility:

Printable single pages or the entire manual.

Digital Binding:

N/A (Digital PDF)

Digital Paper Type:

N/A (Digital PDF)

Operating Systems:

Fully compatible with Windows and MAC computers.

⚙️ Engine Specifications

Engine Options 1996:

Likely includes the M111 inline-4 (e.g., C220, C230) and M104 inline-6 (e.g., C280, C36 AMG) families. Specific displacements vary.

Horsepower Range:

Approx. 130-190 hp for inline-4, 190-270 hp for inline-6 (including AMG variants).

Torque Range:

Approx. 150-200 lb-ft for inline-4, 200-290 lb-ft for inline-6.

Fuel Delivery:

Bosch Motronic electronic fuel injection (EFI).

Common M111:

M111.920 (2.2L), M111.921 (2.3L, often supercharged in later C36).

Common M104:

M104.941 (2.8L), M104.942 (2.8L), M104.944 (2.8L).

Valve Train:

DOHC (Dual Overhead Camshafts) with 4 valves per cylinder.

Emission Control:

Catalytic converter, EGR (Exhaust Gas Recirculation) where applicable.

🔧 Transmission

Transmission Options:

5-speed manual transmission ( Getrag-sourced for some variants), 4-speed automatic transmission (722.4).

Transmission Options Continued:

5-speed automatic transmission (722.6 'NAG1' introduced later in the W202 lifecycle, may be present in late 1996 models).

Automatic Control:

Electronic control for 722.6; Hydraulic control for 722.4.

Automatic Fluid:

MB 236.1, MB 236.2, MB 236.3, or MB 236.6 depending on transmission variant (e.g., Dexron II/III compatible for older units).

Manual Fluid:

MB 235.1 (e.g., SAE 75W-90 GL-4).

📐 Dimensions

Length:

Approx. 4488 mm (176.7 in)

Width:

Approx. 1716 mm (67.6 in)

Height:

Approx. 1393 mm (54.8 in)

Curb Weight:

Approx. 1400-1550 kg (3086-3417 lbs) depending on engine and equipment.

🛡️ Safety Features

기관 평가:

Early W202 models may have limited modern crash test data. Mercedes-Benz historically prioritized safety, featuring crumple zones, reinforced passenger cell, and advanced restraint systems for its era.

Braking Systems:

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

Airbags:

Driver and front passenger airbags standard.

Seat Belts:

Front and rear seat belts, pre-tensioners for front belts.

💡 Technology Features

Audio System:

Factory cassette or CD player with AM/FM radio. Optional CD changer. Speaker configurations vary by trim.

Cruise Control:

Standard cruise control on most models.

Climate Control:

Manual or optional automatic climate control (Thermatic/Thermotronic).

Early Telematics:

Limited connectivity; no Bluetooth or advanced digital integration common in later vehicles. Optional analog car phone available.

🔧 Maintenance

Oil Change Interval:

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

Transmission Fluid Interval:

Automatic transmission fluid change usually every 60,000 km (37,000 miles) or as per Mercedes-Benz 'A' or 'B' service schedules.

Coolant Interval:

Coolant flush and replacement typically every 2 years or 40,000 km (25,000 miles).

Engine Oil Specification:

MB 229.1 or MB 229.3 (e.g., 0W-40, 5W-40, 5W-30 synthetic).

Coolant Specification:

MB 325.0 (Ethylene Glycol based coolant, typically blue).

Brake Fluid Specification:

DOT 4.

Common Problems:

MAFS (Mass Air Flow Sensor) failure, ABS sensor issues, SRS (Supplemental Restraint System) warning light (often related to seat occupancy sensors or wiring), heater control valve leaks, vacuum line deterioration, rust on wheel arches and sills, sagging headliner.

Typical Wear Items:

Control arm bushings, sway bar links, shock absorbers, brake pads/rotors, exhaust system components.

📚 Vehicle History

Mercedes Benz Legacy:

Founded on engineering excellence, safety, and luxury since the late 19th century.

W202 Introduction:

Introduced in 1993 as the successor to the 190 (W201), establishing the C-Class nameplate. The W202 represented Mercedes-Benz's first compact executive sedan.

W202 Facelift:

Received a significant facelift in 1997, but the 1996 model predates this. Key exterior changes in the facelift included updated bumpers, grille, and clear-lens headlights.

Production Period:

1993-2000

Manufacturing Sites:

Bremen, Germany; East London, South Africa; Tuscaloosa, Alabama, USA (for specific market variants).

🏆 Awards & Recognition

Historical Accolades:

While specific awards for the 1996 model year might be scarce in general public databases, the W202 C-Class generally received praise for its build quality, safety, and refined driving experience, contributing to Mercedes-Benz's reputation as a leader in the luxury segment.